Simulation and Experimental Validation of Stress Analysis for Train Coupler
Article Sidebar
Main Article Content
Abstract
This study investigates the stress distribution in a sand-cast steel train coupler by comparing experimental results with FEM simulation. Strain gauges were attached to the coupler body areas to measure stresses under varying loads ranging from 500 kN to 1900 kN. The results indicated that the experimental and simulation stress values exhibited a linear relationship with increasing load, reaching a maximum of 206 MPa at 1900 kN. This stress value was approximately 30% of the material's yield strength. However, the experimental stress values tended to be slightly higher than the simulated results, with an average difference of less than 10%. This deviation is attributed to casting defects, geometric irregularities, and material-property differences that are difficult to capture in simulations. The specimen's chemical composition aligns with the Association of American Railroads (AAR) M201 Grade E Steel Casting standards, ensuring the material meets industry requirements. The findings suggest that optimizing the post-casting machining process could improve accuracy in future FEM analyses.
Article Details
Section
This work is licensed under a Creative Commons Attribution 4.0 International License.
THIS IS AN OPEN ACCESS ARTICLE UNDER THE CC BY LICENSE http://creativecommons.org/licenses/by/4.0/
References
Karmiadji DW, Haryanto B, Ivano O, Perkasa M, Farid AR. Bogie Frame Structure Evaluation for Light-Rail Transit (LRT) Train: A Static Testing. Automotive Experiences 2021; 4(1): 36–43.
Karmiadji DW, Gozali M, Anwar A, Purnomo H, Setiyo M, Junid R. Evaluation of Operational Loading of the Light-Rail Transit (LRT) in Capital Region, Indonesia. Automotive Experiences 2020; 3(3): 104–114.
Karmiadji DW, Haryanto B, Anwar, Prasetyo B, Irawadi Y, Farid AR, et al. Verification of Urban Light Rail Transit (LRT) Bogie Frame Structure Design Lifetime under Variable Fatigue Loads. Mechanical Engineering for Society and Industry 2022; 2(1): 42–53.
Haryanto B, Nuramin M, Karmiadji DW, Perkasa M, Anwar, Prasetiyo B, et al. Verification of a New Prototype Design of Bogie Monorail Frame with Variation of Static Loading. Mechanical Engineering for Society and Industry 2023; 3(2): 78–85.
Forsberg R, Björnstig U. One Hundred Years of Railway Disasters and Recent Trends. Prehospital and Disaster Medicine 2011; 26(5): 367–373.
Yu Y, Li J, Xie Z, Gao G, Rauf Sheikhi M, Li J. Ballistic Performance of Aluminum Alloy Plates with Polyurea Coatings for High-Speed Train Structures. Composite Structures 2025; 351: 118553.
Gao J, Yuan R, Lin J, Lu S, Wang Y. Thermal Response of High-Speed Train Multi-Layer Composite Floor Structure: Experimental and Numerical Analysis. Thermal Science and Engineering Progress 2023; 46: 102167.
Hao Y, Jia L, Zio E, Wang Y, He Z. A Network-Based Approach to Improving Robustness of a High-Speed Train by Structure Adjustment. Reliability Engineering and System Safety 2024; 243: 109857.
Li T, Peng Y, Qiao Y, Zhu W, Zhang J, Wang K, et al. Experimental Study on Crashworthiness and Lightweight of Cutting-Type Energy-Absorbing Structure of Magnesium Alloy for Trains. Engineering Structures 2024; 301: 117287.
Guo F, He J. Optimal Allocation Method of Electric/Air Braking Force of High-Speed Train Considering Axle Load Transfer. High-Speed Railway 2024; 2(2): 77–84.
Zhang C, Yu Z, Jia L. Train Wheel-Rail Force Collaborative Calibration Based on GNN-LSTM. High-Speed Railway 2024; 2(2): 85–91.
Li J, Wang L, Wang X, Hu Z, Lan H, Wang Z, et al. Effect of Shot Peening Equivalent Impact Force on Fatigue Crack Growth Behavior and Fatigue Life Prediction of Train Brake Discs. Engineering Failure Analysis 2024; 166: 108914.
Yadav OP, Vyas NS. The Influence of AAR Coupler Features on Estimation of In-Train Forces. Railway Engineering Science 2023; 31(3): 233–251.
Xu J, Kang J, Mao W. Effect of Double-Layer-Shell Sand Mold on the Residual Stress of Casting and Itself Crack Tendency. Materials Letters 2023; 335: 133752.
Liu B, Kang J, Yang X, Zhang B, Bian Y. Effects of Hollow Sand Mold on the Microstructure and Mechanical Properties of a Low Pressure Aluminum Alloy Casting. Journal of Materials Research and Technology 2024; 28: 4488–4497.
Powell JP, Palacín R. Passenger Stability Within Moving Railway Vehicles: Limits on Maximum Longitudinal Acceleration. Urban Rail Transit 2015; 1(2): 95–103.
Sharma SK, Chaturvedi S. Jerk Analysis in Rail Vehicle Dynamics. Perspectives in Science 2016; 8: 648–650.
Vukšić Popović M, Tanasković J, Glišić D, Radović N, Franklin FJ. Experimental and Numerical Research on the Failure of Railway Vehicles Coupling Links. Engineering Failure Analysis 2021; 127: 105497.
Chunduru SP, Kim MJ, Mirman C. Failure Analysis of Railroad Couplers of AAR Type E. Engineering Failure Analysis 2011; 18(1): 374–385.
Li HF, Zhao XY, Yang SP, Wei JL, Gu XH, Liu YQ, et al. Fatigue Failure Mechanism of High-Speed Train Bearing Steel after Long-Term Service. Engineering Failure Analysis 2024; 165: 108777.
Chen Y, Jing L, Li T, Ling L, Wang K. Numerical Study of Wheel–Rail Adhesion Performance of New-Concept High-Speed Trains with Aerodynamic Wings. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering) 2023; 24(8): 673–691.
Thejasree P, Dileep Kumar G, Leela Prasanna Lakshmi S. Modelling and Analysis of Crankshaft for Passenger Car using ANSYS. Materials Today: Proceedings 2017; 4(10): 11292–11299.
Milovanović V, Zivković M, Disić A, Rakić D, Zivković J. Experimental and Numerical Strength Analysis of Wagon for Transporting Bulk Material. *IMK-14 – Research & Developement in Heavy Machinery* 2014; 20(4): 61–66.
Sagita RN, Rochiem R, Wibisono AT. Analisa Pengaruh Lama Waktu Tahan Tempering terhadap Struktur Mikro dan Sifat Mekanik Coupler Baja AAR-M201 Grade E. Jurnal Teknik Its Pomits 2017; 16(1): 35–40.