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Multi-Functional Design of a Composite High-Speed Train Body Structure
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
2014 (English)In: Structural and multidisciplinary optimization (Print), ISSN 1615-147X, E-ISSN 1615-1488, Vol. 50, no 3, 475-488 p.Article in journal (Refereed) Published
Abstract [en]

A multi-level, multi-functional, optimisation methodology is suggested for the design of a composite high speed train car body. The structure consists of a layer of inner lining (glass fibre/vinyl ester), a layer of fibrous insulation, and a load carrying sandwich panel (carbon fibre/epoxy face sheets on a PMI core). Besides the most commonly used design constraints, such as mechanical strength, stiffness and geometry, also acoustic and thermal insulation as well as fire safety is included in the optimisation. The results suggest that well over 40 % mass reduction can be achieved with these types of structures.

Place, publisher, year, edition, pages
2014. Vol. 50, no 3, 475-488 p.
Keyword [en]
Rail vehicle, Car body, Optimisation, Multi-physics, Multi-scale, Multi-discipline, Multi-constraint, Finite element, Composite, Sandwich panels, Stiffness, Strength, Acoustics, Thermal, Insulations, Fire, Dynamics, Modal analysis, Composite Lay-up, Weight minimisation
National Category
Vehicle Engineering
Identifiers
URN: urn:nbn:se:kth:diva-122387DOI: 10.1007/s00158-014-1056-4ISI: 000340401600009Scopus ID: 2-s2.0-84905866006OAI: oai:DiVA.org:kth-122387DiVA: diva2:622087
Funder
Vinnova
Note

Updated from "Accepted" to "Published". QC 20140912

Available from: 2013-05-20 Created: 2013-05-20 Last updated: 2017-12-06Bibliographically 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, Sebastian

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