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<p>This study investigates the failure of a coil spring suspension system in a locomotive using an experimental and numerical approach. Fractography of the failure spring utilizing scanning electron microscopy (SEM) is an initial phase in the evaluation process. The result ensures material characteristics by examining surface morphology and identifying chemical composition analysis. The connected coil spring assembly subjected to a finite element analysis (FEA) enables the assessment of spring behavior under typical rail track conditions, including active effort and track curvature; static stress analysis is performed. The dynamic analysis was utilized to analyze the effects of variable loading due to static analysis; it was unable to effectively identify the failure. The middle axle’s inner spring was determined to be the significant failure area by fatigue life assessment using FEA results identified a substantially less extensive fatigue life under dynamic loads. Based on research, dynamic loads improve a fatigue damage and provides significant data to enhance spring design and assist reliability in locomotive suspension systems.</p>

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Failure assessment and evaluation of locomotive coil spring suspension system

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月18日

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  • Thillikkani Shanmugam,
  • Senthil Chandran,
  • Rajasekar Janakiraman,
  • Karthick kumar T

摘要

This study investigates the failure of a coil spring suspension system in a locomotive using an experimental and numerical approach. Fractography of the failure spring utilizing scanning electron microscopy (SEM) is an initial phase in the evaluation process. The result ensures material characteristics by examining surface morphology and identifying chemical composition analysis. The connected coil spring assembly subjected to a finite element analysis (FEA) enables the assessment of spring behavior under typical rail track conditions, including active effort and track curvature; static stress analysis is performed. The dynamic analysis was utilized to analyze the effects of variable loading due to static analysis; it was unable to effectively identify the failure. The middle axle’s inner spring was determined to be the significant failure area by fatigue life assessment using FEA results identified a substantially less extensive fatigue life under dynamic loads. Based on research, dynamic loads improve a fatigue damage and provides significant data to enhance spring design and assist reliability in locomotive suspension systems.