Proof-out of operational strength of cast aluminium gearbox castings for railway vehicles

: Sonsino, C.M.; Lipp, K.; Wiebelhaus, W.; Piepenbreier, E.

Abstract
Cast aluminium gear box casings for railway vehicles are complex shaped components undergoing stochastic stresses during service. Early failures of casings led to broad investigations in order to clarify the causes. By a methodology determining the highly stressed areas, the load spectrum for different operational conditions by service stain measurements, the component related material behaviour, fatigue-life calculations and laboratory proof-out tests criteria for optimum design, material selection and quality control were worked out. The methodology enabled the design of new casings fulfilling the requirement of failureless operational service.