Advanced composite materials for the Railroad cars

Euro-Zel 2011

19th International Symposium

Advanced Composite Materials for the Railroad cars

Presented by Irina GarustovichMoscow State University of Transport Engineers

(MIIT)

1. Introduction 1.1. General concept of the RC 1.2. Materials used in RC building up to date 1.3. New materials search

2. Analytic background for composite application

2.1. Mechanical model 2.2. General concept of composite materials 2.3. Designing

3. Conclusions



The passenger vehicles have all-metal structure with car body length 23.6 m;

Vehicle body represents all-metal rectangular framework consisting of frame, flooring, roof, side and end walls

It is vehicle body that is bearing structure able to withstand all possible kinds of loads the train is exposed to during its life cycle.

Each of the items of vehicle has its own skeleton (vertical braces, ties, beams, bows) covered by steel sheets.

In whole car body frame means center sill, center pivots, crosswise beams, and metal flooring

Low alloy steel is the most common material applied for the railway vehicles (for bearing elements of the vehicle body),

other steel types are mainly used for supporting elements of siding.

List of steel types used for the vehicles: Low alloy steel in accordance to GOST 5058; High grade constructional carbon hot-rolled profiled steel

in accordance to GOST 1050; Carbon hot-rolled bridge steel in accordance to GOST 6713 Carbon steel in accordance to GOST 380;


Steel Advantages

Disadvantages


•reliability, •relative light weight,•proofness, •simplicity of maintenance and operation

1. At low temperatures:

hardness increase, impact strength

and ductility properties decrease;

2. poor resistance to corrosion.


Aggressive

exposure

Temperature drop

Static loads

Dynamic loads

The main parts are complicated large structures consisting of the welded elements. The welding causes unequal heating of the elements. Local heating with following cooling leads to change of metal properties Car body appearance is disimproved by shape defects caused by welding, The welding also increases the number of corrosion problems.

Material technology needs new impulse Demand for new materials, alternative to metal structures, research

Elimination of financial cost of trains, Elimination of safety risks, Elimination of the pollution of the environment due to permanent corrosion of metal elements.



Upon vehicles strength assessment it is reasonable to proceed with the static mechanical model;

The mechanical model of passenger vehicle is given by 9 solids adjacent internally by elastic and absorbing bracings;

Main assumptions:

1. the bodies are assumed to be rigid;

2. the vehicle is running at a constant speed;

3. track is totally rigid and straight;

4. wind distribution is 1000 N per sq. m

To be our customers First Choice




Fibrous composite laminate

Matrix

Advanced composite materials

Carbon

Glass

Boron

Graphite

Polyester

Vinilester

Epoxy

stiffness-to-density ratios

strength-to-density ratios

low thermal expansion

resistance to specific environments



Analytic background for composite applicationGeneral concept of CM



Tensile strength

Modulus of elasticity

Compressive strength

365-390 MPa

210 GPa

365-390 MPa

211,2 MPa

8035 MPa

248,6 kN

Features Steel Composites


f

i

fh

F

t

•Assume that geometric cross section of the car body is thin wall rectangular profile•Initial data for calculations:

1. MT=45 000 kg, V= 160 kmph (44 mps); 2. q= 500 N/sq.m, considering storm conditions q = 1000

N/sq.m; 3. The train is suburban, Mp = 70 kg; 4. The train is going in straight lines

•Definition of forces (wind force, centrifugal force, coupling force, truck force) to assume force flow in projected laminate and its thickness



background for advanced materials application for the railroad cars

the first approach for composite car model. The forces affecting the car body were discussed, the results would

be used for further model configuration and laminate assessment. Unsaturated polyester based resins will be reviewed as potential

matrix material; E-glass fibers will be reviewed as potential reinforcement material. Application of advanced materials would allow new level of car

performance:

1. greater service life of trains,

2. weight savings leading to reduce energy consumption (approximately 0.026 kWh/ton*km)



Documents

Advanced composite materials for the Railroad cars