An experimental investigation of the mechanism and mitigation measures for the coil spring fracture of a locomotive

Wang, Kaiyun; Yang, Yifan; Yang, Yue; Xu, Mingkun; Chen, Shiqian; Ling, Liang; Fei-xiong, Xiao; Zhang, Kailin; Ma, Chengxiang

doi:10.1016/j.engfailanal.2022.106157

Cited by 18 publications

(6 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The primary suspension is located immediately above the axle boxes of the wheelsets and is often formed of steel coil springs; the secondary suspension connects the bogie frame with the car body and is commonly uses airsprings. Recently, however, fatigue fractures of coil springs in the primary suspension have been found to occur frequently for different kinds of railway vehicles in service, including high-speed trains, locomotives and metro vehicles [2][3][4]. Also, according to the statistics of the fractures of coil springs within a metro train, the service life of fractured coil springs varies within a wide range (0.2 million km ~ 1 million km).…”

Section: Introductionmentioning

confidence: 99%

“…Currently, coil springs are generally designed using Goodman diagrams based on the EN 13906 standard [5] to assess their durability. However, recent research results [2][3][4] show that the EN 13906 standard cannot consider the internal resonances within coil springs, which are significant for fatigue life. In these researches the vibration load of coil springs is regarded as a stationary Gaussian load and expressed by its power spectral density (PSD), from which the stress response PSD is obtained by combining it with the structural dynamic properties in the form of a stress frequency response function (FRF).…”

Section: Introductionmentioning

confidence: 99%

“…The first is that it is not appropriate for the vibration load to be assumed to be stationary and Gaussian. The vibration acceleration of the axle box excited directly by the wheel/rail interaction is generally regarded as the vibration load for the coil spring [3,4]. During the service period of railway vehicles, different track types [8], evolving wheel/rail contact surface conditions [9] and different operating modes result in complex and changing wheel/rail forces.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, however, fatigue fractures of coil springs in the primary suspension have been found to occur frequently for different kinds of railway vehicles in service, including high-speed trains, locomotives and metro vehicles. 2–4 Also, according to the statistics of the fractures of coil springs within a metro train, the service life of fractured coil springs varies within a wide range (0.2 million km ∼ 1 million km). Examples of fractured springs are shown in Figure 1.

Figure 1.Examples of fractured coil springs.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Fatigue analysis of coil springs in the primary suspension of a railway vehicle based on synthetic spectrum for time-varying vibration load

Wang

Zhou

Sun

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part F:

View full text Add to dashboard Cite

The fatigue life of coil springs is usually predicted with a stationary Gaussian vibration load and deterministic structural parameters. However, the obtained fatigue life is inconsistent with the observed fatigue life of fractured springs which varies within a wide range. The work aims to propose a method to predict the fatigue life of the coil spring by considering the time-varying vibration load, i.e., root mean square (rms) varies with time and the uncertainties of geometric parameters. First, a synthetic method for time-varying vibration loads is proposed. The time-varying load is decomposed into multiple stationary Gaussian short samples represented by their power spectral density (PSD). These PSDs are synthesized according to the distribution characteristics of spectral values, in which data that are non-Gaussian are processed with the Johnson system. Second, the influence of parameter uncertainties in the coil spring is studied by a Monte Carlo analysis of the stress frequency response function. Finally, the fatigue life is calculated and compared with the results predicted by using the measured stress. The results show that the synthetic spectrum has almost the same damage potential as the measured time-varying load. In comparison with results predicted from the measured stress, the synthetic spectrum gives much better estimates of the fatigue life of the coil spring than the average spectrum. Parameter uncertainties of coil springs significantly affect fatigue life and should be taken into account.

show abstract

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Figure 1.Examples of fractured coil springs.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Fatigue analysis of coil springs in the primary suspension of a railway vehicle based on synthetic spectrum for time-varying vibration load

Wang

Zhou

Sun

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part F:

View full text Add to dashboard Cite

show abstract

“…Wu et al 4 pointed out that the rail corrugation-induced impact with a passing frequency of 78 Hz is the main reason for the modal resonance of the antenna beam in the metro bogie. Wang et al 5 found that the 17th-order wheel OOR could motivate the 1st expansion modal of the coil spring in the locomotives. Similar fatigue failure phenomena of the coil spring in metro bogie were reported, which could be explained by P2 force and rail corrugation response.…”

Section: Introductionmentioning

confidence: 99%

Fatigue stress estimation of metro bogie frame through frequency response functions by using limited sensors

Sun

Lai

et al. 2023

Structural Health Monitoring

View full text Add to dashboard Cite

In this paper, the fatigue state estimation of the metro bogie frame is discussed based on limited sensors through frequency domain methods. The middle-frequency and high-frequency vibration fatigue damage cases of one metro bogie frame is discussed. The main excitations come from the wheel/rail interactions including wheel out-of-roundness and rail irregularities. The most common modal vibration of the bogie frame, where the transom bending deformation is dominant, is taken as the research object to study the possibilities of fatigue failure monitoring on concerned points of the bogie frame transom focusing on specific transfer paths. To eliminate unnecessary input signals which are not closely related to the occurrence of large stress amplitudes, the coherence analysis of different loads including the transmission load, carbody load and wheel-rail impact load is conducted through various methods including the short-time Fourier transform spectrum analysis, the magnitude-squared coherence analysis and the partial directed coherence analysis. Then the power spectral densities (PSDs) of the measured accelerations and cross power spectral densities (CPSDs) are calculated to obtain the transfer functions, whose output is the Y-axis stress at the concerned point. The stress PSDs are obtained using the instantly measured input accelerations and the prepared transfer function. Then the spectral moments and the stress amplitudes distribution functions are calculated through the frequency domain method to overcome the computational burden. The stress reconstructions based on inverse fast Fourier transform are analyzed and the fatigue damage results show good consistency with the experimental ones.

show abstract

Failure Analysis of the Faulty Locomotive Coil Spring

He,

2024

J Fail. Anal. and Preven.

View full text Add to dashboard Cite

An experimental investigation of the mechanism and mitigation measures for the coil spring fracture of a locomotive

Cited by 18 publications

References 29 publications

Fatigue analysis of coil springs in the primary suspension of a railway vehicle based on synthetic spectrum for time-varying vibration load

Fatigue analysis of coil springs in the primary suspension of a railway vehicle based on synthetic spectrum for time-varying vibration load

Fatigue stress estimation of metro bogie frame through frequency response functions by using limited sensors

Failure Analysis of the Faulty Locomotive Coil Spring

Contact Info

Product

Resources

About