Simulation and Experimental Validation of Stress Analysis for Train Coupler

This study investigates the stress distribution in a sand-cast steel train coupler by comparing experimental results with FEM simulation. Strain gauges were attached to the coupler body areas to measure stresses under varying loads ranging from 500 kN to 1900 kN. The results indicated that the experimental and simulation stress values exhibited a linear relationship with increasing load, reaching a maximum of 206 MPa at 1900 kN. This stress value was approximately 30% of the material's yield strength. However, the experimental stress values tended to be slightly higher than the simulated results, with an average difference of less than 10%. This deviation is attributed to casting defects, geometric irregularities, and material-property differences that are difficult to capture in simulations. The specimen's chemical composition aligns with the Association of American Railroads (AAR) M201 Grade E Steel Casting standards, ensuring the material meets industry requirements. The findings suggest that optimizing the post-casting machining process could improve accuracy in future FEM analyses.