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12 From Dot - 31361 - DS1

The document outlines the objectives of TTCI to assess the quality of truck casting materials, including evaluating mechanical properties, investigating alternate casting methods, and proposing changes to quality standards. It details the overall approach involving testing, simulations, and industry surveys to improve casting quality and reduce stresses. The findings will inform updates to the AAR M-201 standards for bolsters and side frames.

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Balaji RG
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30 views1 page

12 From Dot - 31361 - DS1

The document outlines the objectives of TTCI to assess the quality of truck casting materials, including evaluating mechanical properties, investigating alternate casting methods, and proposing changes to quality standards. It details the overall approach involving testing, simulations, and industry surveys to improve casting quality and reduce stresses. The findings will inform updates to the AAR M-201 standards for bolsters and side frames.

Uploaded by

Balaji RG
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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1.

2 Objectives
To assess the state of quality of the truck casting material, TTCI had the following objectives:
• Evaluate mechanical properties of truck castings from multiple manufacturers.
• Investigate alternate casting methods.
• Create new or propose changes to truck casting quality standards.
• Review current foundry NDT methods.
• Propose design changes in truck castings to reduce maximum stresses.
• Conduct an industry survey to determine why side frames and bolsters are removed
from service.

1.3 Overall Approach


• Obtain bolsters from multiple foundries; perform chemical and mechanical testing on these
bolsters and analyze data.
• Investigate alternate casting methods by working with suppliers and by using
computer simulations.
• Propose changes to the AAR M-201 standard to improve casting quality.
• Evaluate the effectiveness of various NDT techniques for truck castings in production and in
repair facilities. Evaluate feasibility of radiography as the sole NDT method for truck
castings.
• Employ finite element analysis (FEA) to determine location and magnitude of maximum
stress in a side frame or bolster, then attempt to reduce maximum stress by 20 percent by
analyzing design changes.
• Take proposed AAR M-201 standard changes and other alternate parameters and apply them
to bolsters obtained from a smaller set of foundries. Perform chemical and mechanical
testing on these bolsters and compare to the results from the earlier testing.
• Conduct surveys of multiple railcar manufacturers and repair shops to determine why truck
castings are removed from service.

1.4 Scope
TTCI conducted a comprehensive review of the quality of materials commonly used for bolster
and side frame castings. The results from the material property analysis, NDT effectiveness
evaluations, foundry process simulations, and suggested design changes will be used to improve
the existing practices and standards for AAR M-201 Grade B+ bolsters and side frames.

1.5 Organization of the Report


The report is organized by the following sections:
• Section 2: Initial chemical and mechanical testing
• Section 3: Alternative casting methods

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