Dynamic size optimization approach to support railway carbody lightweight design process

The transition to a globalised electrical power supply pushes rolling stock manufacturers to find structural solutions for reducing the power required by the vehicles. Within a market where details can make the difference in economic terms, the concept of design optimization is becoming established. However, current industrial procedure for the evaluation of carbody structural strength, in static field and according to EN 12663-1:2015 standard, does not include any optimization process. More in general, optimization processes, and especially dynamic optimization, are not widely used for designing of railway vehicles. In this framework, the present paper proposes a new dynamic optimization approach to support the design of railway vehicle carbodies subjected to static loads. Proposed methodology aims to minimize the mass of the metallic structure, working on the thicknesses of the optimized components, maintaining the baseline geometry. The constraint function was imposed on the first natural vibration frequency of the system. The optimization strategy is based on a dynamic size optimization process in conjunction with modal analysis techniques, applied on the single carbody shell. The procedure has involved the roof assembly of a single tram vehicle body. The proposed approach is resulted numerically efficient in terms of calculation times. Encouraging results have been achieved in terms of mass saving and mechanical behaviour of the carbody shell. Optimized components were 21% lighter than the original, that corresponds to 3% if evaluated on the total mass of the single carbody metallic structure. The methodology turns out to be a useful tool for supporting designers to reduce the mass of the carbody structures, reducing overdimensioning condition that could affect the carbody structure.