Session: 12-03-05: General: Mechanics of Solids, Structures and Fluids

Paper Number: 142827

142827 - Design, Analysis and Test of Truck Frame and Bolster for Railway Vehicle 

The design and structural integrity of the truck play a pivotal role in ensuring the overall performance, safety, and reliability of the rail vehicle, making it a critical component in the transportation infrastructure of North America. The design of railway trucks encompasses a multitude of factors crucial for ensuring operational efficiency, safety, and longevity. These factors include axle load, maximum operating and design speed, wheel diameter, dynamic envelop, journal box arrangement, service life, running safety, stability, ride quality, and maintainability. Adherence to industry standards set by organizations like the Federal Railroad Administration (FRA), American Public Transportation Association (APTA), and Association of American Railroads (AAR) is paramount in the design process.

 

For one of the rail vehicle projects in North American market, Finite Element Analysis (FEA) is utilized to guarantee the structural integrity of railway truck components, particularly the frame and bolster, under both testing and revenue service conditions. FEA allows for the calculation of stresses in the frame and bolster for static and fatigue load scenarios. Static loading cases are simulated to ensure that stresses remain below half of the material's yield stress, addressing concerns of safety and longevity. Additionally, fatigue stress calculations consider cyclic loads together with consideration of vehicle acceleration and braking, which are crucial for assessing the long-term durability of the components.In the analysis of static loading cases, Von-Mises stresses are calculated, providing insight into the distribution of stress within the material. The modified Goodman method is employed to determine the endurance limit using the yield strength of the material, ensuring that fatigue failure is mitigated effectively. By employing these sophisticated analytical techniques, the potential failure points are anticipated and the design is optimized for maximum strength and reliability.

 

Static and fatigue testing are then conducted to validate the design, By comparing the results of theoretical simulations with empirical testing, the design is revised for optimization. To make sure that the truck negotiates with the track efficiently, rotation resistance test is conducted as well to provide additional safety to the revenue operation of the rail vehicle.

The design and validation process for railway trucks involves a comprehensive approach that integrates theoretical analysis, adherence to industry standards, and empirical testing. By leveraging advanced analytical techniques like FEA and conducting rigorous testing, the design and manufacturing of the truck meet the industry standard and customer requirements. The rail vehicle has been put into revenue service, the onsite performance demonstrates effective approach in truck design, which is adopted into continuous improvements within organization.

Presenting Author: Yanbo Yin CRRC MA Corporation

Presenting Author Biography: Dr. Yin Yanbo's academic journey commenced with the attainment of his bachelor's and master's degrees from Tsinghua University. His pursuit of scholarly excellence led him to North Carolina State University in the United States, where he completed his Ph.D. in 2007. Dr. Yin's professional trajectory began at Bombardier Transportation, where he contributed to the research and development endeavors in rail vehicle technology. Notable projects under his purview included the Long Island Rail Road (LIRR), Metro-North Railroad (MNR), and the John F. Kennedy Airport Express (JFK) in the United States, as well as various transportation initiatives across Canada, Malaysia, and South Korea.

In 2012, Dr. Yin transitioned to ABB, assuming the role of a technical project manager. Here, he played a pivotal role in market development and oversaw the implementation of ABB traction inverters in North America. Noteworthy accomplishments during his tenure include the successful refurbishment of Newark Liberty International Airport, the Dallas Area Rapid Transit (DART) project, and the auxiliary inverter project for MPI locomotives. Dr. Yin spearheaded technology transfer initiatives from Europe to North America, facilitating localized production to align with regional manufacturing standards.

Subsequently, in 2015, Dr. Yin joined Wabtec (later Faiveley), focusing on the development of rail vehicle door systems and air conditioning technology. His contributions extended to pivotal projects such as the Boston subway, New York City intercity railway, and Ottawa light rail vehicle initiatives in Canada. Notably, he played a key role in the implementation of intelligent maintenance systems for subway vehicle door systems.

In 2019, Dr. Yin assumed a pivotal role at CRRC MA, where he engaged in diverse activities ranging from bidding processes to research, development, production, and manufacturing of rail vehicle projects. Leading the center's foundational research and development endeavors, Dr. Yin delved into areas such as smart manufacturing, intelligent maintenance, additive manufacturing, and intelligent driving, cementing his reputation as a leading figure in the field of rail vehicle

Authors:

Haifeng Hong CRRCMA
Shihai Xue CRRC-Changchun
Wenkang Zhang CRRC Changchun
Long Zhang CRRCMA
Yanbo Yin CRRC MA Corporation
Lvxian Wu CRRCMA
Peng Lu CRRCMA
Qiubo Chen CRRCMA