scholarly journals Conventional Fuel Tank Blunt Impact Tests: Test and Analysis Results

2014 ◽  
Author(s):  
Karina Jacobsen ◽  
Michael Carolan ◽  
Benjamin Perlman
Keyword(s):  
Finite Element ◽  
Dynamic Loading ◽  
Fuel Tank ◽  
Test Tank ◽  
Impact Tests ◽  
Impact Location ◽  
Blunt Impact ◽  
Fuel Tanks ◽  
Post Test ◽  
The Impact

The Federal Railroad Administration’s Office of Research and Development is conducting research into fuel tank crashworthiness. A series of impact tests are planned to measure fuel tank deformation under two types of dynamic loading conditions — blunt and raking impacts. This paper describes the results of the first set of blunt impact tests for two retired EMD F-40 locomotive fuel tanks, Tank 232 and Tank 202. On October 8, 2013 and October 9, 2013, the FRA performed impact tests on two conventional passenger locomotive fuel tanks at the Transportation Technology Center (TTC) in Pueblo, Colorado. Each fuel tank was emptied of fluid and mounted on a crash wall with the bottom surface exposed. A rail cart modified with a “rigid” indenter was released to impact the center of the bottom of each fuel tank at about 6 mph. A center-impact on Tank 232 was chosen to impact between two baffles. A center-impact on Tank 202 was chosen to impact on a baffle. In the first test, Tank 232 was impacted by the indenter at 4.5 mph. The maximum residual indentation on the bottom of the tank measured approximately 5 inches. The tank deformed across the middle longitudinal span of the tank forming a diamond-shaped indention. In the second test, Tank 202 was impacted by the indenter at 6.2 mph. The maximum residual indentation on the bottom of the tank measured approximately 1.5 inches. The bottom of the tank deformed with an “X” shape spanning out from the location of square indenter at the center of the tank. Post-test autopsies revealed the deformation of the interior structures, i.e. baffles and attachments. There was no damage to the baffles in Tank 232. Deformation to the interior structure of Tank 202 was limited to the baffle directly beneath the impact location, which folded in the area near the impact location. Material coupons were cut and tensile testing performed to determine the properties of the materials used in each tank. Prior to the test, computer models were developed from measurements taken on the test articles. Material properties were estimated based on Brinell hardness measurements. Computer analyses were conducted to determine the conditions for the test, i.e. instrumentation, location of impact, target impact speeds and to predict the deformation behavior of the tank. Post-test, the resulting stress-strain relationships for the bottom sheets and baffles of both tanks were used to update the finite element models of the two tanks. The models were also updated to reflect the actual geometry of the tanks as confirmed by measurements of the tank interiors. The results of the finite element (FE) models run at the test conditions with the updated tank details are compared with the results from the test itself. Specifically, the deformation progression and the residual dent depth are compared between the tests and the models. In accidents, fuel tanks are subjected to dynamic loading, often including a blunt or raking impact from various components of the rolling stock or trackbed. Current design practice requires that fuel tanks have minimum properties adequate to sustain a prescribed set of static load conditions. Current research is intended to increase understanding of the impact response of fuel tanks under dynamic loading.

scholarly journals Test Requirements of Locomotive Fuel Tank Blunt Impact Tests

2013 ◽  
Author(s):  
Karina Jacobsen ◽  
Michael Carolan ◽  
Patricia Llana
Keyword(s):  
Dynamic Loading ◽  
Lessons Learned ◽  
Fuel Tank ◽  
Bottom Surface ◽  
Loading Conditions ◽  
Impact Tests ◽  
Blunt Impact ◽  
Fuel Tanks ◽  
Test Requirements ◽  
The Impact

The Federal Railroad Administration’s Office of Research and Development is conducting research into passenger locomotive fuel tank crashworthiness. A series of impact tests are planned to measure fuel tank deformation under two types of dynamic loading conditions. This paper describes the test requirements for the preliminary tests in this series — a blunt impact of conventional locomotive fuel tanks. Current design practice requires that Tier 1 locomotive fuel tanks have minimum properties adequate to sustain a prescribed set of static load conditions [1]. In accidents, fuel tanks are subjected to dynamic loading, often including a blunt or raking impact from various components of the rolling stock or trackbed. Current research is intended to increase understanding of the impact response of fuel tanks under dynamic loading. Utilizing an approach that has been effective in increasing the structural crashworthiness of passenger railcars, improved strategies can be developed that will address the types of loading conditions which have been observed to occur in a collision or derailment event. The improvement strategies developed by this research program can then be applied to alternative fuel tank designs, such as diesel multiple unit (DMU) tanks. This paper describes test requirements for conducting two preliminary tests. These tests are referred to as preliminary because they will be used to evaluate the loading setup and instrumentation planned for the larger series of tests. These preliminary tests will evaluate a blunt impact on the bottom surface of two conventional passenger locomotive fuel tanks. The test articles chosen for the preliminary tests are fuel tanks removed from two retired EMD F-40 locomotives. While these fuel tanks do not reflect the current state of locomotive fuel tank manufacturing or design, they are suitable for means of these tests. Each fuel tank will be mounted to a crash wall and impacted on its bottom face by an impact cart with a rigid impactor at a prescribed velocity. The first set of tests is designed to measure the deformation behavior of the fuel tanks. These tests are planned to result in puncture of the bottom surface of each fuel tank. The preliminary tests are targeted for October 2013 at the Transportation Technology Center (TTC) in Pueblo, Colorado. Following this first series of impact tests, a second set of dynamic impact tests is planned to be conducted. This second set will include both blunt and raking impact conditions on conventional fuel tanks, DMU fuel tanks and fuel tanks incorporating improved strategies for impact protection. Lessons learned during the preliminary two tests will be applied during the second set of tests to improve the performance of those tests. Fuel tank research is being performed to determine strategies for increasing the fuel tank impact resistance to mitigate the threat of a post-collision or post-derailment fire.

scholarly journals Results of a Diesel Multiple Unit Fuel Tank Blunt Impact Test

2017 ◽  
Author(s):  
Karina Jacobsen ◽  
Michael Carolan
Keyword(s):  
Research Program ◽  
Impact Test ◽  
Fuel Tank ◽  
Test Material ◽  
Fe Model ◽  
Puncture Resistance ◽  
Blunt Impact ◽  
Fuel Tanks ◽  
Post Test ◽  
The Impact

The Federal Railroad Administration’s Office of Research and Development is conducting research into passenger locomotive fuel tank crashworthiness. A series of impact tests is being conducted to measure fuel tank deformation under two types of dynamic loading conditions — blunt and raking impacts. The results of this research program assist in development of appropriate standards for puncture resistance requirements to be applied to alternatively-designed fuel tanks, such as on diesel multiple unit (DMU) passenger rail equipment. This paper describes the results of the first blunt impact test performed on a DMU fuel tank. On June 28, 2016, FRA performed a dynamic impact test of a fuel tank from a DMU rail vehicle. The test was performed at the Transportation Technology Center (TTC) in Pueblo, Colorado. An impact vehicle weighing approximately 14,000 pounds and equipped with a 12-inch by 12-inch impactor head struck the bottom surface of a DMU fuel tank mounted vertically on an impact wall. The impact occurred on the bottom of the fuel tank at a location centered on two baffles within the fuel tank. The target impact speed was 11.5 mph, and the measured impact speed 11.1 mph. The test resulted in a maximum indentation of approximately 8 inches, the bottom of the tank bending away from the wall, and buckling of several internal baffles. Following the test, the tank was cut open to inspect the damage to the internal structure. This revealed that the buckling behavior of the baffles was isolated to the baffles immediately adjacent the impact location, each one buckling as the tank deformed inward. Prior to the test, finite element analysis (FEA) was used to predict the behavior of the tank during the test. The FE model of the tank required material properties to be defined in order to capture plastic deformation. The combination of metal plasticity, ductile failure, and element removal would permit the model to simulate puncture for this tank at sufficiently-high impact speeds. The pre-test FE model results compared very favorably with the test measurements, and both the pre-test model and the test resulted in similar modes of deformation to the DMU fuel tank. Following the test, material coupons were cut from undamaged areas of the fuel tank and subjected to tensile testing. The post-test FE model was updated with the material behaviors from the post-test material testing. This test is part of a research program investigating puncture resistance of passenger locomotive fuel tanks. The objective of this research program is to establish the baseline puncture resistance of current locomotive fuel tanks under dynamic impact conditions and to develop performance requirements for an appropriate level of puncture resistance in alternative fuel tank designs, such as DMU fuel tanks. Future tests are planned within this research program. The lessons learned during the series of tests support finite element (FE) modeling of impact conditions beyond what was tested. Additional tests investigating the puncture resistance of fuel tanks during sideswipe or raking collisions are also planned.

scholarly journals Fuel Tank Integrity Research: Fuel Tank Analyses and Test Plans

2013 ◽  
Author(s):  
Karina Jacobsen ◽  
Patricia Llana ◽  
Michael Carolan ◽  
Laura Sullivan
Keyword(s):  
Dynamic Loading ◽  
Deformation Behavior ◽  
Impact Testing ◽  
Fuel Tank ◽  
Loading Conditions ◽  
Dynamic Impact ◽  
Research Activities ◽  
Blunt Impact ◽  
Fuel Tanks ◽  
The Impact

The Federal Railroad Administration’s Office of Research and Development is conducting research into fuel tank crashworthiness. Fuel tank research is being performed to determine strategies for increasing the fuel tank impact resistance to mitigate the threat of a post-collision or post-derailment fire. In accidents, fuel tanks are subjected to dynamic loading, often including a blunt or raking impact from various components of the rolling stock or trackbed. Current design practice requires that fuel tanks have minimum properties adequate to sustain a prescribed set of static load conditions. Current research is intended to increase understanding of the impact response of fuel tanks under dynamic loading. Utilizing an approach that has been effective in increasing the structural crashworthiness of railcars, improved strategies can be developed that will address the types of loading conditions which have been observed to occur in a collision or derailment event. U.S. rail accident surveys reveal the types of threats fuel tanks are exposed to during collision, derailments and other events. These include both blunt impacts and raking impacts to any exposed side of the tank. This research focuses on evaluating dynamic impact conditions for fuel tanks and investigating how fuel tank design features affect the collision performance of the tank. Research activities will include analytical modeling of fuel tanks under dynamic loading conditions, dynamic impact testing of fuel tank articles, and recommendations for improved fuel tank protection strategies. This paper describes detailed finite element analyses that have been developed to estimate the behavior of three different fuel tanks under a blunt impact. These analyses are being used to understand the deformation behavior of different tanks and prepare for planned testing of two of these tanks. Observations are made on the influence of stiffeners, baffles, and other design details relative to the distance from impact. This paper subsequently describes the preliminary test plans for the first set of tests on conventional passenger locomotive fuel tanks. The first set of tests is designed to measure the deformation behavior of the fuel tanks with a blunt impact of the bottom face of the tanks. The test articles are fuel tanks from two retired EMD F-40 locomotives. A blunt impact will be conducted by securing the test articles to a crash wall and impacting them with an indenter extending from a test cart. This set of tests is targeted for late summer 2013 at the Transportation Technology Center (TTC) in Pueblo, Colorado. Both blunt and raking impact conditions will be evaluated in future research. Tests are also being planned for DMU fuel tanks under dynamic loads.

scholarly journals Results of a Conventional Fuel Tank Blunt Impact Test

2015 ◽  
Author(s):  
Karina Jacobsen ◽  
Michael Carolan
Keyword(s):  
Impact Test ◽  
Ductile Failure ◽  
Fuel Tank ◽  
Bottom Surface ◽  
Fe Model ◽  
Puncture Resistance ◽  
Impact Speed ◽  
Blunt Impact ◽  
Fuel Tanks ◽  
Post Test

The Federal Railroad Administration’s Office of Research and Development is conducting research into passenger locomotive fuel tank crashworthiness. A series of impact tests is being conducted to measure fuel tank deformation under two types of dynamic loading conditions — blunt and raking impacts. This program is intended to result in a better understanding of design features that improve the puncture resistance of passenger locomotive fuel tanks. One reason for performing this program is to aid in development of appropriate standards for puncture resistance to be applied to alternatively-designed fuel tanks, such as on diesel multiple unit (DMU) passenger rail equipment. This paper describes the results of the third blunt impact test of retired F-40 locomotive fuel tanks. The test setup was designed for the Transportation Technology Center (TTC) in Pueblo, Colorado, to impart blunt impacts to the bottom of each fuel tank specimen. The specimens tested to date are from FRA-owned retired F-40 passenger locomotives. To conduct the test, each tank was emptied of fluid and mounted on a crash wall with the bottom surface exposed. A rail cart modified with a “rigid” indenter measuring 12 inches by 12 inches, was released to impact the bottom of fuel tank at a target impact speed. The first two tests, conducted on October 8 and 9, 2013, were designed to impact the center of two different tank designs. Tests were conducted at impact speeds of 4.5 and 6.2 mph and caused maximum residual dents of 5 inches and 1.5 inches, respectively. On August 20, 2014 the test of fuel tank 234 was conducted to impact the tank off-center between two baffles. Force-deformation measurements were collected for each tank during the three tests. The series of tests provide information regarding the influence of tank design on puncture resistance. In the test of tank 234, the target impact speed was 12.5 mph, and the actual impact occurred at 11.2 mph. The test resulted in a residual dent depth of approximately 9 inches, and buckling of several internal baffles. The impact did not result in puncture of the tank. Following the test, the tank was cut open to permit examination of the baffles. This examination revealed a different baffle geometry than was modeled based on pre-test measurements. Finite element analysis (FEA) was used to predict the behavior of the tank during the test. The FE model of the tank required several material properties to be defined in order to capture puncture behavior. The combination of metal plasticity, ductile failure, and element removal would permit the model to simulate puncture for this tank. Following the test, the tank was cut open, revealing a different baffle arrangement than had been initially thought. The post-test FE model was then updated to include the actual baffle arrangement of tank 234. With the actual baffle arrangement included in the model, the FE results are in fairly good agreement with the test. Additional changes to the ductile failure criterion were also made in the post-test model. The objective of this research program is to establish the baseline puncture resistance of current passenger locomotive fuel tanks under dynamic impact conditions and to develop performance requirements to ensure an appropriate level of puncture resistance in alternative fuel tank designs, such as DMU fuel tanks.

Response of Mild Steel Pipes Under High Mass Low Velocity Impacts

2014 ◽  
Author(s):  
Shamsoon Fareed ◽  
Ian May
Keyword(s):  
Finite Element ◽  
Mild Steel ◽  
Impact Energy ◽  
High Mass ◽  
Low Velocity ◽  
Element Analysis ◽  
Steel Pipes ◽  
Impact Tests ◽  
The Finite Element Analysis ◽  
The Impact

Accidental loads, for example, due to heavy dropped objects, impact from the trawl gear and anchors of fishing vessels can cause damage to pipelines on the sea bed. The amount of damage will depend on the impact energy. The indentation will be localized at the contact area of the pipe and the impacting object, however, an understanding of the extent of the damage due to an impact is required so that if one should occur in practice an assessment can be made to determine if remedial action needs to be taken to ensure that the pipeline is still serviceable. There are a number of parameters, including the pipe cross section and impact energy, which influence the impact behaviour of a pipe. This paper describes the response, and assesses the damage, of mild steel pipes under high mass low velocity impacts. For this purpose full scale impacts tests were carried out on mild steel pipe having diameter of 457 mm, thickness of 25.4 mm and length of 2000 mm. The pipe was restrained along the base and a 2 tonnes mass with sharp impactor having a vertical downward velocity of 3870 mm/sec was used to impact the pipe transversely with an impact energy of 16 kJ. It was found from the impact tests that a smooth indentation was produced in the pipe. The impact tests were then used for validation of the non-linear dynamic implicit analyses using the finite element analysis software ABAQUS. Deformations at the impact zone, the rebound velocity, etc, recorded in the tests and the results of the finite element analysis were found to be in good agreement. The impact tests and finite element analyses described in this paper will help to improve the understanding of the response of steel pipes under impact loading and can be used as a benchmark for further finite element modelling of impacts on pipes.

Updated Fuel Tank Puncture Survey: 1995-2020

2021 ◽  
Author(s):  
Karina Jacobsen
Keyword(s):  
Fuel Tank ◽  
Technical Data ◽  
Passenger Rail ◽  
Blunt Impact ◽  
Field Investigations ◽  
Fuel Tanks ◽  
Serious Injury ◽  
Conducting Research ◽  
Railroad System ◽  
General Operation

Abstract The Federal Railroad Administration’s Office of Research, Development and Technology has been conducting research into passenger fuel tank crashworthiness. The occurrence of a fuel tank puncture during passenger rail collisions and derailments increases the potential of serious injury and fatality for crew and passengers due to the possibility of fire. The purpose of the FRA research is to help support regulatory and standard development with technical data. In the last decade, the research has focused on understanding how fuel tanks are punctured during an impact and how various tank designs respond to common types of loading in collisions, derailments and general operation. Throughout the research, surveys have been conducted to determine the most likely scenarios that are causing fuel tank punctures. A previous FRA survey found that fuel tank punctures occur under two types of loading conditions: a blunt impact or a raking impact. A limited number of accident/incidents were evaluated in this survey. These incidents showed that fuel tanks are punctured on any side that is not protected or shielded. The purpose of this paper is to report on a recently conducted fuel tank puncture survey updated to include the last decade. This paper identifies and describes accidents and incidents that led to breached fuel tanks in freight and passenger trains traveling on the general railroad system in the U.S. between 2008 and 2020. The results include data from the FRA’s Railroad Accident/Incident Reporting System (RAIRS), queried from 1995 to 2020. This data include the number of recorded accidents/incidents and other trends like fuel spillage, operating authority and cause of accident/incident. RAIRS data showed accidents/incidents with fuel tank puncture ranging from 10 to 55 accidents/incidents per year. Additionally, more detailed results are shared from field investigations recently conducted by the FRA or Volpe Center. These more detailed investigations provide additional insight into the types of loading that may lead to a fuel tank puncture. This survey supplements the RAIRS data with more detailed information from field investigations. The paper finally discusses the conditions that lead to fire and the associated hazards.

Study Regarding the Influence of the Fuel Tank Constructive Characteristics on Slosh-Noise Effect

2016 ◽  
Vol 834 ◽  
pp. 22-27 ◽  
Author(s):  
Oana Maria Manta Balas ◽  
Radu Balas ◽  
Cristian Vasile Doicin
Keyword(s):  
The Body ◽  
Fuel Tank ◽  
Noise Effect ◽  
Great Achievement ◽  
Fuel Tanks ◽  
Entire Vehicle ◽  
Body In White ◽  
Innovative Potential ◽  
The Impact ◽  
The Waves

The aim of this article is to highlight the impact of the fuel movements inside the plastic fuel tank (waves) for the client perception of noise. Today there isn’t a clear methodology regarding the reproducing the fuel waves, but there are different approaches to be taken into account and also there is an innovative potential. Due to the fast technological progress the body in white and not only, the entire vehicle became lighter and lighted. A consequence of this great achievement is that the client can hear easier the sound produced by different components of the car. The plastic fuel tank can be considered such a component. The authors have done a deep analysis of present automotive fuel tanks and propose solutions for breaking the waves produced inside fuel tanks, so as to reduce the slosh noise effect. The studies will be continued during the doctoral approach of the first author.

Relationship Between Charpy V-Notch Impact Value and Fracture Mechanics Toughness: Added Value of Finite Element Analysis and Instrumented Impact Tests

2011 ◽  
Author(s):  
Philippe Thibaux ◽  
Filip Van den Abeele ◽  
Philippe Burlot
Keyword(s):  
Finite Element ◽  
Master Curve ◽  
Impact Test ◽  
Crack Arrest ◽  
Smooth Transition ◽  
Unstable Crack ◽  
Impact Tests ◽  
The Difference ◽  
Energy Dissipated ◽  
The Impact

Each structure is designed with resistance versus the fracture, which requires the knowledge of the fracture resistance of the material. If no fracture mechanics data of the material is available, a KJC can be inferred from the master curve approach. The master curve approach relates a fracture toughness of 100 MPAm1/2 to the impact transition temperature T27J with a shift of 18°C. Although this relationship was successfully applied to a large number of experiments, some steels deviate significantly from the previous relationship, which can even lead to non-conservative design. In the present paper, instrumented impact tests (Charpy V-Notch CVN) and compact tensile (CT) tests were performed on two materials, one thermomechanically (TM-) rolled and one normalized steel. The difference between T0 and T27J was found to be different for these materials. Furthermore, the normalized steel exhibits a smooth transition from brittle to ductile behaviour, while the TM-rolled material shows a very steep transition. Extra information is gained by combining the instrumentation of the impact test and the finite element simulations of both the CT and impact tests. From the instrumented tests, it is also possible to determine the load at unstable crack propagation, the amount of energy dissipated at that moment, the load at crack arrest and the energy dissipated after crack arrest. From the finite element simulation, one learns about the constraints ahead of the crack tip for both configurations. The investigation teaches us that the smooth transition of the normalized material is related to a high energy dissipated after crack arrest, while the TM-rolled material has a much lower crack arrest load. The difference between T0 and T27J is then discussed by decomposing the total energy in the impact test between crack initiation, propagation and arrest. It is compared with KJC, which determines the toughness at unstable crack propagation, by reviewing the literature and local stress states computed from finite element.

scholarly journals Relationship Between Matrix Cracking and Delamination in CFRP Cross-Ply Laminates Subjected to Low Velocity Impact

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3990 ◽  
Author(s):  
Riming Tan ◽  
Jifeng Xu ◽  
Wei Sun ◽  
Zhun Liu ◽  
Zhidong Guan ◽  
...  
Keyword(s):  
Finite Element ◽  
Large Scale ◽  
Matrix Cracking ◽  
Low Velocity Impact ◽  
Low Velocity ◽  
Velocity Impact ◽  
Matrix Cracks ◽  
Impact Location ◽  
The Matrix ◽  
The Impact

The effect of matrix cracking on the delamination morphology inside carbon fiber reinforced plastics (CFRP) laminates during low-velocity impact (LVI) is an open question. In this paper, the relationship between matrix cracking and delamination is studied by using cross-ply laminates. Several methods, including micrograph, C-scan, and visual inspection, were adopted to characterize the damage after LVI experiments. Based on the experimental results, finite element (FE) models were established to analyze the damage mechanisms. The matrix cracking was predicted by the extended finite element method (XFEM) and the Puck criteria, while the delamination was modeled by cohesive elements. It was revealed that the matrix crack in the bottom ply not only promoted the outward propagation of delamination but also contributed to the narrow delamination beneath the impact location. Multiple matrix cracks occurred in the middle ply. The ones close to the plate center initiated the delamination and prevented large-scale delamination beneath the impact location. For the cracks that were far away, no significant effect on delamination was found. In conclusion, the stress redistribution caused by the crack opening determines the delamination.

scholarly journals Fuel Tank Crashworthiness: Loading Scenarios

2011 ◽  
Author(s):  
Karina Jacobsen
Keyword(s):  
Oblique Impact ◽  
Fuel Tank ◽  
Passenger Rail ◽  
Equipment Safety ◽  
Impact Location ◽  
Fuel Tanks ◽  
Serious Injury ◽  
Conducting Research ◽  
Railroad System ◽  
The U.S

The Federal Railroad Administration’s Office of Research and Development is conducting research into fuel tank crashworthiness. The breaching of fuel tanks during passenger rail collisions and derailments increases the potential of serious injury and fatality due to fire. This paper identifies and describes common collision loading scenarios for locomotive fuel tanks on the U.S. general railroad system. Developing scenarios that characterize this situation is the first step in crashworthiness research methodology for improving rail equipment safety. A survey of accidents within the U.S. between 1995 and present was used to identify fuel tank impact scenarios as follows: impact with adjacent railcar component; oblique impact with another railcar; rollover leading to impact with another railcar; derailment or rollover leading to grounding; and impact with rail. These collision scenarios are further categorized by the types of collision modes experienced by the fuel tank, i.e. impact type and impact location. These loading conditions establish targets for evaluating current levels of fuel tank integrity and potentially developing improved strategies for enhancing fuel tank integrity.

Sign in / Sign up

Export Citation Format

Share Document