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Monobloc Railway Wheel Ø957 mm
Curving curve lateral flange guidance and axle static wheel load certification according to EN 13979-1 and GOST standards.
Railway wheels experience severe multiaxial fatigue loading consisting of high vertical axle loads compounded by lateral wheelset steering forces when traversing tight curves. The curved S-profile disk accommodates axial thermal expansion during tread brake application while minimizing stresses in the wheel rim and hub fillets. This FEA verification validates stress distributions and web compliance under the most critical EN 13979-1 operating condition: 1.25P static wheel load coupled with 0.7P lateral flange impact.
1. Geometry & FEA Mesh
- •High-strength wheel steel grade 2 (ГОСТ 10791: E = 210 GPa, ν = 0.28, yield strength 580 MPa).
- •Accurate B-Rep solid revolution of standard Ø957 mm tread wheel with S-curved web transition and inner hub bore Ø190 mm.
- •Machined rim geometry including standard 1:20 / 1:40 conical rolling tread and 28 mm height guide flange.
- •Refined 3D solid mesh with 137,890 elements and 108,400 active degrees of freedom.
2. Loads & Boundary Conditions
- •Rigid cylindrical constraint on the inner axle press-fit bore representing the interference-fit axle shaft.
- •Vertical tread contact force P_v = 156.2 kN (1.25 × 125 kN static wheel load) applied to a localized patch on the wheel tape.
- •Lateral flange guidance force P_lat = 87.5 kN (0.7 × 125 kN) applied directly to the contact zone on the flange face.
3. Simulation Results & Findings
- ✓Peak von Mises stress σ_vm = 182.0 MPa observed in the concave transition fillet between the S-web and the inner rim flange.
- ✓Maximum displacement magnitude |u| = 1.295 mm at the outer edge of the wheel rim under extreme lateral bending.
- ✓Safety factor SF = 3.18 against material yield, comfortably satisfying all UIC and EN 13979-1 railway safety criteria.
Rolling stock manufacturers utilize WebCAE's instant solver to iterate wheel web profiles and verify EN 13979-1 fatigue limits in seconds right in the browser. Transitioning heavy B-Rep solid meshes to the native desktop engine allows engineering teams to certify wheel designs with zero friction.
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