ISSN (Online): 2812-9709
Journal Menu
Archive
Last Edition
Vol.3, No.3, 2024: pp.110-117
Investigation of the causes of the fracture of the drive shaft of the electric locomotive
Authors:
Dušan Golubović1
, Raul Turmanidze1
1University of East Sarajevo, Faculty of Mechanical Engineering, East Sarajevo, Bosnia and Herzegovina
2Georgian Technical University (GTU), Department of Production Technologies of Mechanical Engineering,
Tbilisi, Georgia
Received: 14 May 2024
Revised: 11 July 2024
Accepted: 5 August 2024
Published: 30 September 2024
Abstract:
The paper provides a systematic analysis of the origin, spread, and causes of shaft failure in the four-axle electric locomotive series 441. Based on this analysis, recommendations for preventive diagnostic maintenance are provided to timely identify the condition and avoid shaft failure, which is a vital component of the locomotive. Failure to maintain it in a timely manner can lead to catastrophic human, ecological, and material consequences. The paper also presents and explains the fracture surfaces of the locomotive’s hollow drive shaft, following a railway incident that caused the derailment of the rail vehicle, resulting in significant material damage. The presented fracture analysis is based on research into the mechanisms of failure, which by their appearance and action cause the formation of an initial crack. The dominant factor in the formation of the initial crack is material fatigue, and the potential presence of inclusions or local initial notches in the material structure formed during the shaft manufacturing process. Research has shown that the measured residual internal stresses after the shaft failure reached up to 470 MPa, significantly exceeding the allowable 300 MPa.
Keywords:
Drive shaft, Electric locomotive, Reliability, Material fatigue, Fracture, Maintenance
References:
[1] A. Adiman, B. Budiarto, S. Siswanto, Fracture failure analysis on drive shaft component of diesel locomotive. IOP Conference Series: Earth and Environmental Science, 878(1), 2021: 012066. https://dx.doi.org/10.1088/1755-1315/878/1/012066
[2] M. Maglio, E. Kabo, A. Ekberg, Railway wheelset fatigue life estimation based on field tests. Fatigue & Fracture of Engineering Materials & Structures, 45(9), 2022: 2443-2456. https://doi.org/10.1111/ffe.13756
[3] J.-W. Gao, G.-Z. Dai, Q.-Z. Li, M.-N. Zhang, S.-P. Zhu, J.A.F.O. Correia, G. Lesiuk, A.M.P. De Jesus, Fatigue assessment of EA4T railway axles under artificial surface damage. International Journal of Fatigue, 146, 2021:106157.
https://doi.org/10.1016/j.ijfatigue.2021.106157.
[4] C. Yuan, Y. Li, K. Yang, L. Lu, L. Zou, W. Li, D. Zeng, Damage Analysis and Finite Element Simulation of Fretting Wear on Press-Fitted Surface of Railway Axle. Tribology, 40(4), 2020: 520-530. https://doi.org/10.16078/j.tribology.2019186
[5] B. Ebrahimi, N. Henderson, Recommendations to Improve Quality of Safety Indicators in the Railway Industry. 2023 Annual Reliability and Maintainability Symposium (RAMS), 23-26 January 2023, Orlando, USA, 2023, pp.1-6. https://doi.org/10.1109/RAMS51473.2023.10088188
[6] H. Guo, X. Li, X. Liu, An analysis method for fatigue life of rail vehicle axles considering rotation effect of wheelset. Advances in Mechanical Engineering, 14(9), 2022: 16878132221127834. https://doi.org/10.1177/16878132221127834
[7] J. Luo, S.Wang, X. Liu, S. Geng, Fatigue life prediction of train wheel shaft based on load spectrum characteristics. Advances in Mechanical Engineering, 13(2), 2021:1687814021992153. https://doi.org/10.1177/1687814021992153
[8] C. Zhu, J. He, J. Peng, Y. Ren, X. Lin, M. Zhu, Failure mechanism analysis on railway wheel shaft of power locomotive. Engineering Failure Analysis, 104, 2019: 25-38. https://doi.org/10.1016/j.engfailanal.2019.05.013
[9] V. Vuković, Technical and technological feasibility and economic indicators of wreath surfacing of monoblock wheels, quality ER7, for the speed of railway vehicles up to 120 km/h, PhD thesis. University of Novi Sad, Technical Faculty ”Mihajlo Pupin”, Zrenjanin, 2014.
[10] Ž. Adamović, Ž. Milošević, D. Kalabić, V. Vuković, M. Adamović, Machine and plant diagnostics. Society for Energy Efficiency of Bosnia and Herzegovina, Banja Luka, Bosnia and Herzegovina, 2008.
[11] A. Pourheidar, L. Patriarca, S. Beretta, D. Regazzi, Investigation of Fatigue Crack Growth in Full-Scale Railway Axles Subjected to Service Load Spectra: Experiments and Predictive Models. Metals, 11(9), 2021: 1427.
https://doi.org/10.3390/met11091427
[12] M. Bayraktar, N. Tahrali, R. Guclu, Reliability and fatigue life evaluation of railway axles. Journal of Mechanical Science and Technology, 24, 2010: 671-679. https://doi.org/10.1007/s12206-009-1219-1
[13] D.V. Rudavskyi, Yu.I. Kaniuk, Z.A. Duriagina, V.V. Kulyk, M.S. Shefer, I.Ya. Dolinska, Assessing surface fatigue crack growth in railway wheelset axle. Archives of Materials Science and Engineering, 106(2), 2020: 59-67.
https://doi.org/10.5604/01.3001.0014.6973
[14] F. Guo, S. Wu, J. Liu, X. Wu, W. Zhang, An innovative stepwise time-domain fatigue methodology to integrate damage tolerance into system dynamics. Vehicle System Dynamics, 61(2), 2022: 550-572.
https://doi.org/10.1080/00423114.2022.2051567
[15] M. Leite, M. A. Costa, T. Alves, V. Infante, A.R. Andrade, Reliability and availability assessment of railway locomotive bogies under correlated failures. Engineering Failure Analysis, 135, 2022: 106104.
https://doi.org/10.1016/j.engfailanal.2022.106104
[16] B. Bjegojevic, M.C. Leva, N. Balfe, S. Cromie, L. Longo, Physiological Measurements for Real-time Fatigue Monitoring in Train Drivers: Review of the State of the Art and Reframing the Problem. Proceedings of the 31st European Safety and Reliability Conference, 19-23 September 2021, Angers, France, pp.2744-2751.
https://doi.org/10.3850/978-981-18-2016-8_437-cd
[17] S.F. Seyedan Oskouei, M. Abapour, M. Beiraghi, Identifying critical components for railways rolling stock reliability: a case study for Iran. Scientific Reports, 14(1): 2024: 12080. https://doi.org/10.1038/s41598-024-62841-2
[18] V.A. Olentsevich, V.V. Kondratiev, B.O. Kuznetsov, A.I. Karlina, Economic efficiency of the introduction of the automated locomotive reliability management system. SHS Web of Conferences, 112, 2021: 00049.
https://doi.org/10.1051/shsconf/202111200049
[19] M.-S. So, H.-B. Jun, J.-H. Shin, Failure Analysis to Derive the Causes of Abnormal Condition of Electric Locomotive Subsystem. Journal of Society of Korea Industrial and Systems Engineering. The Society of Korea Industrial and Systems Engineering, 41(2), 2018: 84-94 https://doi.org/10.11627/jkise.2018.41.2.084
[20] M. Maglio, T. Vernersson, J.C.O. Nielsen, A. Pieringer, P. Söderström, D. Regazzi, S. Cervello, Railway wheel tread damage and axle bending stress – Instrumented wheelset measurements and numerical simulations. International Journal of Rail Transportation, 10(3), 2021: 275-297. https://doi.org/10.1080/23248378.2021.1932621
[21] International technical standard UIC 811-2- 2ed., Technical specification for the supply of axles for tractive and trailing stock – Tolerances, 2004.
[22] S. Stefanović, Z. Adamović, V. Vuković, R. Milišić, S.Vidović, D. Malešević, Movement of rail vehicles. Society for Energy Efficiency of Bosnia and Herzegovina, Banja Luka, Bosnia and Herzegovina, 2008.
[23] Ž. Stojanović, B. Matijević, S. Stanisavljev, S. Erić, Investigation of fractures mechanisms of railway axles. Zaštita materijala, 62(1), 2021: 51-62. https://doi.org/10.5937/zasmat2101051S
[24] K. Czapczyk, A fatigue testing in complex stress state in the context of problems in the diagnosis and detecting defects in materials of wheels in locomotives. Journal of KONES Powertrain and Transport, 19(4), 2012: 149-154.
[25] T. Makino, H. Sakai, Fatigue property of railway axles for Shinkansen vehicles. Nippon Steel & Sumitomo Metal, Technical Report No.105, 2013: p.56-62.
© 2024 by the authors. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 5
Number 1
March 2026.
How to Cite
D. Golubović, R. Turmanidze, Investigation of the Causes of the Fracture of the Drive Shaft of the Electric Locomotive. Advanced Engineering Letters, 3(3), 2024: 110-117.
https://doi.org/10.46793/adeletters.2024.3.3.3
More Citation Formats
Golubović, D., & Turmanidze, R. (2024). Investigation of the Causes of the Fracture of the Drive Shaft of the Electric Locomotive. Advanced Engineering Letters, 3(3), 110-117.
https://doi.org/10.46793/adeletters.2024.3.3.3
Golubović, Dušan, & Raul Turmanidze. “Investigation of the Causes of the Fracture of the Drive Shaft of the Electric Locomotive.“ Advanced Engineering Letters, vol. 3, no. 3, 2024, pp. 110-117.
https://doi.org/10.46793/adeletters.2024.3.3.3
Golubović, Dušan, and Raul Turmanidze. 2024. “Investigation of the Causes of the Fracture of the Drive Shaft of the Electric Locomotive.“ Advanced Engineering Letters, 3 (3): 110-117.
https://doi.org/10.46793/adeletters.2024.3.3.3
Golubović, D., and Turmanidze, R. (2024). Investigation of the Causes of the Fracture of the Drive Shaft of the Electric Locomotive. Advanced Engineering Letters, 3(3), pp. 110-117.
doi: 10.46793/adeletters.2024.3.3.3.