A Comprehensive Assessment of the Impact of the Hydraulic Vibration Damper Malfunctions on the KVZ-TsNII Passenger Bogie Frame Using the Femap Software Package

Purpose: To determine the effect of malfunctions of the hydraulic vibration damper on the KVZ-TsNII passenger bogie frame. Methods: The stress-strain state of the passenger car bogie frame under the influence of static and dynamic loads has been determined by applying the Femap software package. The causes of malfunctions in hydraulic vibration dampers have been identified, with the primary cause being the accumulation of wear products in the channels, resulting from the friction of the rod against the inner surface of the cylinder. Results: The calculations have demonstrated a high degree of agreement with the operational data from the actual passenger car bogie operation, and have identified the weak points in the bogie. These are the points of the hydraulic vibration damper attachment to the bogie frame. In the event of the damper functioning correctly, the equivalent stresses in these locations do not exceed the permissible values. However, in the event of failure, cracks are formed in the bogie frame. It is imperative, therefore, to implement supplementary design solutions with the objective of enhancing the reliability of the operation of the vibration damper. Practical significance: The modification of the hydraulic vibration damper of the I and II KVZ-TsNII type bogie by the incorporation of a neodymium magnet with a diameter of 20 mm will facilitate the removal of metal shavings from the oil resulting from the friction of the rod against the cylinder walls, thereby enhancing its reliability.