Load-deflection prediction and stress verification in extreme large deformation of rubber suspensions used in rail vehicles

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Load-deflection prediction and stress verification in extreme large deformation of rubber suspensions used in rail vehicles

Luo, R.K. / Peng, L.M. / Wu, X.P. / Mortel, W.J.

Rubber suspensions are important components in railway vehicles. The offset sandwich mount is a type of rubber spring used on rail vehicles as the primary suspension above the axlebox on a bogie. In this installation, a pair of mounts is arranged within a vee configuration, such that the movements in all planes are controlled by a combined shear and compression displacement. This article evaluates the important aspects in the rubber suspension design when using a higher order material properties in an extreme large deformation. On one hand, using a higher order of material model has enabled prediction of larger deformations that are required for the actual product in the ultimate loading used in rail dynamic environment. On the other hand, using a higher order of material model with full integration elements, however, may mislead the design concept to an incorrect direction. It is important to note that the accuracy of the stress calculation is not guaranteed by a reasonable load-deflection prediction, even validated against a test result. Three methods to check the reliability of the calculated stresses are proposed. The investigation has been validated against a laboratory test. It is suggested that a higher order of material model should be used with reduced integration elements.