Development and validation of models for multi-physics structural optimization of components for railway vehicles

The railway industry is experiencing major transformations, driven by the demand for energy-efficient and structurally optimized components. Manufacturers face the challenge of reducing energy consumption while maintaining or improving the mechanical performance of vehicles. The integration of innovative materials and the development of advanced design methodologies focused on structural efficiency, including optimization techniques, can facilitate this transition. This research work presents the development of several structural optimization procedures applied to the main railway vehicle components, from the structural point of view, such as the carbody shell, bogie frame, and bolster beam. These methodologies combine dynamic, topological, and size optimization techniques to enhance complex system designs, also integrating manufacturing constraints related to the casting process. The optimization processes consider both static and dynamic loads, resulting compliant to the key European standards. The versatility of these optimization methods has been demonstrated, allowing them to be applied to a wide range of components with distinct mechanical and geometric characteristics. The results are promising, highlighting the potential of structural optimization to foster innovation in railway vehicle design. Future developments will aim to refine these methodologies and extend their application to new components, enhancing both energy efficiency and structural performance across the industry.