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1 ECS Weld Geometry Standards www.esveld.com www.rail.tudelft.nl FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology Esveld Consulting Services

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Page 1: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

1

ECSECS Weld Geometry StandardsWeld Geometry Standards

www.esveld.comwww.esveld.com www.rail.tudelft.nlwww.rail.tudelft.nl

FORCE-BASED ASSESSMENT

OFWELD GEOMETRY

FORCE-BASED ASSESSMENT

OFWELD GEOMETRY

Coenraad EsveldCoenraad EsveldDelft University of Technology

Esveld Consulting ServicesDelft University of Technology

Esveld Consulting Services

Page 2: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

www.esveld.comwww.esveld.com www.rail.tudelft.nlwww.rail.tudelft.nl

DAMAGE DUE TO POOR WELD GEOMETRYDAMAGE DUE TO POOR WELD GEOMETRY

Page 3: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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EXISTING WELD GEOMETRY STANDARDSEXISTING WELD GEOMETRY STANDARDS

For example

Versine: 0 < p < 0.3 mm

For example

Versine: 0 < p < 0.3 mm

p < 0.3 mmp < 0.3 mm

Grind off topGrind off top

Page 4: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

www.esveld.comwww.esveld.com www.rail.tudelft.nlwww.rail.tudelft.nl

The dynamic contact force as a function of the first

time derivative:

The dynamic contact force as a function of the first

time derivative:

VELOCITY APPROACHVELOCITY APPROACH

z

v

u(t) = z(t) M

K

2dyn

dzF C v* dx

2dyn

dzF C v* dx

Page 5: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

www.esveld.comwww.esveld.com www.rail.tudelft.nlwww.rail.tudelft.nl

QI ≤ 1: Accepted QI > 1: Rejected

QI ≤ 1: Accepted QI > 1: Rejected

QUALITY INDICES (QI)QUALITY INDICES (QI)

max max

norm

norm

dzF dxQI 1 OK

dzFdx

max max

norm

norm

dzF dxQI 1 OK

dzFdx

Page 6: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

www.esveld.comwww.esveld.com www.rail.tudelft.nlwww.rail.tudelft.nl

FORCE-BASED STANDARDSFORCE-BASED STANDARDS

Velocity FDyn Inclination

40 km/h 5 kN 3.2 mrad

80 km/h 15 kN 2.4 mrad

140 km/h 35 kN 1.8 mrad

200 km/h 65 kN 0.9 mrad

300 km/h 140 kN 0.7 mrad

100 km/h 50 kN 1.4 mrad

QI=1QI=1

Co

nve

ntio

nal

Co

nve

ntio

nal

HS

LH

SL

HH

HH

Imp

lem

ente

d in

RA

ILP

RO

FIm

ple

men

ted

in R

AIL

PR

OF

To

tal f

orc

e in

pri

nci

ple

22

5 k

NT

ota

l fo

rce

in p

rin

cip

le 2

25

kN

Page 7: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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NEW VERSUS OLD NORMNEW VERSUS OLD NORM

VelocityVersine

[mm]Inclination

[mrad]

40 km/h 0.96 3.2

80 km/h 0.72 2.4

140 km/h 0.54 1.8

200 km/h 0.27 0.9

300 km/h 0.21 0.7

Old Norm 0.30 1.0

0

dz 2z

dx2

0.3 1.0mrad2

0

dz 2z

dx2

0.3 1.0mrad2

0

2 xz z sin

0

2 xz z sin

2m 2m

02z02z

0z 0.3mm0z 0.3mm

For 80 km/h the new norm is 2.4 times more favorable than the old norm, provided short waves have been ground off.For 80 km/h the new norm is 2.4 times more favorable than the old norm, provided short waves have been ground off.

Page 8: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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LATERAL GEOMETRY STANDARDSLATERAL GEOMETRY STANDARDS

Velocity Versine

40 km/h 1.0 mm

80 km/h 0.7 mm

140 km/h 0.5 mm

200 km/h 0.5 mm

300 km/h 0.5 mm

QI=1QI=1

Imp

lem

ente

d in

RA

ILP

RO

FIm

ple

men

ted

in R

AIL

PR

OF

Page 9: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

www.esveld.comwww.esveld.com www.rail.tudelft.nlwww.rail.tudelft.nl

ASSESSMENT OLD AND NEW ON PRORAILASSESSMENT OLD AND NEW ON PRORAIL

RP002432RP002432

RP002945RP002945

RP002949RP002949

RP003125RP003125

Old norm: Rejected, New: OK

Old norm: Rejected, New: OK

Old norm: OK, New: Rejected

Old norm: Rejected, New: Rejected

Page 10: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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SELECTION ON PRORAILSELECTION ON PRORAIL

0

0 .2

0 .4

0 .6

0 .8

1

Cum

ulat

ive

Fre

que

ncy

C D FM oerd ijk - D ord rech t (V S R T)

D e lft - D en H aag

Lage Zw a luw e - H o lland s D iep

0 1 2 3 4 5 6 7 8 9W eld Q ua lity Inde x [-] (140 km /h)

8 1%

60%

3 1%

1.8 mrad (140 km/h)1.8 mrad (140 km/h)

Limit at 80 km/hLimit at 80 km/h

100 welds per group100 welds per group

Page 11: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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OLD VERSUS NEW STANDARDSOLD VERSUS NEW STANDARDS

0

0.2

0.4

0.6

0.8

1

Cum

ulat

ive

Fre

quen

cy

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Maximum Absolute Inclination of Weld Geometry (25 mm base) [mrad].

46%

New Standards300 140 80 40 km/h

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

3%

58%

73%Population 239 welds

0

0.2

0.4

0.6

0.8

1

Cum

ulat

ive

Fre

quen

cy

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Maximum Absolute Inclination of Weld Geometry (25 mm base) [mrad].

46%

New Standards300 140 80 40 km/h

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

3%

58%

73%Population 239 welds

QI norm at 140 km/h is 3 times more favorable than old norm

0

0.2

0.4

0.6

0.8

1

Cum

ulat

ive

Fre

quen

cy

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Maximum Absolute Inclination of Weld Geometry (25 mm base) [mrad].

46%

New Standards300 140 80 40 km/h

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

3%

58%

73%Population 239 welds

0

0.2

0.4

0.6

0.8

1

Cum

ulat

ive

Fre

quen

cy

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Maximum Absolute Inclination of Weld Geometry (25 mm base) [mrad].

46%

New Standards300 140 80 40 km/h

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

Old Norm (0 – 0.3 mm) isindependent of line speed16 % passed

3%

58%

73%Population 239 welds

QI norm at 140 km/h is 3 times more favorable than old norm

Page 12: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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y = 18,62x + 20,93

R2 = 0,09

0

50

100

150

0 0,25 0,5 0,75 1 1,25 1,5

versine [mm]

max

. dyn

. co

nta

ct f

orc

e [k

N] y = 4,33x

R2 = 0,91

0

50

100

150

0 5 10 15 20 25

max. discretised gradient (5 mm basis) [mrad]

max

. dyn

. co

nta

ct f

orc

e [k

N]

Low correlationforce and versineLow correlation

force and versineHigh correlation

force and QIHigh correlation

force and QI

CALCULATED DYNAMIC FORCESCALCULATED DYNAMIC FORCES

Page 13: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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Dynamic force linear with QI

Dynamic force linear with QI

Dynamic force linearwith train speed

Dynamic force linearwith train speed

0

20

40

60

80

100

120

140

160

0 2 4 6 8 10

max. weld slope [mrad]

F d

yn [

kN]

v = 300 km/h

v = 140 km/h

v = 80 km/h

v = 40 km/h

y = 0,28x

R2 = 0,98

0

20

40

60

80

100

0 50 100 150 200 250 300

train speed [km/h]

F d

yn [

kN]

slope: 5 mrad

CALCULATED DYNAMIC FORCESCALCULATED DYNAMIC FORCES

Page 14: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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AXLE BOX ACCELERATIONSAXLE BOX ACCELERATIONS

Dynamic amplification less

than 2.2

Dynamic amplification less

than 2.2

y = 0,23x + 1,11

R2 = 0,59

1

1,2

1,4

1,6

1,8

2

2,2

0 0,5 1 1,5 2 2,5 3

QI (140 km/h)

DA

F (

75

0 H

z)

Page 15: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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Procedure: Sample weld geometry with digital straightedge Filter measured signal Determine 1st derivative (inclination) Normalize with intervention value for line speed Calculate QI. QI < 1: OK, otherwise: grinding.

Procedure: Sample weld geometry with digital straightedge Filter measured signal Determine 1st derivative (inclination) Normalize with intervention value for line speed Calculate QI. QI < 1: OK, otherwise: grinding.

PRACTICAL IMPLEMENTATIONPRACTICAL IMPLEMENTATION

Page 16: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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PRACTICAL IMPLEMENTATIONPRACTICAL IMPLEMENTATION

Page 17: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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PDA SCREENPDA SCREEN

V = 140 km/hQI = 1.06V = 140 km/hQI = 1.06

QI uniquely shows where to grindQI uniquely shows where to grind

Page 18: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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DES

KTO

P

SO

FTW

AR

ED

ES

KTO

P

SO

FTW

AR

E

All data and graphs can be shown on a PC; Results in pdf-format can directly be emailed to customer.

All data and graphs can be shown on a PC; Results in pdf-format can directly be emailed to customer.

Page 19: ECS Weld Geometry Standards   1 FORCE-BASED ASSESSMENT OF WELD GEOMETRY Coenraad Esveld Delft University of Technology

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ECSECS Weld Geometry StandardsWeld Geometry Standards

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CONCLUSIONSCONCLUSIONS

1. Theory based on first derivative works fine in practice;

2. Steel straightedge is absolutely inadequate;

3. Instead electronic straightedges with QI (RAILPROF);

4. High correlation of force and QI, low correlation with versine;

5. With RAILPROF QI measurement: You see what you do; Higher quality; Less rejections provided short waves are ground properly

(also negative welds allowed); Extension of life cycle.

1. Theory based on first derivative works fine in practice;

2. Steel straightedge is absolutely inadequate;

3. Instead electronic straightedges with QI (RAILPROF);

4. High correlation of force and QI, low correlation with versine;

5. With RAILPROF QI measurement: You see what you do; Higher quality; Less rejections provided short waves are ground properly

(also negative welds allowed); Extension of life cycle.