Substitution of corrugated sheets in a railway vehicle's body structure by a multiple-requirement based selection process

Wennberg, David; Stichel, Sebastian; Wennhage, Per

doi:10.1177/0954409712467139

Cited by 14 publications

(15 citation statements)

References 10 publications

(10 reference statements)

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“…They proposed to design the shape of the rib and the thickness distribution of the aluminum extruded carbody using a design process based on structural optimization. In 2012, David performed a sandwich panel substitution process to reduce the weight of corrugated sheets in the floor and roof of rolling stock carbodies [8].…”

Section: Introductionmentioning

confidence: 99%

A lightweight design approach for an EMU carbody using a material selection method and size optimization

2016

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This study proposes a weight reduction design approach for urban transit carbody using a material selection method and size optimization. First, the material selection method, which uses specific stiffness and strength indices to predict the weight reduction rate, is set up when the materials of the under-frame and roof structure are substituted. The CFRP was chosen as the best weight reduction material in terms of the material selection method but was not appropriate for application to an urban transit carbody as a thin panel because of outof-plane deformation. Therefore, we applied CFRP-AL honeycomb sandwich composites to the under-frame and roof structures, and the size optimization method was subsequently applied to derive a lightweight composite hybrid carbody design. Finally, the proposed approach was applied to an urban transit carbody, i.e., a Korean electrical multiple units carbody made of aluminum extrusion profiles. The weight of the optimized composite hybrid carbody design was 29.0% lighter than that of the original K-EMU. The resulting composite hybrid carbody design satisfied the design guidelines of the Performance test standard for K-EMU according to the corresponding FE simulations.

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Section: Introductionmentioning

confidence: 99%

A lightweight design approach for an EMU carbody using a material selection method and size optimization

2016

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“…To reduce the car body weight and improve the dynamic properties of the car body, a sandwich panel substitution process was performed on corrugated board of the floor of a rail vehicle car body by Wennberg et al, 9 and they found that the mass of car body could be reduced by 600-700 kg, and the varying importance of the longitudinal, transverse and shear properties of the floor panels can be improved. Hudson et al 10 performed a multiple objective optimisation of low mass and cost on composite sandwich panels for the interior floor structure of a metro car.…”

Section: Introductionmentioning

confidence: 99%

Car body floor vibration of high-speed railway vehicles and its reduction

Gong

Wang

Duan

et al. 2019

Journal of Low Frequency Noise, Vibration and Active Control

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An on-site test has been performed to address the problem of feet numbness caused by the floor vibration of high-speed railway vehicles. Analysis of the floor vibration performance indicates that the vibration of the car body chassis transmitted to the floor by the elastic supports is significantly amplified in the frequency range of 20-50 Hz. This overlaps with the frequency range in which human lower extremities are most sensitive, leading to feet numbness. A refined finite element model of the car body, including the floor panels is developed to further study the vibration mechanism of the floor. Results show that due to the inappropriate design of the elastic support stiffness, the deformations of the floor above the bogie centre for several typical modes in the frequency range of 20-50 Hz are significantly amplified. When the excitation frequencies transmitted from the car body chassis were close to the eigenfrequencies of the floor, the local resonance of the floor will occur, which is the root cause of human feet numbness. The dynamic stiffness of the elastic support is further optimised, and the experimental verification shows that the vibration transmissibility from the car body chassis to the floor in the frequency range of 20-50 Hz has been significantly reduced, and the problem of feet numbness has been solved.

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“…Generally speaking, the freight railway vehicles are designed in such a manner that significant attention has been given to lightweighting. 1,2,[22][23][24] This has been driven in the main by the consideration for reduced emissions and impact on the infrastructure.…”

Section: Introductionmentioning

confidence: 99%

Selection and ranking of the main beam geometry of a freight wagon for lightweighting

Matsika

O'Neill

Grasso

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part F:

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The traditional freight wagons employ I-beam sections as the main load-bearing structures. The primary loads they carry are vertical (from loading units) and axial (from train traction and buffers). Ease of manufacturing has played an important role in the selection of the I-beam for this role. However, with lightweighting increasingly becoming an important design objective, an evaluation needs to be done to assess if there are other existing or new section profiles (geometry) that would carry the same operational loads but are lighter. This paper presents an evaluation of 24 section profiles for their ability to take the operational loads of freight wagons. The profiles are divided into two categories, namely ???conventional ??? made by wagon manufacturers (including the I-beam)??? and ???pre-fabricated??? sections. For ranking purposes, the primary design objectives or key performance indicators were bending stress, associated deflection and buckling load. Subsequently, this was treated as a multi-criteria decision-making process. The loading conditions were applied as prescribed by the EU standard EN 12663-2. To carry out structural analysis, finite element analysis was implemented using ANSYS software. To determine the validity of the finite element analysis results, correlation analysis was done with respect to beam theory. Parameters considered were: maximum stress, deflection, second moment of area, thickness, bending stiffness and flexural rigidity. The paper discusses the impreciseness related to the use of beam theory since the local stiffness of the beam is neglected leading to an inaccurate estimation of the buckling load and the vertical displacement. Even more complicated can be the estimation of the maximum stress to be used for comparison when features such as spot welds are present. The nominal stress values computed by means of Navier equation lead to an inaccurate value of the stress since it neglects the variations in the local stiffness, which can lead to an increase in the bending stress values. The main objective of the paper is the applicability of particular section profiles to the railway field with the aim of lightweighting the main structure. Sections commonly adopted in civil applications have also been investigated to understand the stiffness and strength under railway service loads. The common approach reported in literature so far makes use either of the beam theory1 or topological finite element approach2 to determine the optimised shape under the action of the simplified loading conditions. Although the previous approaches seem to be more general, the assumptions made affect the optimisation process since the stress state differs from that attained under the actual service load in the real structure. In this paper, the use of complex shape cross sections and detailed finite element models allows to take account of the real behaviour in terms of stiffness distribution and local stress effects due to manufacturing features like welds. The structural assessment carried out with the ...

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Substitution of corrugated sheets in a railway vehicle's body structure by a multiple-requirement based selection process

Cited by 14 publications

References 10 publications

A lightweight design approach for an EMU carbody using a material selection method and size optimization

A lightweight design approach for an EMU carbody using a material selection method and size optimization

Car body floor vibration of high-speed railway vehicles and its reduction

Selection and ranking of the main beam geometry of a freight wagon for lightweighting

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