No06SCI2009JMST 235 pp1225-1233
No06SCI2009JMST 235 pp1225-1233
No06SCI2009JMST 235 pp1225-1233
net/publication/245571559
Reliability Analysis and Preventive Maintenance for Fatigue Life of End Beam
for Uncovered Freight Car
CITATIONS READS
4 230
5 authors, including:
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Shape Optimization of Impeller Blades for Bidirectional Axial Flow Pump View project
All content following this page was uploaded by Seok Heum Baek on 02 November 2020.
(Manuscript Received March 12, 2007; Revised February 14, 2008; Accepted September 1, 2008)
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Abstract
As the cumulative running times of a locomotive truck increases, degradation such as fatigue, wear, and deterioration
occur. Particularly the container train and uncovered freight train, their maintenance cost during their lifetime is three
times more than the manufacturing cost. Generally, for the freight train, corrective maintenance to repair a bad part
after a breakdown is not adapted; however, preventive maintenance that fixes a bad part before a breakdown is. There-
fore, it is important and necessary to establish a system of optimal preventive maintenance and exact maintenance pe-
riod. This study attempts to propose a preventive maintenance procedure that predicts a repair period using reliability
function and instantaneous failure rate based on fatigue test and load history data. Additionally, this method is applied
to the end beam of an uncovered freight train, which is the brake part, and its usefulness is examined and analyzed.
Keywords: Preventive maintenance; Cumulative fatigue damage; Miner’s rule; Maximum likelihood estimator; Kaplan-Meier estimator
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
objectives.
1. Introduction
According to the time of maintenance executed,
The performance of locomotive truck frames de- maintenance is usually divided into two major catego-
creases as the cumulative running time increases. Its ries: corrective maintenance (CM) and preventive
causes are expected to be fatigue, wear, and deteriora- maintenance (PM) [6-11]. The former corresponds to
tion. New inspection and repair methods are needed the actions that occur after the system breaks down,
for their safety because freight trains require higher while the latter corresponds to the actions that take
speed and longer running time. In the case of con- place while the system is operating. Most investiga-
tainer and uncovered freight trains, the maintenance tions on preventive maintenance have been limited by
cost is about three times more than their manufactur- regular inspection time or components management.
ing cost during their lifetime [1, 2]. Therefore, it is Since the performance test or endurance test of freight
important to establish an optimal preventive mainte- trains is achieved in proving railroad, its reliability
nance schedule to minimize the total cost with the estimation is very difficult to obtain.
desired or specified levels of operational safety and Reliability estimation function can be predicted by
reliability [3-5]. It can also maximize the availability probability density function, cumulative distribution
of the components and optimize some other specified function, or hazard rate function, which is a function
†This paper was recommended for publication in revised form by Associate of replacement time (or fatigue crack initiation time)
Editor Chongdu Cho based on the maintenance records. The preventive
*
Corresponding author. Tel.: +82 51 2007651, Fax.: +82 51 2007656
maintenance of freight trains is very useful because
E-mail address: [email protected]
© KSME & Springer 2009 the demand prediction of their parts through reliabil-
1226 S.-H. Baek et al. / Journal of Mechanical Science and Technology 23 (2009) 1225~1233
1/ m
⎛ n m⎞
⎜ ∑ ln ti ⎟
η = ⎜ i =1 ⎟ (3)
⎜ r ⎟
⎜⎜ ⎟⎟
⎝ ⎠
-
to (6), respectively. 300
T-type welding, R= 1
Fracture
250 No Fracture
R (t ) = exp ⎢⎜ − ⎟ ⎥
⎣ 6 i =1
(4) = 0.405
⎦
⎢⎣⎝ η ⎠ ⎥⎦ 150
P = 95%
50%
5%
⎡⎛ t ⎞ m ⎤ 100
F (t ) = 1 − exp ⎢⎜ − ⎟ ⎥ (5)
⎢⎣⎝ η ⎠ ⎥⎦ 50
52.8
f (t ) = ⎜ ⎟ (6)
η ⎝η ⎠ ⎢⎣⎝ η ⎠ ⎥⎦ 4
10 10
5
10
6
10
7
Furthermore, the hazard rate function (instantane- Fig. 3. P-S-N curve for SS400 steel.
ous failure rate function) is the ratio of probability
3. Freight train preventive maintenance sched-
density function to reliability function. It is expressed
uling
as Eq. (7).
3.1 P-S-N curve of SS400 steel
m −1
m⎛ t ⎞ The material of the end beam for an uncovered
h(t ) = ⎜ ⎟ (7)
η ⎝η ⎠ freight train is SS400 steel. Its fatigue test was per-
formed by the Schenck-type twisting and bending
The Kaplan-Meier estimator [12, 14] for fatigue fatigue testing machine under the maximum bending
data with censored observations is used in this study. moment of 4 kg·m, frequency of 1,800 rpm, and
It is compared with the median that corresponds to stress ratio of -1 (Fig. 2). The static and dynamic test
more than 50% of the failure probability. The Kaplan- results of the T-type welded specimens are introduced
Meier estimator of hazard rate function and reliability in the references [2]. See references for further details.
function are expressed as Eqs. (8) and (9), respec- A P-S-N (probabilistic-stress-life) curve can be ob-
tively. tained from JSME S002.
Fig. 3 shows the P-S-N curve for SS400 steel. The
⎛ dj ⎞ relationship between stress amplitude and fatigue life
R (t ) = ∏ (1 − h j (t ) ) = ∏ ⎜1 −
⎜ nj
⎟
⎟
(8) is given in Eq. (10).
j∈t j < t j∈t j < t ⎝ ⎠
dj log N = 6.728 − 0.0094∆s / 2 ± 0.405 (10)
h j (t ) = (9)
nj
The mean of the fatigue limit by the JSME statisti-
cal S-N testing method was 52.8 MPa.
where n is the total number of units, nj and dj denote
the number of subjects that survive just before time tj
3.2 Estimation of loading history
and the number of failure occurring at time tj , respec-
tively. It is very difficult to change the size of the end beam
1228 S.-H. Baek et al. / Journal of Mechanical Science and Technology 23 (2009) 1225~1233
Stress
G1 G2 G3 G4 G5 G6
(MPa)
Min. 0.51 36.26 36.75 70.65 31.14 3.41
Max. 7.74 48.26 51.62 94.14 72.02 6.96
Mean 3.71 8.47 8.83 13.28 0.13 0.4
Location
Modified Palmgren-Miner rule
number
Fig. 7. Result of the rainflow cycle counting histogram.
Mean stress
Life Damage Year
correction
G1 Unlimited 0 Unlimited
G2 983,700 1.02×10-6 46.79
G3 360,400 2.77×10-6 17.14
None
G4 209,800 4.77×10-6 7.98
G5 5,146,000 1.94×10-7 244.78
G6 170×106 5.88×10-9 8,086
G1 23.2×106 4.31×10-8 4,833
G2 35,350 2.83×10-5 7.36
G3 36,550 2.74×10-5 7.61
Goodman
G4 14,010 7.14×10-5 2.92
G5 50,780 1.97×10-5 10.58
G6 11.5×106 8.69×10-8 2,397
100
Parametric
reliability function
95% lower bound
80
95% upper bound
Reliability function, %
60
40
20
0 2 4 6 8 10 12 14
Fatigue life, year
Table 3. Estimation of the two-parameter Weibull distribu- Table 4. Percentile and hazard function for cumulative failure
tion. probability.
vent failure during the random failure period. Fur- Des., 12 (4) (1999) 614-621.
thermore, the middle inspection of the end beam [4] C. Marquardt and H. Zenner, Lifetime Calculation
should be performed within 1.5 years for planned under Variable Amplitude Loading with the Appli-
preventive maintenance. cation of Artificial Neural Networks, Int. J. Fatigue,
27 (8) (2005) 920-927.
[5] C. H. Bae, Y. Chu, H. J. Kim, J. H. Lee and M. W.
4. Conclusions
Suh, A Study on Maintenance Reliability Alloca-
This study performed the reliability analysis of fa- tion of Urban Transit Brake System Using Hybrid
tigue accumulation damage in a freight train using the Neuro-Genetic Technique, Journal of Mechanical
damage summation method. The main results are as Science and Technology, 21 (1) (2007) 32-47.
follows. [6] R. Cooke and J. Paulsen, Concepts for Measuring
(1) The fatigue life for the end beam of a freight Maintenance Performance and Methods for Analys-
train is predicted at a variable amplitude loading with ing Competing Failure Modes, Reliability Engineer-
the modified Miner hypothesis of cumulative damage. ing and System Safety, 55 (2) (1997) 135-141.
The longer the running time of the end beam is, the [7] I. Gertsbakh, Reliability Theory: With Application
higher the failure rate. Therefore, preventive mainte- to Preventive Maintenance, Springer-Verlag Berlin
nance is available if a specific failure rate is applied to Heidelberg New York, (2000).
the maintenance schedule. [8] S. E. Rigdon and A. P. Basu, Statistical Methods for
(2) The shape, scale, and median parameters in the the Reliability of Repairable Systems, Wiley, New
approximated Weibull distribution are 2.92, 7.24, and York, (2000).
6.386 years, respectively. The median above is simi- [9] R. K. Mobley, An Introduction to Preventive Main-
lar to the median evaluated by the Kaplan-Meier tenance, Second Edition, Butterworth-Heinemann,
method. (2002).
(3) Due to the different local life distributions of the [10] Y. Zhao, V. Volovoi, M. Waters and D. Mavris, A
end beam, random failure probability is very high. Sequential Approach for Gas Turbine Power Plant
Therefore, middle inspection of the truck frame Preventative Maintenance Scheduling, ASME J.
should be performed within 1.5 years (instantaneous Eng. Gas Turbines Power, 128 (4) (2006) 796-805.
failure rate of 1%) for planned preventive mainte- [11] Y. H. Park and J. Tang, Optimum Replacement
nance. Interval for Mechanical Components Based on Fa-
tigue Reliability, ASME J. Pressure Vessel Technol.,
129 (4) (2007) 683-688.
Acknowledgment
[12] B. W. Turnbull, Nonparametric Estimation of a
This study was supported by research funds from Survivorship Function with Doubly Censored Data,
Dong-A university. Journal of the American Statistical Association, 69
(345) (1974) 169-173.
[13] G. Li, On Nonparametric Likelihood Ratio Esti-
References
mation of Survival Probabilities for Censored Data,
[1] S. H. Baek, K. Y. Lee, S. S. Cho and W. S. Joo, Statistics & Probability Letters, 25 (2) (1995) 95-
Reliability-based Optimization for Fatigue Mainte- 104.
nance Planning of Freight Car, 10th International [14] W. Q. Meeker and L. A. Escobar, Statistical
Conference on the Mechanical Behavior of Materi- Method for Reliability Data, John Wiley & Sons,
als, The Mechanical Behavior of Materials X: Ses- (1998).
sion 14, Korea, (2007) 1369-1372. [15] M. Matsuishi and T. Endo, Fatigue of metals sub-
[2] S. H. Baek, S. S. Cho and W. S. Joo, Fatigue Life jected to varying stress-fatigue lives under random
Prediction Based on the Rainflow Cycle Counting loading. Proc. Kyushu District Meeting, JSEM, Fu-
Method for the End Beam of a Freight Car Bogie, kuoka, Japan, (1968) 37-40.
Int. J. Automotive Technology, 9 (1) (2008) 95-101. [16] S. D. Dowing and D. F. Socie, Simplified Rain-
[3] Z. H. Jiang, L. H. Shu and B. Benhabib, Steady- flow Cycle Counting Algorithms, Int. J. Fatigue, 4
State Reliability Analysis of Repairable Systems (1) (1982) 31-40.
Subject to System Modifications, ASME J. Mech. [17] H. Wang, N. H. Kim and Y. J. Kim, Safety Enve-
S.-H. Baek et al. / Journal of Mechanical Science and Technology 23 (2009) 1225~1233 1233
lope for Load Tolerance and its Application to Fa- Cho is currently a Professor at the Vehicle Engineering at
tigue Reliability Design, ASME J. Mech. Des., 128 Kangwon National University in Kangwon-do, Korea. Dr.
(4) (2006) 919-927. Cho works on crack growth modeling and composite
[18] C. H. McInnes and P. A. Meehan, Equivalence of design and optimization, and his research interests are in
Four-point and Three-point Rainflow Cycle Count- the areas of structural optimization and inverse and identi-
ing Algorithms, Int. J. Fatigue, 30 (3) (2008) 547- fication problems, and X-ray diffraction, brittle collapse
559. and crack propagation, fatigue fracture phenomena.
[19] M. A. Miner, Cumulative Damage in Fatigue,
Journal of Applied Mechanics, 12 (1945) 159-164. Hyun-Su Kim received a B.S.
[20] J. J. Xiong and R. A. Shenoi, A Reliability-based degree in Mechanical Engineering
Data Treatment System for Actual Load History, from Seoul National University in
Fatigue Fract. Engng. Mater. Struct., 28 (10) 1978. He then went on to receive
(2005) 875-889. his M.S. from KAIST in 1980 and
[21] W. Nelson, Applied Life Data Analysis, John Ph.D. degree from University of
Wiley & Sons, (1982). Iowa in 1989. Dr. Kim is cur-
[22] Fe-safe Software Package Ver. 5, Volume 3- rently a Professor at the Mecha-
Signal Processing Reference Manual, Section 7, 1- nical Engineering at Dong-A University in Busan, Korea.
14, Safe Technology Limited, (2003). His research interests are in the area of high temperature
[23] MINITAB User’s Guide #2, Data Analysis and creep fatigue, bio-engineering, design using the finite
Quality Tools, Minitab Inc, (2000). element method, optimization, and MEMS.
[24] R. B. D'Agostino and M. A. Stephens, Goodness-
of-Fit Techniques, Marcel Dekker, (1986). Won-Sik Joo received a B.S.
[25] E. Castillo, M. Lopez-Aenlle, A. Ramos, A. Fer- degree in Mechanical Engineering
nandez-Canteli, R. Kieselbach and V. Esslinger, from Dong-A University in 1968.
Specimen Length Effect on Parameter Estimation in He then went on to receive his
Modelling Fatigue Strength by Weibull Distribution, M.S. from Dong-A University in
Int. J. Fatigue, 28 (9) (2006) 1047-1058. 1978 and Ph.D. degree from
Kookmin University in 1988. Dr.
Joo is currently a Professor at the
Seok-Heum Baek received a B.S. Mechanical Engineering at Dong-A University in Busan,
and M.S. degree in Mechanical Korea. His research interests are in the area of creep and
Engineering from the Dong-A fatigue in high temperature alloy, fatigue design, and
University in 2001 and 2003, strength evaluation.
respectively. He is currently a
Ph.D. student at the School of
Mechanical Engineering at Dong-
A University in Busan, Korea.
Student Baek works on ceramic composite design and
robust and reliability-based design, and his research inter-
ests are in the areas of trade-off analysis in multicriteria
optimization, design under uncertainty with incomplete
information, and probabilistic design optimization.