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Keywords: railway-car body, structural optimization.

Summary

A railway vehicle should be eco-friendly and have a higher fuel efficiency than other vehicles. So requirements for a railway vehicle have increased recently. If the design is made to satisfy the safety of a railway vehicle, the vehicle becomes heavy. If the mass of the vehicle is increased, the operating speed is decreased and the manufacturing cost is increased. When designing a railway vehicle, the safety and the weight should be considered simultaneously. In a large scale problem such as a railway vehicle, when the design of one part is changed, the performance of the other parts cannot be maintained. So design changes are very difficult. Design depending on the intuition and know-how of designers is also difficult. In order to overcome these difficulties, a systematic design process is needed for the design of a railway-car. In recent years, there have been many applications for the design of the structure of a vehicle body using aluminum material. The aluminum railway-car body consists of sandwich panels, and a sandwich panel is made of units which are placed side by side and welded along the edges of facing plates. A unit is fabricated from an extrusion process and constructed with webs and ribs. In this research, the design flow for an aluminum railway-car body is introduced to reduce mass while the safety regulations are guaranteed. The proposed design process consists of three steps. They are the conceptual design using topology optimization, the discrete design with orthogonal arrays (DDOA) and the detailed design using size optimization. In topology optimization, the locations which should be reinforced are identified. The designers should redraw the initial models for the next step based on the results of the topology optimization. In the DDOA, the optimum solutions are obtained by selecting the factors and levels considering the manufacturing process. The factors and levels can be changed according to the kinds of vehicle, the manufacturing process, designed parts, etc. When the characteristic function is defined, the purpose of the design must be clear and accurate. In the final step, the mass of a railway-car body is reduced using size optimization. The passenger car among the various railway vehicles is designed using the proposed design process. The passenger car is a railway vehicle for transporting passengers. The safety and convenience of the passengers have to be guaranteed. Based on the safety regulations for a passenger car, the characteristic function for the DDOA and the formulation for the size optimization are generated. New rib shapes for a passenger car are obtained. The mass of a passenger car is decreased by about 14 percent compared to the mass of an existing a passenger car while the safety regulations are satisfied. The proposed design process is well developed for large scale problems such as the railway-car body.

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Front Page Browse CCP CSETS CTR IJRT Other Authors Search Purchase Guide FAQ Contact us	Civil-Comp Proceedings ISSN 1759-3433 CCP: 98 PROCEEDINGS OF THE FIRST INTERNATIONAL CONFERENCE ON RAILWAY TECHNOLOGY: RESEARCH, DEVELOPMENT AND MAINTENANCE Edited by: J. Pombo Paper 21 A Design Process for a Railway-Car Body with Aluminium Extrusion Panels using Structural Optimization H.A. Lee¹, S.B. Jung², H.H. Jang², D.H. Shin², J.U. Lee³, K.W. Kim³ and G.J. Park⁴ ¹Center of Novel Synthesis of Structural and Mechanical Systems, Hanyang University, Seoul, Korea ²Department of Mechanical Engineering, Hanyang University, Seoul, Korea ³R&D Center, Hyundai Rotem Company, Uiwang City, Korea ⁴Department of Mechanical Engineering, Hanyang University, Ansan City, Korea doi:10.4203/ccp.98.21 purchase the full-text of this paper Full Bibliographic Reference for this paper H.A. Lee, S.B. Jung, H.H. Jang, D.H. Shin, J.U. Lee, K.W. Kim, G.J. Park, "A Design Process for a Railway-Car Body with Aluminium Extrusion Panels using Structural Optimization", in J. Pombo, (Editor), "Proceedings of the First International Conference on Railway Technology: Research, Development and Maintenance", Civil-Comp Press, Stirlingshire, UK, Paper 21, 2012. doi:10.4203/ccp.98.21 Keywords: railway-car body, structural optimization. Summary A railway vehicle should be eco-friendly and have a higher fuel efficiency than other vehicles. So requirements for a railway vehicle have increased recently. If the design is made to satisfy the safety of a railway vehicle, the vehicle becomes heavy. If the mass of the vehicle is increased, the operating speed is decreased and the manufacturing cost is increased. When designing a railway vehicle, the safety and the weight should be considered simultaneously. In a large scale problem such as a railway vehicle, when the design of one part is changed, the performance of the other parts cannot be maintained. So design changes are very difficult. Design depending on the intuition and know-how of designers is also difficult. In order to overcome these difficulties, a systematic design process is needed for the design of a railway-car. In recent years, there have been many applications for the design of the structure of a vehicle body using aluminum material. The aluminum railway-car body consists of sandwich panels, and a sandwich panel is made of units which are placed side by side and welded along the edges of facing plates. A unit is fabricated from an extrusion process and constructed with webs and ribs. In this research, the design flow for an aluminum railway-car body is introduced to reduce mass while the safety regulations are guaranteed. The proposed design process consists of three steps. They are the conceptual design using topology optimization, the discrete design with orthogonal arrays (DDOA) and the detailed design using size optimization. In topology optimization, the locations which should be reinforced are identified. The designers should redraw the initial models for the next step based on the results of the topology optimization. In the DDOA, the optimum solutions are obtained by selecting the factors and levels considering the manufacturing process. The factors and levels can be changed according to the kinds of vehicle, the manufacturing process, designed parts, etc. When the characteristic function is defined, the purpose of the design must be clear and accurate. In the final step, the mass of a railway-car body is reduced using size optimization. The passenger car among the various railway vehicles is designed using the proposed design process. The passenger car is a railway vehicle for transporting passengers. The safety and convenience of the passengers have to be guaranteed. Based on the safety regulations for a passenger car, the characteristic function for the DDOA and the formulation for the size optimization are generated. New rib shapes for a passenger car are obtained. The mass of a passenger car is decreased by about 14 percent compared to the mass of an existing a passenger car while the safety regulations are satisfied. The proposed design process is well developed for large scale problems such as the railway-car body. purchase the full-text of this paper (price £20) go to the previous paper go to the next paper return to the table of contents return to the book description purchase this book (price £110 +P&P)
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