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Monash's Prof Rhys Jones (middle) uses the infrared test camera to
measure stresses in an Australian bogie.
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One major challenge facing the railway industry is the reduction of
rollingstock tare weight without compromising safety or durability.
With potential use of new materials and designs in both
rollingstock and rail infrastructure it is critical to develop a
means to accurately assess the safety of new designs and products
which could develop flaws when in operational service.
The two major aims of this project were to: a) develop the loading
spectrum for design purposes appropriate to the Australian railway
systems and b) develop improved design and analysis procedures to
convert the design spectrum into improved designs based on both
stress and durability. Specifically, the project aimed to develop
designs and assessment processes for bogies and wheels.
The project was completed in 2005, and made significant advances in
bogie design and understanding how to assess bogie designs. The
benefits to the rail industry of incorporating the research
outcomes include:
- Potential to carry higher loads (as a result of less tare, as well
as higher gross loads due to stronger bogies)
- Enhanced purchasing decisions for new rollingstock
- Reduced risk of catastrophic failure, which could include
derailment
- Potential for a rail company to sustain/protect its reputation as a
safe mode of transport
Evaluated by STEM Partnerships in 2006, the project was estimated
to have the potential to deliver a risk-free-value to the rail
industry of $4 million over the next 15 years, and an expected
value of $0.8 million taking into account the risks involved in
delivering the technology to industry.
Results to date:
- Completed instrumentation of a bogie from Freight Australia capable
of capturing the vertical load spectrum and structural response on
standard gauge track
- Development of unique design philosophy and tools for rapid
assessment of safety and durability in rail components under
Australian operational loads completed
- Application of stress based design tools for durability wheel
geometries completed
- Development of automated failure (by fracture) assessment
capability for rail structures using NASTRAN
- Commissioned infrared testing facility for infrastructure
assessment via thermal imaging camera and proved facility as a
valuable resource for industry for: validating finite element
designs; assessing the fatigue performance of sideframes and
bogies; finding sub-surface casting defects in sideframes and
bogies; assessing the level of optimisation in sideframes and
bogies; and predicting the effect of small casting defects on the
durability and safety of sideframes and bogies.
- A number of Rail CRC participants have utilised the research and
Rail CRC testing facility to assist their infrastructure assessment
needs.
Project Leader: Professor Rhys Jones (Monash)
Project Manager: Mr Doug Cumming (Bradken)
