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ExcelCalcs Lego-Like Way to Engineering

Like a child selecting parts to construct a Lego model engineers bring together blocks of science to create new designs. These building blocks could be a load calculation, a beam calculation, a weld calculation, a fatigue calculation or any other calculation from a myriad of engineering topics. As...

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Railway Vehicle Design

Engineering Services

MoreVision has a particular expertise in the structural design of railway rolling stock and running gear. Being active in railway industries from across the globe we have a good perspective on all the various standards used in different countries and on different vehicle types. MoreVision services are used by rolling stock manufacterers and operators alike heading failure investigations and supporting engineering teams. MoreVision has been invited on a number of occasions to present papers at the Institute of Mechanical Engineers including "Crash Design of Steel Bodyshells for Virgin" and "The Future of Railway Vehicle Design"

Railway Bodyshell Design

MoreVision were involved from the start of the in the concept design and preliminary calculations of the class 22x bodyshells. Later in the project MoreVision were commissioned by Bombardier to undertake an independent design audit of the Virgin Voyager Bodyshells. They were asked to consider the fatigue design aspects of the bolster, in particular dealing with issues arising from the tilting mechanism. Further support to the project was required in the management of subcontractor supporting calculations. In the final stages MoreVision were asked to prepare and present a paper called "Crash Design of Steel Bodyshells for Virgin" which was delivered at a seminar held at the Institute of Mechanical Engineers.

Having completed the design of the bodyshell ADtranz commissioned MoreVision to undertake the final analysis runs and preparation of all the reports for submission to the client and approval authority. This bodyshell was particular interesting as it was constructed from a fabricated steel chassis and body ends with sidewalls and roof made from wide body aluminium extrusions. The sub-assemblies were bolted together to form the complete bodyshell. Analysis included a static strength assessment, fatigue strength assessment and bolted joint assessment for each of the bodyshell types.

MoreVision have undertaken design work in Europe, for example the structural design of AM96 Electrical Multiple Units and I11 coaches for BN, SNCB Belgium.

A generic rail vehicle may be sold to a number of different clients. Each client have their own particular preference for seating layout. This means that the positions and sizes of doors and windows change between each order. MoreVision have parameterised this problem so that once window and door sizes have been defined a program which automatically generates a finite element model. In this way any problems regarding resonance, strength of fatigue strength of the bodyshell can be understood during the project definition and tendering stage. The program even produces a bill of materials for tendering purposes.

Bogies, Trucks and Adapters

MoreVision works very closely with its client partners. Typically models are supplied by the client by email and Morevision are asked to undertake the static and fatigue assessments and prepare the reports for submission to the end client. MoreVision has developed a number of programs to post-process finite element results which help to reduce the cost of fatigue assessments.

Non-Tilting Bogies for Virgin - The bogie is used on the non-tilting Virgin Voyager vehicles.

Tilting Bogies for Virgin - The bogie is used on the tilting Virgin Voyager vehicles.

Bolster Adapter for Double-Deck Bodyshell - This is a half model of an adapter for a double-deck bodyshell. The vehicles are for use in France so two fatigue assessments were performed to show that is compliant with UK and French fatigue standards. The methods of assessment are completely different.

Caracas Bogie - This is a half model of bogie which in in service in Caracas in Venezuela.

M6 Bogie Adapter - The M6 vehicles are for use in France so two fatigue assessments were performed to show that is compliant with UK and French fatigue standards. The methods of assessment are completely different.

Bolster Adapter for Tilting Train - Bogies are attached to the bodyshell via adapters. design of the adapter is often just as extensive as the design of the bogie. This particular adapter is further complicated due to the tilting mechanism on the train.

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Fatigue of Welded Structures

Engineering Services

MoreVision has developed a number of programs to post-process finite element results, calculate fatigue damage and to plot damage directly onto the FE mesh. The assessments cover code of practices used in many countries (UK - BS7608, US - AISC LRFD, France -UIC 515-4 Goodman Diagram, German DIN 15 018, Swedish Volvo standards)

Fracture Mechanics If a component is subject to repeated applications of structural loading then it will be susceptible to fatigue failure. Stresses act on small flaws inherent in the material causing then to grow until they break. Two approaches can be employed to assess this situation:
    • Fatigue Life Assessment.
    • Fracture Mechanics Approach.
Using stress information derived from an ANSYS structural analysis MoreVision have developed custom programs to assess fatigue life or to study crack growth.

Our library of programs includes methods of assessment used in various countries following a number of codes:
Fatigue Life Assessment
    • UK - BS7608 (fabricated steel), BS8118 (aluminium), BS5400 (bridges), BS2573 (cranes).
    • US - AISC LRFD.
    • France - UIC 515-4 Goodman Diagram (railway).
    • German DIN 15 018 (cranes).
    • Swedish Volvo standards (automotive, construction equipment).
Fracture Mechanics Approach
    • UK - PD6493 (fracture).

The fatigue life of a welded structure it totally dependant upon the choice of welded detail. In the following examples the detail on the left hand side of the page is improved by adopting the detail on the right hand side. Just three examples are given though there are generally many ways of optimising a fabricated structure.

1) Weld reinforcement and weld toe re- profiling

The fatigue life of this butt weld is improved by grinding the weld reinforcement flush with the parent plate. This reduces the stress concentration at the weld toe. Paradoxically it could be further enhanced if the weld toes are dressed back 1 to 2mm below the thickness of the parent plate! The benefit from the removal of poor quality material at weld toes which contains fatigue prone inherent flaws outweighs the slight increase in stress due to loss of net section.

2) Removal of weld stop starts

The presence of stop start defects in a weld will reduce the fatigue life of a weld.

3) Do not weld on plate edges

Welds on the edge of a stressed plate have a lower fatigue life than welds which stop 10mm short of the edge.

Consultancy Projects - Fatigue Analysis Of Welded structures

Finite element stress analysis.

Understand fatigue classification of welds.

Understand how to select appropriate stress from finite element model for fatigue assessment.

Software developed by MoreVision to take benefit from fatigue enhancement methods (like toe grinding, TIG dressing and stress relieving).

View fatigue classification directly on finite element model.

View damage directly on finite element model.

Export results to spreadsheet for detailed analysis and verification.

Fatigue assessment of rollercoasters.

Fatigue assessment of railway bodyshells and running gear.

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