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Substitution of corrugated sheets in a railway vehicle's body structure by a multiple-requirement based selection process
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Rail Vehicles. KTH, School of Engineering Sciences (SCI), Centres, The KTH Railway Group. KTH, School of Engineering Sciences (SCI), Centres, VinnExcellence Center for ECO2 Vehicle design.
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Rail Vehicles. KTH, School of Engineering Sciences (SCI), Centres, VinnExcellence Center for ECO2 Vehicle design. KTH, School of Engineering Sciences (SCI), Centres, The KTH Railway Group.ORCID iD: 0000-0002-8237-5847
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures. KTH, School of Engineering Sciences (SCI), Centres, VinnExcellence Center for ECO2 Vehicle design.ORCID iD: 0000-0003-0198-6660
2014 (English)In: Proceedings of the Institution of mechanical engineers. Part F, journal of rail and rapid transit, ISSN 0954-4097, E-ISSN 2041-3017, Vol. 228, no 2, 143-157 p.Article in journal (Refereed) Published
Abstract [en]

To simplify construction, reduce weight and improve mechanical properties, a sandwich panel substitution process is performed on corrugated sheets in the floor and roof of a rail vehicle car body. A requirement based selection is used to design the sandwich panels with the corrugated sheet mechanical characteristics as boundaries. Car body stiffness is evaluated by modal analysis. The derived panels reduce the mass of the car body by 600-700kg. Results show the varying importance of the longitudinal, transverse and shear properties of the floor and roof panels, as well as how efficient the corrugated sheets actually are.

Place, publisher, year, edition, pages
2014. Vol. 228, no 2, 143-157 p.
Keyword [en]
sandwich panels, lightweight, corrugated sheet, rail vehicle, modal analysis
National Category
Vehicle Engineering Reliability and Maintenance Other Materials Engineering
Research subject
Järnvägsgruppen - Fordonsteknik
Identifiers
URN: urn:nbn:se:kth:diva-33757DOI: 10.1177/0954409712467139ISI: 000330771400003Scopus ID: 2-s2.0-84892577539OAI: oai:DiVA.org:kth-33757DiVA: diva2:417232
Funder
Vinnova
Note

QC 20140310

Available from: 2011-05-16 Created: 2011-05-16 Last updated: 2017-12-11Bibliographically approved
In thesis
1. Light-weighting Methodology in Rail Vehicle Design through Introduction of Load Carrying Sandwich Panels
Open this publication in new window or tab >>Light-weighting Methodology in Rail Vehicle Design through Introduction of Load Carrying Sandwich Panels
2011 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Lightweight design in rail vehicles has been important for quite some time. Structures have been optimised to fulfill their purpose and cut unnecessary weight to reach allowable axle loads. Classically this is done by using steel, thin-walled structures, throughout the car body, or, alternatively, power-pressed aluminum profiles.

The use of composites and sandwich structures has, however, been somewhat limited in the railway industry, especially when considering High-Speed trains. The anticipated weight savings, and reduced complexity of this type of structure are believed to have great potential in the future. This thesis covers the development of methods for structural stiffness design of lightweight, load carrying, sandwich panels for high-speed rail vehicles. Focusis on reducing the weight of the vehicles while simplifying the construction to reduce manufacturing costs and assembly times. Significant work is put into understanding the dynamic influence this type of structure has on the car body.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2011
Series
Trita-AVE, ISSN 1651-7660 ; 2011:36
Keyword
sandwich panels, rail vehicle, lightweight, optimisation, carbody
National Category
Vehicle Engineering Reliability and Maintenance Other Materials Engineering
Identifiers
urn:nbn:se:kth:diva-33646 (URN)978-91-7501-002-1 (ISBN)
Presentation
2011-05-31, S40, KTH, Teknikringen 8, Stockholm, 08:39 (English)
Opponent
Supervisors
Projects
Multifunctional body panels
Funder
TrenOp, Transport Research Environment with Novel Perspectives
Note
QC 20110516Available from: 2011-05-16 Created: 2011-05-13 Last updated: 2012-06-12Bibliographically approved
2. Multi-Functional Composite Design Concepts for Rail Vehicle Car Bodies
Open this publication in new window or tab >>Multi-Functional Composite Design Concepts for Rail Vehicle Car Bodies
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Structures and material combinations, tailored for multiple purposes, are within the reach of vehicle manufacturers. Besides reducing the environmental impact of the transportation sector these multi-functional structures can reduce costs, such as development, manufacturing and maintenance, and at the same time offer improved comfort to the passengers. This thesis sets out to develop multi-functional design algorithms and evaluate concepts for future composite high speed train car bodies with the objective of optimising the amount of mass needed to fulfil all functions of the structure.

In a first step complete composite car bodies were developed, optimised and evaluated based on global stiffness requirements and load cases. The knowledge gained in this step was used as requirements for the strength and stiffness of panels during the continued development of the multi-functional optimisation which, besides strength and stiffness, later also considers sound transmission, thermal insulation, geometric restrictions, manufacturability and fire safety. To be able to include fire safety in the analysis, a method for simulating the high temperature response of layered composite structures was needed, and developed.

Significant weight reductions are proven when utilising carbon fibre in the load carrying structure of the vehicle, on component level as high as 60%. Structures can be made significantly thinner when using the algorithms developed in this thesis and wall thickness is reduced by 5-6 cm. Analysis carried out and extensive literature surveys also suggest significant cost savings in manufacturing, maintenance and use-phase, even thou the raw material cost can be significantly higher as compared to the conventional steel or aluminium alternatives.

Results from drive cycle simulations showed that the benefit, with respect to reduced energy consumption, is in the range of 0.5-0.8% per reduced weight percentage, comparable to both automotive and air applications.

The algorithms and methods established in this thesis can be directly applied for the development and analysis of future high speed train car bodies.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2013. ix, 59 p.
Keyword
Car body, Composite, Finite element, Lightweight, Multi-discipline, Multi-functional, Optimisation, Rail Vehicles, Sandwich Panels
National Category
Vehicle Engineering
Identifiers
urn:nbn:se:kth:diva-122391 (URN)978-91-7501-751-8 (ISBN)
Public defence
2013-06-10, Kollegiesalen, plan04, Brinellvägen 8, KTH Royal Institute of Technology, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20130521

Available from: 2013-05-21 Created: 2013-05-20 Last updated: 2013-05-21Bibliographically approved

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Stichel, SebastianWennhage, Per

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Proceedings of the Institution of mechanical engineers. Part F, journal of rail and rapid transit
Vehicle EngineeringReliability and MaintenanceOther Materials Engineering

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