PSI - Issue 46

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2021) 000–000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2021) 000–000

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Procedia Structural Integrity 46 (2023) 49–55

5th International Conference on Structural Integrity and Durability A method to reduce computation time in finite element simulations of deep rolling 5th International Conference on Structural Integrity and Durability

J. Bialowas a *, M. Pletz b , S. Gapp a , J. Maierhofer a a Materials Center Leoben Forschung GmbH, Roseggerstraße 12, 8700 Leoben, Austria b Designing Plastics and Composite Materials, Department of Polymer Engineering and Science, Montanuniversität Leoben, Franz-Josef-Straße 18, 8700 Leoben, Austria J. Bialowas a *, M. Pletz b , S. Gapp a , J. Maierhofer a a Materials Center Leoben Forschung GmbH, Roseggerstraße 12, 8700 Leoben, Austria b Designing Plastics and Composite Materials, Department of Polymer Engineering and Science, Montanuniversität Leoben, Franz-Josef-Straße 18, 8700 Leoben, Austria

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers Abstract Wheelset axles are railway components which have to meet the highest safety requirements. Compressive residual stresses at the surface increase the endurance limit of wheelset axles which must withstand rotating bending. Deep rolling is a surface treatment method to induce such favorable stresses, but their prediction is still challenging both with experimental and computational methods. The computation time for such a finite element analysis is high. Explicit computations with the use of mass scaling and the application of a coarser mesh are commonly used possibilities to reduce the computation time. In this work, a solution for an implicit model of the deep rolling process will be presented which uses a combination of coupled boundary conditions and so called “shadow” elements. With this setup it is possible to reduce the computation time by a factor of 25 compared to previous models with similar accuracy and resolution. © 2021 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers. Keywords: deep rolling; wheelset axle; work hardening; coupled boundary conditions; finite element modeling 1. Introduction Deep rolling is a surface treatment process with a wide range of applications. The aircraft, automotive and railroad industries are researching the effects of deep rolling on their components such as turbine blades by Bäcker et al. Abstract Wheelset axles are railway components which have to meet the highest safety requirements. Compressive residual stresses at the surface increase the endurance limit of wheelset axles which must withstand rotating bending. Deep rolling is a surface treatment method to induce such favorable stresses, but their prediction is still challenging both with experimental and computational methods. The computation time for such a finite element analysis is high. Explicit computations with the use of mass scaling and the application of a coarser mesh are commonly used possibilities to reduce the computation time. In this work, a solution for an implicit model of the deep rolling process will be presented which uses a combination of coupled boundary conditions and so called “shadow” elements. With this setup it is possible to reduce the computation time by a factor of 25 compared to previous models with similar accuracy and resolution. © 2021 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers. Keywords: deep rolling; wheelset axle; work hardening; coupled boundary conditions; finite element modeling 1. Introduction Deep rolling is a surface treatment process with a wide range of applications. The aircraft, automotive and railroad industries are researching the effects of deep rolling on their components such as turbine blades by Bäcker et al.

* Corresponding author. Tel.: +43-3842-45922-549 E-mail address: jakob.bialowas@mcl.at * Corresponding author. Tel.: +43-3842-45922-549 E-mail address: jakob.bialowas@mcl.at

2452-3216 © 2021 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers. 2452-3216 © 2021 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers.

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers 10.1016/j.prostr.2023.06.009