Multi-Stage Topology Optimization for Structural Redesign of Railway Motor Bogie Frames

This study presents a comprehensive structural optimization workflow for a railway motor bogie frame, aimed at developing an innovative and lightweight design compliant with the reference European standards. The methodology integrates a two-stage topology optimization process, supported by an extensive numerical simulation campaign and a dedicated sensitivity analysis to identify the most critical load scenarios. In the first optimization stage, a global evaluation of the frame performance revealed that increasing the number of optimization parameters leads to a rise of approximately 50% in solver iterations. Symmetry constraints proved essential for simplifying both the optimization and the subsequent geometric reconstruction. The minimum feasible feature dimension strongly affected the final solution, modifying the material distribution and enabling a mass reduction of about 18%. The second optimization stage, focused on the cross beams, highlighted the relevance of manufacturing constraints in guiding the solver toward practical configurations. Static and fatigue assessments confirmed stress distributions consistent with the original frame, providing designers with a reliable basis for future material upgrades. Finally, the dynamic analysis showed a first natural frequency above 60 Hz, with variations in the first eigenvalue within 1% and preservation of the local flexural mode shape, ensuring full compatibility with the original frame interfaces and enabling seamless replacement with the optimized configuration.