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Optimisation of sandwich panels for the load carrying structure of high-speed 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.
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
2012 (English)In: International Journal of Aerospace and Lightweight Structures, ISSN 2010-4286, Vol. 2, no 1, 19-40 p.Article in journal (Refereed) Published
Abstract [en]

This paper investigates how various requirements, such as stiffness, strength, buckling, thickness and area density, influence the choice of load carrying sandwich panels for highspeed rail vehicles. Requirements on the load carrying structure are defined where after various sandwich alternatives are chosen to match these requirements. The initial panels are optimised with the software package HyperWorks. Refined optimisation results are then studied by Finite Element Analysis. A total weight reduction of over 30% of the load carrying structure is achieved.

Place, publisher, year, edition, pages
Research Publishing Services, 2012. Vol. 2, no 1, 19-40 p.
Keyword [en]
Finite element method, Sub modeling, Composites
National Category
Composite Science and Engineering Vehicle Engineering
Research subject
Järnvägsgruppen - Fordonsteknik
Identifiers
URN: urn:nbn:se:kth:diva-90379DOI: 10.3850/S2010428612000207OAI: oai:DiVA.org:kth-90379DiVA: diva2:505267
Funder
TrenOp, Transport Research Environment with Novel Perspectives
Note

QC 20120504

Available from: 2012-05-04 Created: 2012-02-23 Last updated: 2013-05-21Bibliographically approved
In thesis
1. 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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