• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.4
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• pp.86-92
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• 2017

In this study, a running performance evaluation and roller rig test was conducted to evaluate the applicability of a composite bogie frame, which has the role of the primary suspension. The composite bogie frame was made of a GEP224 glass/epoxy prepreg. Vehicle dynamic analysis was carried out on the composite bogie with three different kinds of side beam thicknesses (50 mm, 80 mm, and 150 mm). From the results, the composite bogie with a side beam thickness of 80 mm satisfied all the dynamic design requirements. Although the composite bogie with the side beam thickness of 50mm also met the design requirements, its critical speed was just a 2% margin to the requirement. In contrast, the model of the side beam thickness of 150mm did not meet the ride comfort. In addition, a composite bogie frame with the side beam thickness of 80 mm was fabricated and installed on a complete bogie. Moreover, the roller rig test using the fully equipped bogie was performed to evaluate the critical speed. During the test, the lateral excitation was imposed on the wheelsets to realize the rail irregularity. There was no divergence of the lateral displacement of the wheelsets while increasing the speed. The measured critical speed was similar to the predicted result.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.10a
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• pp.859-860
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• 2012

• Proceedings of the KSR Conference
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• 2010.06a
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• pp.627-632
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• 2010

Recently the research for lightening the railway vehicle is actively made according to the demand of the environment-friendly technology development contributing to the energy cost reduction and the green growth. The railway vehicle lightweight research is expanded to the load-supporting first structure from the secondary structure which doesn't support the load. After the composite car body development used in the Korean tilting train is completed, the composite bogie frame development in which the weight reduction efficiency is large is progressed. In this paper, distributed strain was monitored when the train load was added to the central part of the composite bogie side-frame. By using the optical fiber which was attached to the lower part of the side-frame and the developed Brillouin correlation domain analysis (BOCDA) system, the strain distribution could be measured with 3cm step over 3m section. This strain distribution was compared with the design value by the FE analysis when the load of 14ton and 18ton added. This experiment can verify the manufactured composite bogie side-frame.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.10a
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• pp.797-798
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• 2012

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.3
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• pp.283-289
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• 2015

In this study, the lightweight design of a brake bracket for a composite bogie was studied by considering two brake bracket models with thicknesses of 12t and 9t, respectively. For achieving this goal, finite element analysis and topology optimization were conducted. Firstly, the largest cross-sectional areas of the vertical and horizontal plates of the brake bracket were selected as the design variables. As the constraint, the Z-axis displacement of the brake bracket was increased by 2.5 units from the initial displacement value. The minimum volume fraction of the design regions was chosen as the objective function. The full model comprised a composite bogie frame and brackets attached together. However, to reduce the analysis time, 1D beam elements were used instead of the composite bogie frame by ensuring its equivalence with the full model. The result revealed that the weights of the 12t and 9t models of the brake bracket were reduced to 60 kg and 31 kg, respectively.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.3
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• pp.303-309
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• 2015

In this study, a vehicle dynamic analysis and roller rig test were performed to evaluate the applicability of a suspensionless composite bogie to railway vehicles. A vehicle dynamic analysis was carried out under different rubber bushing stiffness values. The stiffness of the rubber bushing that plays a role in guiding wheel sets was varied in the range of 10-100 MN/m, in 10-MN/m steps. Based on the results, the composite bogie with a rubber bushing stiffness of more than 40 MN/m satisfied the design requirements. In addition, a rubber bushing with a stiffness of 81 MN/m was fabricated, and a roller rig test was performed. Based on the test results, the vehicle equipped with the composite bogie had a critical speed of 363 km/h, which agreed with the simulation result within an error of 10%.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.8
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• pp.913-920
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• 2011

We describe the evaluation of the fatigue life and strength of a lightweight railway bogie frame made of glass fiber/epoxy 4-harness satin-woven composites. To obtain the S-N curve for the evaluation of the fatigue characteristics of the composite bogie frame, we performed a tension-compression fatigue test for composite specimens with different stacking sequences of the warp direction, fill direction, and $0^{\circ}/90^^{\circ}$ direction. We used a stress ratio (R) of -1, a frequency of 5 Hz, and an endurance limit of $10^7$. The fatigue strength of the composite bogie frame was evaluated by a Goodman diagram according to JIS E 4207. The results show that the fatigue life and strength of the lightweight composite bogie satisfy the requirements of JIS E 4207. Given its weight, its performance was better than that of a conventional metal bogie frame based on an SM490A steel material.

• Composites Research
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• v.28 no.6
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• pp.372-377
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• 2015

In this study, we analyzed process numerically when a bogie frame skin is manufactured by applying resin transfer molding process using composite material instead of steel. Processing time was compared based on the various thickness of bogie frame skin and the weight variation of a skin was also considered. As a result, RTM processing time decreases and the weight of a bogie reduces as the thickness of frame skin increases with the assumption that fiber volume is constant inside the skin. By considering these results as the information to estimate the production cost, trade-off between two fields, processing time and structural properties, can be performed in design optimization to produce bogie frame.

• Composites Research
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• v.23 no.5
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• pp.22-29
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• 2010

This paper describes the evaluations of tension-compression fatigue characteristics and life for glass fiber/epoxy laminate composite applied to railway bogie to reduce weight. Test samples of tension-compression fatigue were composed of glass fiber/epoxy 4-harness woven laminate composites with different stacking sequence of warp-direction, fill-direction and ${\pm}45^{\circ}$-direction. The tension-compression fatigue test was conducted with stress ratio (R) of -1 and frequency of 5Hz. Goodman diagram were used to evaluate the fatigue characteristics and life of glass fiber/epoxy 4-harness satin woven laminate composite. Anti-buckling jig was designed to prevent buckling of specimen under compression load. The test results showed that the fatigue characteristics of glass fiber/epoxy 4-harness satin woven laminate composite with stacking sequence of warp-direction had a good performance in comparison with that of SM490 used to conventional metal railway bogie.

• Composites Research
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• v.23 no.6
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• pp.19-25
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• 2010

This paper describes the optimum design of bolt locations for metal joint parts of railway bogie frame made of glass fiber/epoxy 4-harness satin woven laminate composite and PVC foam core. The optimum design analysis was done by sub-problem approximation method using Ansys Parameter Design Language(APDL). The sub-modeling method was introduced to conduct the detailed recalculation for the only target parts and reduce calculating time. The structural analysis for composite bogie frame was performed according to JIS E 4207. The results showed that the optimum design analysis using sub-modeling method was able to obtain faster and more precise results than that of the entire model by the control of mesh size for the target parts, and the maximum Von-Mises stress has been reduced in comparison with its original dimensions due to the optimum design of bolt locations.