A strategy for lightweight designing of a railway vehicle car body including composite material and dynamic structural optimization

Rolling stock manufacturers are finding structural solutions to reduce power required by the vehicles, and the lightweight design of the car body represents a possible solution. Optimization processes and innovative materials can be combined in order to achieve this goal. In this framework, we propose the redesign and optimization process of the car body roof for a light rail vehicle, introducing a sandwich structure. Bonded joint was used as a fastening system. The project was carried out on a single car of a modern tram platform. This preliminary numerical work was developed in two main steps: redesign of the car body structure and optimization of the innovated system. Objective of the process was the mass reduction of the whole metallic structure, while the constraint condition was imposed on the first frequency of vibration of the system. The effect of introducing a sandwich panel within the roof assembly was evaluated, focusing on the mechanical and dynamic performances of the whole car body. A mass saving of 63% on the optimized components was achieved, corresponding to a 7.6% if compared to the complete car body shell. In addition, a positive increasing of 17.7% on the first frequency of vibration was observed. Encouraging results have been achieved in terms of weight reduction and mechanical behaviour of the innovated car body.