ANSYS software use in development

cycle of products in Kovis

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Uroš Grivc, David Deržič

Company KOVIS presentation

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Company KOVIS presentation

• Kovis Group is made of 4 separate companies: Kovis Livarna, Kovis, Kovis BP and Kovis Transporti

• Production of components for railway vehicles, for instance brake discs, bearing housings (axle boxes) and various parts for railway and other industry.

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Company KOVIS presentation

Markets Customers

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Sales activities Direct export

Company KOVIS presentation

R&D department tasks:

• Existing designs verification for specific projects

• New designs (optimization)

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Examples of ANSYS use

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General example of the brake disc analysis

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Avg.HTC - OMEGA [W/m^2 K]

[Rad/s]

CFD RESULTS VENTILATION LOSSES

Transient thermal results

[W]

[km/h]

Structural

Structural results: - Bolt force - Stress - Deformation - etc.

t

WHEEL MOUNTED DISC

• Express double-deck intercity passanger train

• Brake disc dimensions: Doutside=750mm, Dinside=460 mm, t=48,5mm

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Braking mass per disc => 8425 kg

Maximum speed => 200 km/h

Emergency braking energy => 13 MJ

WHEEL MOUNTED DISC

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WHEEL MOUNTED DISC

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WHEEL MOUNTED DISC

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CFD RESULTS

AXLE MOUNTED DISC

• Freight trains

• Brake disc dimensions: Doutside=590mm, Dinside=322 mm, t=170mm

Braking mass per disc => 11250 kg

Maximum speed => 170 km/h

Emergency braking energy => 12,5 MJ

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AXLE MOUNTED DISC GOALS

• LOWER VENTILATION LOSSES

• BETTER HEAT DISSIPATION

• LOWER MASS

• LONGER LIFE CICLE

IDEAS TO ACHIEVE GOALS:

• Optimized hub, mounting bracket

and cooling fin design with

(CFD, FEM, TOPOLOGY OPT.)

• Material type

Starting geometry

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AXLE MOUNTED DISC COOLING FIN SHAPE DESIGN VIA SHAPE PARAMETERIZATION - OVER 150 candidate geometries - 2D rotating domain - SST turb. model - Heat transfer

LOW DRAG DESIGN HIGH WENTILATION DESIGN

• INPUT PARAMETERS • OUTPUT PARAMETERS

Dimension parameters

- Mass flow - Ventilation loses - Avg HTC - Thermal power dissipation - Area, mass of the fin

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AXLE MOUNTED DISC TOPOLOGY OPTIMIZATION

TRANSIENT THERMAL

STRUCTURAL

NEW OPTIMISED DESIGN

OF THE MOUNTING BRACKET

TRANSIENT BODY TEMPERATURE

TRANSFER

OPTIMIZING THE

MOUNING BRACKET

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AXLE MOUNTED DISC

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AXLE MOUNTED DISC

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K25 axle box

• Background

• High series

• A lot of competitors

• 25 tons per axle load

• Goals

• Casting weight reduction of min. 10%

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K25 axle box

• Base for the analysis – existing test for 25t axlebox

• According to that test we made an initial analysis

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K25 axle box • Boundary conditions

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K25 axle box • Optimization

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K25 axle box • Final result

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K25 axle box • Final result: -13% in casting weight

Future plans

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Future with ANSYS

• Weight optimization on existing products

• Disc connecting elements optimization

• Cracks and fatigue evaluation

• Hot spots prediction

• New products development

• Two way coupled simulations

• …

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Thank you for your attention!

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