Investigation of Fatigue in Welded Seams of Y25 Type Bogie Body Using Finite Element Method

Abstract

In this study, the fatigue strength of the weld seams on the Y25 type bogie frame, commonly used in freight wagons, was investigated comprehensively using the finite element method (FEM). The loads applied to the bogie frame were determined according to the EN 13749 standard, which is valid in the railway industry. The fatigue strengths of the weld seams were evaluated according to the DVS 1612 standard, which is valid in the railway industry, and these values were interpreted according to the EN 15085-3 standard. A detailed finite element model of the model was created in ANSYS Workbench, and the amounts and locations of the fatigue loads specified in the EN 13749 standard were applied to the bogie frame. Stress-strain calculations were performed on the frame model under these conditions. The calculated stresses on the body were transferred, together with the CAD model, to the Limit-CAE finite element program. For consistency of stresses, the same finite element mesh was used in both finite element programs for bogie body. The fatigue strengths in the weld seams were calculated in the Limit-CAE finite element program. The evaluation and interpretation of the stress factors obtained in the weld seams according to the stress categories were carried out in accordance with the EN 15085-3 standard. It was observed that the weld seams defined on the bogie web met the structural requirements. In the study, important findings regarding the safety and strength performance of the weld seams on the body are presented.

Keywords

• DVS 1612
• EN 13749
• EN 15085-3
• Fatigue
• Finite Element Analysis
• MKJ
• Seam Weld.

References

1. [1]. Gürbüz, O. (2022). Y 25 tipi Boji gövdesinin Sonlu Elemanlar Yöntemiyle Yapısal Analizleri. (Master’s Thesis), Sivas Cumhuriyet Üniversitesi Fen Bilimleri Enstitüsü, Sivas.
2. [2]. Pokkula, R., & Gupta, T. V. K. (2021). Finite element method based evaluation of bogie bolster design. International Journal of Vehicle Structures & Systems, 13(2), 160-163. (https://doi.org/10.4273/ijvss.13.02.05)
3. [3]. Seo, J. W., Hur, H. M., Kwon, S. J., & Moon, K. H. (2023). Effect of multiple weld repairs on fatigue strength of bogie frame of railroad vehicle. Advances in Mechanical Engineering, 15(11), 16878132231213596. (https://doi.org/10.1177/16878132231213596)
4. [4]. Seo, J. W., Kwon, S. J., Lee, C. W., Lee, D. H., & Goo, B. C. (2021). Fatigue strength and residual stress evaluation of repair welding of bogie frame for railway vehicles. Engineering Failure Analysis, 119, 104980. (https://doi.org/10.1016/j.engfailanal.2020.104980)
5. [5]. Ozsoy, M., Pehlivan, K., Firat, M., Ozsoy, N., & Ucar, V. (2015). Structural strength and fatigue life calculation of Y32 bogie frame by finite element method. Acta Physica Polonica A, 128(2B). (http://dx.doi.org/10.12693/APhysPolA.128.B-327)
6. [6]. Karmiadji, D. W., Haryanto, B., Ivano, O., Perkasa, M., & Farid, A. R. (2021). Bogie frame structure evaluation for light-rail transit (lrt) train: a static testing. Automotive Experiences, 4(1), 36-43. (https://doi.org/10.31603/ae.4252)
7. [7]. Zhou, W., Zhang, G., Wang, H., Peng, C., Liu, X., Xiao, H., & Liang, X. (2022). Experimental fatigue evaluation of bojie frames on metro trains. Machines, 10(11), 1003. (https://doi.org/10.3390/machines10111003)
8. [8]. Fuštar, B., Lukačević, I., & Dujmović, D. (2018). Review of fatigue assessment methods for welded steel structures. Advances in Civil Engineering, 2018(1), 3597356. (https://doi.org/10.1155/2018/3597356)

9. [9]. Slavchev, S., Maznichki, V., Stoilov, V., Enev, S., & Purgic, S. (2018). Comparative analysis of fatigue strength of an y25ls-k bogie frame by methods of UIC AND DVS 1612. Czech Republic. (https://doi.org/10.24867/MD.11.2019.1.1-4)
10. [10]. Dižo, J., Harušinec, J., & Blatnický, M. (2017). Structural analysis of a modified freight wagon bogie frame. In MATEC Web of Conferences (Vol. 134, p. 00010). EDP Sciences. (https://doi.org/10.1051/matecconf/201713400010)
11. [11]. Jonsson, B., Barsoum, Z., & Sperle, J. O. (2012). Weight optimization and fatigue design of a welded bogie beam structure in a construction equipment. Engineering Failure Analysis, 19, 63-76. (https://doi.org/10.1016/j.engfailanal.2011.09.006)
12. [12]. Daniyan, I., Mpofu, K., Fameso, F., & Adeodu, A. (2020). Numerical simulation and experimental validation of the welding operation of the railcar bogie frame to prevent distortion. The International Journal of Advanced Manufacturing Technology, 106(11), 5213-5224. (https://doi.org/10.1007/s00170-020-04988-6)
13. [13]. Zhang, H. (2025). Welding technology of railway locomotive bogie frame based on high-frequency pulse MAG joints. Australian Journal of Mechanical Engineering, 1-12. (https://doi.org/10.1080/14484846.2025.2548166)
14. [14]. Zhangyi, Zhou. , Yunhua, Huang., Yang, Yang., & Junjun, Ding (2018). Study on Fatigue Strength of Welds in Bojie Frame Based on Structural Stresses. 西南交通大学学报, 53(5), 937-944. (https://doi.org/10.3969/j.issn.0258-2724.2018.05.009)
15. [15]. Cera, A., Mancini, G., Leonardi, V., & Bertini, L. (2008). Analysis of methodologies for fatigue calculation for railway bojie frames. In 8th World Congress on Railway Research (Vol. 1, pp. 3-2).
16. [16]. Lu, Y., Lu, C., Zhang, D., Chen, T., Zeng, J., & Wu, P. (2019). Numerical computation methods of welding deformation and their application in bogie frame for high-speed trains. Journal of Manufacturing Processes, 38, 204-213. (https://doi.org/10.1016/j.jmapro.2019.01.013)
17. [17]. Xie, M. X., Xin, Q. K., Long, J., Zeng, X. L., & Zhang, L. J. (2023). Fatigue life analysis of fillet weld with root gap in bogie tie rod seat under road traffic load. Engineering Failure Analysis, 153, 107596. (https://doi.org/10.1016/j.engfailanal.2023.107596)
18. [18]. Vega, B., & Pérez, J. Á. (2024). Comparative analysis of fatigue strength of a freight wagon frame. Welding in the World, 68(2), 321-332. (https://doi.org/10.1007/s40194-023-01577-5)
19. [19]. Novak, D., Burušić, L., Tomerlin, D., Kozak, D., & Samardžić (2025). Application and Possibilities of Robotic Welding in the Freight Wagons Production. 13th International Scientific-Professional Conference SBW 2025, Slavonski Brod.
20. [20]. Dusza, M. (2023). Freight car model with Y25 bogies stability analysis. Rail Vehicles/Pojazdy Szynowe. 2023;3-4:13-24. (https://doi.org/10.53502/RAIL-175725)
21. [21]. Sebesan, I., Zaharia, N. L., Spiroiu, M. A., & Fainus, L. (2015). Rubber suspension, a solution of the future for railway vehicles. Materiale Plastice, 52(1), 93-96.
22. [22]. DVS 1612. (2017). Design and endurance strength assessment of welded joints with steels in rail vehicle construction (Standard). Germany.
23. [23]. EN 15085-3. (2007). Railway applications - Welding of railway vehicles and components (Standard).
24. [24]. Gregory, E. N., & Armstrong, A. A. (2005). Welding symbols on drawings. Elsevier.
25. [25]. Erdin E. (2024). Kaynak Ders Notları. https://web.hitit.edu.tr/dosyalar/materyaller/[e-mail]. Hitit University. (accessed at 13.09.2025).
26. [26]. Karakaş, Ö., & Gülsöz, A. (2007). Kaynaklı Birleştirmelerin Statik ve Yorulma Dayanımına Etki Eden Faktörler. Makine ve Mühendis, 48(573).
27. [27]. Zboinski, K., Dusza, M. (2017). Bifurcation analysis of 4-axle rail vehicle models in a curved track. Nonlinear Dyn 89, 863–885 . (https://doi.org/10.1007/s11071-017-3489-y)
28. [28]. Pagaimo, J., Magalhães, H., Costa, J. N., & Ambrósio, J. (2020). Derailment study of railway cargo vehicles using a response surface methodology. Vehicle System Dynamics, 60(1), 309–334. (https://doi.org/10.1080/00423114.2020.1815810)
29. [29]. Lobanov, L., Makhnenko, O., Pustovoy, A., Solovey, S. (2020). Development of Welded Elements of the Railway Freight Car Bogie with Increased Characteristics of Fatigue Resistance and Survivability. (pp. 273–279). Springer, Cham. (https://doi.org/10.37434/as2020.03.02)
30. [30]. Zhai, W., Stichel, S., & Ling, L. (2025). Train–track coupled dynamics problems in heavy-haul rail transportation. Vehicle System Dynamics, 63(7), 1187–1240. (https://doi.org/10.1080/00423114.2025.2494834)