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Fatigue design and test on Chevron rubber springs used in rail vehicles

Luo, RK; Mortel, WJ; Spinks, AD; Wu, XP; (2010) Fatigue design and test on Chevron rubber springs used in rail vehicles. In: Heinrich, G and Kaliske, M and Lion, A and Reese, S, (eds.) CONSTITUTIVE MODELS FOR RUBBER VI. (pp. 249 - 254). CRC PRESS-TAYLOR & FRANCIS GROUP

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Abstract

This paper is about the fatigue design issues on rubber-to-metal bonded springs used in railway industry. The investigation, based on the actual fatigue loads, is carried out on these failed and modified products using a method of continuum mechanics. To simplify the simulation, a non-linear quasi-static analysis is carried out and then the residual stresses are superimposed to obtain the effective stress range to predict the metal crack initiation. For the rubber parts of the spring a three-dimensional effective stress criterion is employed to predict the fatigue crack initiation. The fatigue crack initiation for the metal parts of the failed component is predicted at 225 K cycles under specified fatigue load against total metal broken at 700 K cycles from the test. For the rubber spring, subsequently modified and optimised, the total fatigue life for the metal parts of the component, is 8.0 million cycles against 1 75 million cycles from the test without any crack observed. The rubber fatigue crack initiation is predicted at 90 K cycles against crack onset around 79 K cycles and crack length 40 mm at 145 K cycles from the test. From the design point of view it is important to optimize the rubber profile under this very tight allowable space to provide the maximum support of the metal interleaves and at the same time to meet the minimum requirements of the manufacture process.

Type:Proceedings paper
Title:Fatigue design and test on Chevron rubber springs used in rail vehicles
Event:6th European Conference on Constitutive models for Rubber
Location:Dresden, GERMANY
Dates:2009-09-07 - 2009-09-10
ISBN-13:978-0-415-56327-7
Keywords:INTEGRATED DYNAMIC SIMULATION, RESIDUAL-STRESS, CRACK GROWTH, LIFE
UCL classification:UCL > School of BEAMS > Faculty of Engineering Science > Civil, Environmental and Geomatic Engineering

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