Abstract
The rising economic and environmental pressures associated with the generation and consumption of energy necessitates the need for lightweighting of railway vehicles. The railway axle is a prime candidate for lightweighting of the unsprung mass. The reduction of unsprung mass correlates to reduced track damage, energy consumption and total operating costs. This paper presents the design of a lightweight multifunctional hybrid metallic-composite railway axle utilising coaxial skins. The lightweight axle assembly comprises a carbon fibre reinforced polymer composite tube with steel stub axles bonded into either end. The structural hybrid metallic-composite railway axle is surrounded by coaxial skins each performing a specific function to meet the secondary requirements. A parametric sizing study is conducted to explore the sensitivity of the design parameters of the composite tube and the stub axle interaction through the adhesive joint. The optimised design parameters of the axle consist of a; composite tube outer diameter of 225 mm, composite tube thickness of 7 mm, steel stub axle extension thickness of 10 mm and a bond overlap length of 100 mm. The optimised hybrid metallic-composite railway axle design concept has a mass of 200 kg representing a reduction of 50% over the solid steel version.
Highlights
The worldwide imperative to reduce carbon dioxide (CO2) emissions poses a challenge to the transportation sector which accounts for approximately 25% of the total emissions generated [1]
Vehicle lightweighting is a means of reducing Carbon dioxide (CO2) emissions as a consequence of less energy being required for propulsion
A prototype, filament wound, carbon fibre reinforced polymer (CFRP) tube axle was manufactured for the British Rail Advanced Passenger Train [6]
Summary
The worldwide imperative to reduce carbon dioxide (CO2) emissions poses a challenge to the transportation sector which accounts for approximately 25% of the total emissions generated [1]. A prototype, filament wound, carbon fibre reinforced polymer (CFRP) tube axle was manufactured for the British Rail Advanced Passenger Train [6]. This initial concept showed a mass savings of 70%. 3. Composite Railway Axle Design Incorporating Coaxial Skins. Construction of the unoptimised structural hybrid metallic-composite railway axle de-. Compliance with the secondary requirements is achieved through the use of coaxial skins integrated with the structural HMC railway axle assembly. Other skins with unique functions could be incorporated into the overall design
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