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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
Advanced Composite Materials for the Railroad cars
Advanced Composite Materials for the Railroad cars
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;
Advanced Composite Materials for the Railroad cars
Steel Advantages
Disadvantages
Advanced Composite Materials for the Railroad cars
•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.
Advanced Composite Materials for the Railroad cars
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.
Advanced Composite Materials for the Railroad cars
Advanced Composite Materials for the Railroad cars
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
To be our customers First Choice
To be our customers First Choice
Advanced Composite Materials for the Railroad cars
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
Advanced Composite Materials for the Railroad cars
Advanced Composite Materials for the Railroad cars
Analytic background for composite applicationGeneral concept of CM
Advanced Composite Materials for the Railroad cars
Advanced Composite Materials for the Railroad cars
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
Advanced Composite Materials for the Railroad cars
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
Advanced Composite Materials for the Railroad cars
Advanced Composite Materials for the Railroad cars
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)
Advanced Composite Materials for the Railroad cars
Advanced Composite Materials for the Railroad cars