Numerical and experimental characterization of a railroad switch machine

This contribution deals with the numerical and experimental characterization of the structural behavior of a railroad switch machine. Railroad switch machines must meet a number of safety-related conditions such as, for instance, exhibiting the appropriate resistance against any undesired movements of the points due to the extreme forces exerted by a passing train. This occurrence can produce very high stress on the components, which has to be predicted by designers. In order to assist them in the development of new machines and in defining what the critical components are, FEA models have been built and stresses have been calculated on the internal components of the switch machine. The results have been validated by means of an ad-hoc designed experimental apparatus, now installed at the facilities of the Department of Industrial Engineering of the University of Bologna. This apparatus is particularly novel and original, as no Standards are available that provide recommendations for its design, and no previous studies have dealt with the development of similar rigs. Moreover, it has wide potential applications for lab tests aimed at assessing the safety of railroad switch machines and the fulfilment of the specifications by many railway companies

On Hirth Ring Couplings: Design Principles Including the Effect of Friction

Rings with Hirth couplings are primarily used for the accurate positioning of axial-symmetric components in the machine tool industry and, generally, in mechanical components. It is also possible to use Hirth rings as connection tools. Specific industries with special milling and grinding machines are able to manufacture both tailor made and standard Hirth rings available on stock. Unfortunately, no international standard (for instance ISO, DIN or AGMA) is available for the production and the design of such components. In the best-case scenario, it is possible to find simplified design formulae in the catalogue of the suppliers. The aim of this work is to provide some accurate formulae and computational methods for design to provide better awareness on the limitations and the potential of this type of connection. The work consists of five parts: (i) a review of the base calculation derived mainly from the catalogues of manufacturers; (ii) an improved calculation based on a new analytical method including the friction phenomenon; (iii) an experimentation run for validating the method; (iv) a case study applied to a machine tool; and, (v) a closed form formulation to determine an upper threshold for friction, thus ensuring the Hirth coupling regular performance

A Practical Approach to Gear Design and Lubrication: A Review

The modern design of mechanical parts, such as gears, goes through the continuous demand for a high level of efficiency and reliability, as well as an increased load carrying capacity and endurance life. The aim of the present paper was to perform a review and to collect practical examples in order to provide interesting tips and guidelines for gear design, including both its dimensioning and its lubrication. From this point of view, this paper is particularly novel, as it is a full-comprehensive collection of all the tools supporting gear design. Several practical aspects have been taken into account, including the definition of the right profile shifting, the selection of a proper lubricant, and the definition of the quality grade and of the tolerances needed to obtain the correct backlash. Finally, a numerical example is provided, addressing the research of the best solution to fit a given space, while maximizing the transmittable torque over weight ratio for two mating spur gears

A methodology for the lightweight design of modern transfer machine tools

This paper deals with a modern design approach via finite elements in the definition of the main structural elements (rotary table and working unit) of an innovative family of transfer machine tools. Using the concepts of green design and manufacture, as well as sustainable development thinking, the paper highlights the advantages derived from their application in this specific field (i.e., the clever use of lightweight materials to allow ruling out high-consumption hydraulic pump systems). The design is conceived in a modular way, so that the final solution can cover transfers from four to 15 working stations. Two versions of the machines are examined. The first one has a rotary table with nine divisions, which can be considered as a prototype: this machine has been studied in order to set up the numerical predictive model, then validated by experimental tests. The second one, equipped with a rotary table with 15 divisions, is the biggest of the range: this machine has been entirely designed with the aid of the previously developed numerical model. The loading input forces for the analyses have been evaluated experimentally via drilling operations carried out on a three-axis CNC unit. The definition of the design force made it possible to accurately assess both the rotary table and the working units installed in the machine

INFLUENCE OF THE STIFFNESS AND FRICTIONAL CHARACTERISTICS ON THE SHANK TORQUE OF SCREWS IN BOLTED JOINTS

This work aims at determining the influence of tribological and stiffness characteristics of a bolted joint on the residual shank torque of the screw. Even if it is commonly accepted to consider such a residual torque equal to half the torque at the thread, the literature lacks experimental data about the topic. The residual shank torque combines with the axial preload and the external loads to bring about the overall stress on the screw. Hence, the higher the residual torque, the lower the admissible external load for given size and class of the screw. From there stems the need for an analytical tool allowing the designer to calculate the residual torque as a function of the key parameters of the joint

Numerical and Experimental Characterization of a Railroad Switch Machine

This contribution deals with the numerical and experimental characterization of the structural behavior of a railroad switch machine. Railroad switch machines must meet a number of safety-related conditions such as, for instance, exhibiting the appropriate resistance against any undesired movements of the points due to the extreme forces exerted by a passing train. This occurrence can produce very high stress on the components, which has to be predicted by designers. In order to assist them in the development of new machines and in defining what the critical components are, FEA models have been built and stresses have been calculated on the internal components of the switch machine. The results have been validated by means of an ad-hoc designed experimental apparatus, now installed at the facilities of the Department of Industrial Engineering of the University of Bologna. This apparatus is particularly novel and original, as no Standards are available that provide recommendations for its design, and no previous studies have dealt with the development of similar rigs. Moreover, it has wide potential applications for lab tests aimed at assessing the safety of railroad switch machines and the fulfilment of the specifications by many railway companies

Fatigue response of as built DMLS processed Maraging Steel and effects of machining and heat and surface treatments

The main motivations for this study arise from the need for an assessment of the fatigue performance of DMLS produced Maraging Steel MS1, when it is used in the \u201cas fabricated\u201d state. The literature indicates a lack of knowledge from this point of view, moreover the great potentials of the additive process may be more and more incremented, if an easier and cheaper procedure could be used after the building stage. The topic has been tackled experimentally, investigating the impact of heat treatment, machining and micro-shot-peening on the fatigue strength with respect to the \u201cas built state\u201d. The results indicate that heat treatment significantly enhances the fatigue response, probably due to the relaxation of the post-process tensile residual stresses. Machining can also be effective, but it must be followed (not preceded) by micro-shot-peening, to benefit from the compressive residual stress state generated by the latter

Effects of build orientation and thickness of allowance on the fatigue behaviour of 15–5 PH stainless steel manufactured by DMLS

The present study is focused on the fatigue strength of 15–5 PH stainless steel, built by Direct Metal Laser Sintering. Six-specimen sets were manufactured, mechanically and thermally treated and tested under rotating bending fatigue. The study investigates the effects of the build orientation (parallel, perpendicular, or 45° inclined with respect to the vertical stacking direction) and of allowance for machining (1 mm or 3 mm at gage). The results, processed by an ANOVA methodology, indicate that allowance for machining has a beneficial effect on the fatigue response. Removing the surface irregularities, averagely leads to a 19% enhancement of the fatigue limit. The build orientation also becomes beneficial, when the slanted samples are included in the experiment. In this case, a fatigue strength increase up to 20% can be achieved. Further developments will include the investigation of the effects of heat and surface treatments, involving also further materials in the study.The authors wish to acknowledge the support of European Commission through the project “Advanced design rules for optimal dynamic properties of additive manufacturing products – A_MADAM”, which has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No 734455.Publishe

Fatigue Response of As-Built DMLS Maraging Steel and Effects of Aging, Machining, and Peening Treatments

The main motivations for this study arise from the need for an assessment of the fatigue performance of DMLS-produced Maraging Steel MS1, when it is used in the \u201cas fabricated\u201d state. The literature indicates a lack of knowledge from this point of view; moreover, the great potentials of the additive process may be more and more incremented, if an easier and cheaper procedure could be used after the building stage. The topic has been tackled experimentally, investigating the impact of heat treatment, machining, and micro-shot-peening on the fatigue strength with respect to the \u201cas built state\u201d. The results indicate that heat treatment may improve the fatigue response, as an effect of the relaxation of the process-induced tensile residual stresses. Machining can also be effective, but it must be followed (not preceded) by shot-peening, to benefit from the compressive residual stress state generated by the latter. Moreover, heat treatment and machining are related by a strong positive interaction, meaning their effects are synergistically magnified when they are applied together. The experimental study has been completed by fractographic as well as micrographic analyses, investigating the impact of the heat treatment on the actual microstructure induced by the stacking process

Experimental study on the sensitivity of DMLS manufactured Maraging Steel fatigue strength to the build orientation and allowance for machining

This work derives its motivations from the increasing interest towards Additive Manufacturing and the lack of studies, mainly in the field of fatigue. The effect of build orientation and of allowance for machining on DMLS produced Maraging Steel MS1 has been assessed. The experimental results, properly set up by tools of Design of Experiment, have been statistically processed and compared. The outcomes were that, probably due to effect of the thermal treatment, machining and material properties, the aforementioned factors do not have a significant impact on the fatigue response. This made it possible to work out a global curve that accounts for all the results, consisting in a high amount of data points. This can be regarded as one of the most generable and reliable fatigue models being currently available in the literature. Fracture surfaces have been carefully studied as well, individuating the initiation points being usually located at sub-surface porosities. Micrographies along the stacking direction and the build plane have been performed as well.The authors wish to acknowledge the support of European Commission through the project “Advanced design rules for optimal dynamic properties of additive manufacturing products – A_MADAM”, which has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No 734455.Publishe