The developed holistic methodical approach has high lightweight construction potential with regard to a rail car body. The developed procedure is carried out on a high speed car body. At first the principal force paths are calculated from which force flow optimised structures can be derived. Within this process results of the topology optimisation are used to conclude favourable lightweight solutions. Novel basic design principles for car body structures are demonstrated. Based on general findings the application to a car body of a high-speed double-deck car body is performed. For the panelling of the car body a systematic process is described on the basis of the benefits of sandwich elements. This allows more favourable selection and construction of the sandwich elements adapted to the requirements. In a further step the car body segment in the area of the running gears is selected as an example of further construction advantages. As a result the varied and extensive requirements of the conceptual design of this segment present a special challenge. The design of the running gear segment consists of a bending and torsion restistant structure. Based on the specific findings of the topology opimisation the main load paths have been defined. Due to the methodical approach to determine the load paths and the derivation of an appropriate structure, a closed chain of development can be demonstrated. It is concluded that a weight reduction of up to 30% compared with comparable car bodies is feasible.
Methodology for force flow optimised car body structures and implementation
2012
14 Seiten, 9 Bilder, 12 Quellen
Aufsatz (Konferenz)
Datenträger
Englisch
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