Weight Reducing of Aluminum Extrusion Profiles of a Railway-Car Body Based on Topology and Size Optimization

알루미늄 압출재로 이루어진 철도차량 차체의 경량화를 위한 최적설계 방안 연구

  • Han, Soon-Woo (Railway Structure Research Div., Korea Railroad Research Institute) ;
  • Jung, Hyun-Seung (Railway Structure Research Div., Korea Railroad Research Institute)
  • 한순우 (한국철도기술연구원 구조연구실) ;
  • 정현승 (한국철도기술연구원 구조연구실)
  • Received : 2010.11.10
  • Accepted : 2010.12.17
  • Published : 2011.02.01


In this study, we discussed the weight reducing of a urban railway-car body, in particular, of the Korean EMU, by optimizing topology and size of aluminum extrusion profiles. The heaviest parts of aluminum railway-car bodies, i.e., the base plate of underframe and side panels of side frame composed of double skin structures are considered for optimization. Topology optimization process is applied to obtain get an optimized rib structure for the base plate. The thickness of ribs and plates of the topologically optimized base plate and the existing side panel are also optimized by employing the size optimization process. The results are verified by comparing the maximum von Mises stresses and maximum deformation in the case of the existing design with those in the case of the optimized design. It is shown that the weight of a base plate and side panel can be reduced by 12% and that the weight of the whole car body can be reduced by 8.5%.


Aluminum Railway Carbody;Weight Reducing;Topology Optimization;Size Optimization


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