Strength Analysis of Welded Joints on the Side of a Railway Bogie Frame with Variations in Welding Speed Using the Finite Element Method

Ojo Kurdi; Achmad Widodo; MSK Tony Suryo Utomo; Mochamad Cahyo Adi Nugroho

doi:https://doi.org/10.47001/ICJES/2025.411008

Authors

Ojo Kurdi

Faculty of Engineering, Department of Mechanical Engineering, Diponegoro University, Indonesia

Achmad Widodo

Faculty of Engineering, Department of Mechanical Engineering, Diponegoro University, Indonesia

MSK Tony Suryo Utomo

Faculty of Engineering, Department of Mechanical Engineering, Diponegoro University, Indonesia

Mochamad Cahyo Adi Nugroho

Faculty of Engineering, Department of Mechanical Engineering, Diponegoro University, Indonesia

Abstract

The development of Electric Multiple Units (EMU/KRL) as environmentally friendly transportation requires a reliable and structurally safe bogie system. One critical aspect of the bogie side frame is the quality of its welded joints, which directly affects structural integrity and operational safety. This study investigates the strength and performance of welded joints on a railway side frame by varying the Gas Metal Arc Welding (GMAW) travel speed using ER70S-6 filler metal on 12.5 mm SS400 steel. An integrated experimental–numerical approach was applied. Butt-joint specimens were prepared according to ASTM E8/E8M to obtain tensile strength, strain, elastic modulus, density, and Poisson’s ratio at travel speeds of 10, 15, 20, 25, and 30 cm/min. These mechanical properties were used as material inputs and validation parameters for the Finite Element Method (FEM) model. The welded region of the side frame was simulated in ANSYS Workbench under four service load scenarios: vertical static, traction, braking, and lateral (cornering). Structural responses including von Mises stress, total deformation, and safety factor were evaluated at critical welded interfaces, namely the web–liner/cover and web–top plate joints. Both experimental and FEM results exhibit consistent trends showing that travel speed influences the strength–ductility balance and stress distribution within the side frame structure. The 20 cm/min travel speed condition was selected as the primary validated case, while 15 and 25 cm/min were used for comparison. The findings highlight the importance of travel speed control in ensuring weld quality and supporting the structural reliability of railway bogie side frames.

Keywords

Bogie Side Frame Finite Element Method (FEM) GMAW Tensile Strength Welding Travel Speed

Citation of this Article

Ojo Kurdi, Achmad Widodo, MSK Tony Suryo Utomo, & Mochamad Cahyo Adi Nugroho. (2025). Strength Analysis of Welded Joints on the Side of a Railway Bogie Frame with Variations in Welding Speed Using the Finite Element Method. International Current Journal of Engineering and Science (ICJES), 4(11), 42-47. Article DOI: https://doi.org/10.47001/ICJES/2025.411008

References

Y. Uemura and T. Tsuji, “Finite Element Evaluation of Welded Joints in Railway Bogie Structures,” Engineering Structures, vol. 230, p. 111643, 2021.
I.M. Ilyasa, I. A. Hendaryanto, and A. Winarno, “Analisis Kekuatan Struktur pada Desain Traction Rod Kereta Api Lokomotif dengan Metode Finite Element Analysis (FEA),” Jurnal Teknik Mesin, vol. 8, no. 2, pp. 190–199, 2024.
H. Soebagyo and G. C. Kusuma, “Pemeriksaan Sambungan Las Aluminium pada Struktur Kereta Api Ringan dengan Metode Non-Destructive Test,” Jurnal Ilmiah Rekayasa & Inovasi, vol. 1, 2019.
ASTM International, “ASTM E8/E8M – Standard Test Methods for Tension Testing of Metallic Materials,” ASTM, West Conshohocken, PA, USA, 2021.
T. Sedmak et al., “Effect of Welding Parameters on Tensile Properties and Fracture Behavior of Structural Steel Weldments,” Materials, vol. 14, no. 22, p. 6782, 2021.
A.H. Shamsaei et al., “Fatigue Behavior of Welded Steel Components under Multiaxial Loading,” International Journal of Fatigue, vol. 150, p. 106223, 2021.
N. Nishanth and K. Venkatesan, “A Literature Review on Gas Metal Arc Welding (GMAW),” International Journal of Innovative Research in Technology, vol. 7, pp. 370–375, 2022.

[1] Y. Uemura and T. Tsuji, “Finite Element Evaluation of Welded Joints in Railway Bogie Structures,” Engineering Structures, vol. 230, p. 111643, 2021.

[2] I.M. Ilyasa, I. A. Hendaryanto, and A. Winarno, “Analisis Kekuatan Struktur pada Desain Traction Rod Kereta Api Lokomotif dengan Metode Finite Element Analysis (FEA),” Jurnal Teknik Mesin, vol. 8, no. 2, pp. 190–199, 2024.

[3] H. Soebagyo and G. C. Kusuma, “Pemeriksaan Sambungan Las Aluminium pada Struktur Kereta Api Ringan dengan Metode Non-Destructive Test,” Jurnal Ilmiah Rekayasa & Inovasi, vol. 1, 2019.

[4] ASTM International, “ASTM E8/E8M – Standard Test Methods for Tension Testing of Metallic Materials,” ASTM, West Conshohocken, PA, USA, 2021.

[5] T. Sedmak et al., “Effect of Welding Parameters on Tensile Properties and Fracture Behavior of Structural Steel Weldments,” Materials, vol. 14, no. 22, p. 6782, 2021.

[6] A.H. Shamsaei et al., “Fatigue Behavior of Welded Steel Components under Multiaxial Loading,” International Journal of Fatigue, vol. 150, p. 106223, 2021.

[7] N. Nishanth and K. Venkatesan, “A Literature Review on Gas Metal Arc Welding (GMAW),” International Journal of Innovative Research in Technology, vol. 7, pp. 370–375, 2022.