FE-Analysis of stress variation during diamond cutting of prestressed concrete sleepers

Abstract: The manufacturing process ‘long line method’ has shown many advantages when producing prestressed concrete sleepers, such as rapid production and low cost. However, there have been certain difficulties when cutting the 100 m long concrete blocks into sleepers. The sleepers tend to crack when the diamond cutting blade cuts through the last strands. Moreover, the shape and size of the cracks varies from one sleeper to another. Although these cracks may not affect the load carrying capacity, they will not be aesthetically pleasing. No earlier studies within the area have been found, i.e. diamond cutting of prestressed concrete blocks. As a result, there have been certain difficulties when approaching the problem. Finite element analysis has been proven to be a useful tool when analyzing stress variation. Throughout this project, the cutting simulation has been analyzed using the finite element analysis software ABAQUS. To summarize, stress variation has been examined during different cutting depths. The results from the FE model shows that no critical values were reached in the areas expected to have cracks. The true cause of the problem could not be specified. Therefore, further studies are needed yet this thesis could be a good foundation.