246

Advanced Research Journals of Science and Technology

ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY(ARJST)

Medepalli Neil Jones1, P. Subramanayam2.

1 Research Scholar, Department of Mechanical Engineering, MLR Institute of TechnologyDundigal, Hyderabad, India.2 Assistant professor, Department of Mechanical Engineering, MLR Institute of TechnologyDundigal, Hyderabad, India.

*Corresponding Author:

Medepalli Neil Jones, Research Scholar, Department of Mechanical Engineer-ing, MLR Institute of Technology Dundigal, Hyderabad, India.Email: neil.jones15@gmail.comIDOAJ-003-0302-047

Year of publication: 2016Review Type: peer reviewedVolume: III, Issue : II

Citation: Medepalli Neil Jones, Research Scholar "Design And Analysis of Locomotive Bogie AssemblY" Advanced Research Journals of Science and Technology (ARJST) (2016) 246-252

INTRODUCTION TO MINING

It is the process of extracting essential mineral ores geo-logical substances of great value from rocks and earth’s surface, which can be used for a wide range of purposes, is known as mining.

They can be used in industrial applications, in infrastruc-ture or in home wares, in jeweler or other uses.

Underground mines

Ores recovered by mining include metals, coal, oil shale, gemstones, limestone, dimension stone, rock salt, potash, gravel, and clay. Mining is required to obtain any mate-rial that cannot be grown through agricultural processes, or created artificially in a laboratory or factory. Mining in a wider sense includes extraction of any non-renewable resource such as petroleum, natural gas, or even water.

Mining of stones and metal has been a human activity since pre-historic times. Modern mining processes involve prospecting for ore bodies, analysis of the profit potential of a proposed mine, extraction of the desired materials, and final reclamation of the land after the mine is closed.

UNDERGROUND MINING:

There are three major steps in the process of mining ore underground. They are (1) Breaking the ore (2) Loading the broken ore(3) Transporting the ore from the working face to the sur-face.

It is most convenient to sketch technological change in underground mining in terms of these three steps in the mining process, for aside from changes in mining method proper, technological improvements have consisted main-ly of the mechanization of these functions. We shall dis-cuss the successive steps in the process of winning the ore, and shall finally devote a few paragraphs to parallel, changes in such auxiliary functions as drainage and ven-tilation.

Abstract

This project deals with design optimization to improve the life of locomotive trolley. 3D models will be prepared accord-ing to company standards. FEM based analysis will be conducted on assembly to find the location of maximum stress. Static and model analysis will be carried out by applying suitable materials and modifying part by observing the above analysis. Conclusion will be made according to the obtained results to suggest suitable material and minimal geomet-ric modifications to avoid reproduction cost.

DESIGN AND ANALYSIS OF LOCOMOTIVE BOGIE ASSEMBLY

247

Advanced Research Journals of Science and Technology

LOCOMOTIVE:

The first locomotive was invented by Cornish inventor Richard Trevithick in 1804 & the trend of locomotives started with steam engines, and then developed to diesel engines, which ruled the era for quite a lot of time.The diesel engines were very much flexible and would have a considerable hauling power compared to the steam ones. But a drastic change influenced the railways with the invention of electrically operated locomotives. Which was to provide electric power always available for the lo-comotive This took time and even a huge investment to install electric supply lines all over the areas and also provide adequate and correct amount of power for the loco anywhere it goes. The railway also had to install the sub-stations to boost up the power. Railways signed the contract with state electricity boards.

TYPES OF LOCOMOTIVES:

• Steam locomotives• Electric locomotives• Diesel locomotives• Diesel-electric locomotives• Diesel-mechanical locomotives• Diesel-hydraulic locomotive • Gas turbine-electric locomotives

TRANSPORTATION USED IN UNDERGROUND MINING: Once cut, the coal has to be transported from the face area to the surface. There are localized transport systems at the mining face areas to carry the coal from the cut-ting machines to the main transport systems. These lo-calized transport systems (shuttle cars, AFC's, BSL's, etc) are dealt with in following sections relative to the different types of mining. This section refers to the main transport systems out of the mine.

Before the development of suitable conveyor belts, coal was transported from the mine by rail transport systems, but today coal transport is almost invariably by conveyor belts.

Transportation of coal in olden days

HISTORY OF TRANSPORTATION IN UNDERGROUND MINING:

Mining has always been a question of transport In the year 1976 alone a total of l80 million tones of material were moved underground throughout the coal mines of West Germany Of this total, 155 million tons (86.1%) were run of mine coal and 25 million tons (l3.9%) were dirt and materials.

Locomotive haulage was employed to transport approxi-mately 65% of the run-of-mine coal to the shaft, the remaining 35% arriving at pit-bottom by means of belt

conveyors. Locomotives are used almost exclusively to transport dirt and materials in the main haulage roads. Locomotive haulage therefore remains the most signifi-cant form of transport underground in the main haulage roads of West German coalmines. In 1976 locomotives transported about 126 million tones representing 70% of the total transport.

LITERATURE SURVEY

Mr.Pdziewulski, from Military University of Technol-ogy, Poland. Has done the research work on “NUMERI-CAL ANALYSIS OF THE FRONT IMPACT BETWEEN TWO SHUNTING LOCOMOTIVES” and they have given the con-clusion as “The main aim of this study is to carry out dynamic finite element analysis of a crash between two identical hunting locomotives. Numerical simulations in-clude front-end impact of the running locomotive with a stationary one situated on the track. The first design col-lision scenario includes such obstacle for railway vehicles operated on national and regional networks. A considered locomotive based on a popular Polish shunting locomo-tive – SM42.

However, the tested locomotive was slightly modernized in comparison with the original one. Finite element model of the locomotive was developed by the authors. FE analyses were carried out according to the PN-EN 15227 standard, which provides crashworthiness requirements for railway vehicle bodies. LESS-DYNA computer code was used for the simulations. The energy balance was initially checked in order to confirm the accuracy of analysis. The paper presents selected results of analyses focused on the lo-comotive frame behavior. Contours of effective stress for selected moments of time are presented. Time histories of selected parameters are also depicted. The current study is a part of the project focused on modernization of the SM42 locomotive. Therefore, it is required to evaluate the locomotive behavior during the impact test. Dynamic nu-merical simulation is acceptable since the experimental tests on the complete objects under consideration are im-practical and impossible at the moment.”

Mr. A. INDRA REDDY1 P.SRINIVASA KUMAR2 Dr. P H V SESHA TALPA SAI from KLS’ GIT, Belgaum, Karnataka, India. Has done the research work on “Design and Dy-namic Analysis of Locomotive Wheel Axle” and they have given the conclusion as “1. Maximum stress by ANSYS is lower than the yield stress of material. 2. Von-mises stresses [2] are less than ultimate strength. 3. Since the von-mises stresses are less than the ultimate strength, talking deflections into account, 30 NiCrMoV12 steel [1] is preferred as best material for designed Rail wheel axle.”

DESCRIPTION OF BOGIE

A bogie or truck is a wheeled wagon or trolley. The term “bogie” is used in British English, while a “wheel truck”, or simply “truck” is used in American English .In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle, thus serving as a modular subas-sembly of wheels and axles. Bogies take various forms in various modes of transport. A bogie may remain normally attached (as on a railway carriage/car or locomotive, or on a semi-trailer) or be quickly detachable (as the dolly in a road train); it may contain a suspension within it (as most rail and trucking bogies do), or be solid and in turn be suspended (as most bogies of tracked vehicles are); it may be mounted on a swivel, as on a railway carriage/car or locomotive, or additionally jointed and sprung (as in the landing gear of an airliner).A bogie is a structure un-

248

Advanced Research Journals of Science and Technology

derneath a railway vehicle body to which axles and wheels are attached through bearings. The overall term is “run-ning gear”, which covers bogies as well as vehicles with two, or more axles without any bogies .In this case, these axles are directly fitted to the vehicle body via guiding devices and springs, and for very low speeds even without springs .

MODELLING

INTRODUCTION TO CAD:

Computer-aided design (CAD), also known as comput-er-aided design and drafting (CADD), is the use of com-puter technology for the process of design and design-documentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provides the user with input-tools for the purpose of streamlining design processes; drafting, docu-mentation, and manufacturing processes.

INTRODUCTION TO creo 2.0(PRO/ENGINEER)

creo 2.0 is the standard in 3D product design, featur-ing industry-leading productivity tools that promote best practices in design while ensuring compliance with your industry and company standards. Integrated Pro/ENGI-NEER CAD/CAM/CAE solutions allow you to design fast-er than ever, while maximizing innovation and quality to ultimately create exceptional products.

Customer requirements may change and time pressures may continue to mount, but your product design needs remain the same - regardless of your project's scope, you need the powerful, easy-to-use, affordable solution that Pro/ENGINEER provides.

Bogie container

Assembling of bogie

Structural diagram of bogie

Exploded view

STRUCTURAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEMBLY USING EN 19

Total deformation value

The above image is showing equivalent stress value

249

Advanced Research Journals of Science and Technology

The above image is showing equivalent strain value

MODAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEM-BLY USING EN19

Natural frequency value at mode-1

STRUCTURAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEMBLY WITH ADDING ADDITIONAL SUPPORTS USING EN 19

Total deformation value

The above image is showing equivalent stress value, it is also called as von-misses stress which provides the average value of directional and principle stress using von-misses theory of fail-ure.

MODAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEM-BLY WITH ADDING ADDITIONAL SUPPORTS USING EN 19

Natural frequency value at mode-1

STRUCTURAL ANALYSIS OF LOCOMOTIVE WHEEL AS-SEMBLY WITH ADDING ROUNDS TO REDUCE STRESS USING EN 19

The above image is showing equivalent stress value

MODAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEM-BLY WITH ADDING ROUNDS TO REDUCE STRESS US-ING EN 19

Natural frequency value at mode-1

STRUCTURAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEMBLY MODIFIED MODEL USING EN 19

The above image is showing equivalent stress value

250

Advanced Research Journals of Science and Technology

MODAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEM-BLY MODIFIED MODEL USING EN 19

Natural frequency value at mode-1

STRUCTURAL ANALYSIS OF LOCOMOTIVE WHEEL AS-SEMBLY MODIFIED MODEL USING TITANIUM- STEEL

The above image is showing equivalent stress

MODAL ANALYSIS OF LOCOMOTIVE WHEEL ASSEM-BLY MODIFIED MODEL USING TITANIUM- STEEL

Natural frequency value at mode-1

IMPACT ANALYSIS OF LOCOMOTIVE WHEEL ASSEM-BLY MODIFIED MODEL USING TITANIUM- STEEL

The above image is showing total deformation value.

The above image is showing equivalent stress value

The above image is showing equivalent strain value

RESULTS AND CONCLUSION

The above image shows displacement graph

The above image shows stress graph

251

Advanced Research Journals of Science and Technology

STRUCTURAL ANALYSIS MODIFIED MODEL

The above image shows displacement graph

The above image shows stress graph of modified model

Conclusion:

• This thesis work is done on “analysis of locomotive wheel assembly used in underground mining to suggest geometric optimization’s to improve life of the assembly and to compare carrier materials.

• Initially litterateur survey was done as per the receiv-ers researchers maximum of researchers are work only on materials not on geometric optimization hear in this thesis geometric optimization is done as a forward step to make product better.

• Static and model analysis is done on assembly to evalu-ate results and also to find stress concentrated

• Locations as per the analysis result observation bot-tom of carrier (WHEEL ASSEMBLY TO TROLLY CONTACT AREA) and wall are having maximum stress and having 49.724 Hz of frequency.

• Geometric modifications are implemented on assembly by adding additional supports then analysis was done on assemble to compare analysis some more modifica-tions are done and analysis work is carried out , as per the analysis results modified and modified 2 models are showing better results but the frequency was little bit high, so new materials titanium steel alloy was used in-stead of En -19 then above analysis was done , as per the results steel is best it has stabilized the frequency’s .

• Impact analysis was carried on modified 2model to find out impact characteristics.

• As per this thesis report by observing above discursions it concludes that, instead of change of all the materials better to change carrier and supports materials which will not effort the cost in max range , making of some small geometric modifications and adding some supports

will bring the better changes to the locomotive assembly which interns improves the quality and life of the prod-uct.

• Structural and model analysis is done on entire assem-bly to find the stress concentrated areas, from the analy-sis results; wheel assembly is facing maximum stress at wheel joining portion.

• Static and modal analysis is carried out on wheel as-sembly with the variation of material.

• As per the analysis results it can be concluded that

• No need of design modification, design modifica¬tions will decrease the cost effect to the company for making of new molds.

• Better to change the wheel material from EN-19 to Tita-nium steel.

• EN-19 is having some more stress displacement and strain values than titanium steel.

• In continuous usage displacement may effect on yield of wheel Titanium steel is having nearly 55% less displace-ment than EN-19 (present material) so better to use tita-nium steel for wheels.

REFERENCES

1. Pdziewulski ,mkonarzewski, pszurgott. NUMERICAL ANALYSIS OF THE FRONT IMPACT BETWEEN TWO SHUNTING LOCOMOTIVES Journal of KONES Power-train and Transport

2. INDRA REDDY1 P.SRINIVASA KUMAR2 Dr. P H V SE-SHA TALPA SAI3 Design and Dynamic Analysis of Loco-motive Wheel Axle International Journal of Science, Engi-neering and Technology Research (IJSETR),

3. Wei Tang*, Wenjing Wang, Yao Wang, Qiang Li Fatigue Strength and Modal Analysis of Bogie Frame for DMUs Exported to Tunisia Journal of Applied Mathematics and Physics

4. S. Ganesan and K. Panneerselvam VIBRATION RE-DUCTION IN CONVENTIONAL VEHICLES BY INCREAS-ING THE STIFFNESS ON THE CHASSIS FRAME ARPN Journal of Engineering and Applied Sciences

5. Pdziewulski- DEVELOPMENT OF FINITE ELEMENT MODELOF SHUNTING LOCOMOTIVE APPLICABLE FOR DYNAMIC ANALYSES Journal of KONES Powertrain and Transport

6. M. Naveen, K. Jagadeshwar, M. SaiSatish Chandra, T. P. S. Avanish OPTIMIZATION OF A RAILWAY BOGIE In-ternational Journal of Advanced Engineering Technology

7. K.Rambabu1, Y.Venu2 LOCOMOTIVE WHEEL ASSEM-BLY DESIGN OPTIMIZATION USING FINITE ELEMENT ANALYSIS International Journal of Research and Inno-vation in Mechanical Engineering (IJRIME) International Journal of Research and Innovation on Science, Engi-neering and Technology

252

Advanced Research Journals of Science and Technology

AUTHORS

Medepalli Neil Jones, Research Scholar, Department of Mechanical Engineering, MLR Institute of Technology Dundigal, Hyderabad, India.

P. Subramanayam,Assistant professor, Department of Mechanical Engineering, MLR Institute of Technology Dundigal, Hyderabad, India.