Cab Car Research Articles

Variable Stiffness Design and Multiobjective Crashworthiness Optimization for Collision Post of Subway Cab Cars

This paper proposes a variable stiffness collision post (VSCP) structure based on a uniform stiffness collision post (USCP) structure and performs stiffness matching optimization for VSCPs. A collision post structure assembled in a subway front-end frame can maintain the living space and absorb a certain amount of the kinetic energy of an impact. The experiment was applied on USCP, and the finite element model was verified experimentally. To investigate the effects of the stiffness parameters of VSCP on the specific energy absorption response (SEA_VSCP) and the area of intrusion response (S_In), response surface models fitted from design of experiment were adopted with the finite element model. In addition, a multiobjective optimization design was realized by using the global response search method and a Pareto frontier sequence was generated, which was based on the developed response surface model. It was found that the optimal value of SEA_VSCP and S_In responses cannot be achieved at the same time. Finally, a grey relational analysis is propounded to attain a desirable balance between SEA_VSCP and S_In from the Pareto frontier sequence under constraints of the peak crash force of VSCP and energy absorption of the front-end of cab car. The optimization result shows that the crashworthiness of VSCP is better than that of USCP.

Crashworthiness design and experimental validation of a novel collision post structure for subway cab cars

This paper proposes a novel collision post structure designed to improve the crashworthiness of subway cab cars. The structure provides two innovative features: 1) a simpler connection between the post and the car roof, which gives a more reasonable load transfer path to reduce the stress concentration at the joint; and 2) a stiffness induction design that provides an ideal deformation model to protect the safe space of the cab cars. The novel collision post structure was evaluated with finite element analysis, and a prototype cab car was mechanically tested. The results demonstrate that the deformation response was stable and agreed well with the expected ideal mode. The maximum load was 874.17 kN and the responses remained well above the elastic design load of 334 kN as required by the design specification. In addition, there was no significant tearing failure during the whole test process. Therefore, the novel collision post structure proposed has met the requirements specified in new standard to improve the crashworthiness of subway cab cars. Finally, the energy absorption efficiency and light weight design highlights were also summarized and discussed.

Analysis of crush behaviours of a rail cab car and structural modifications for improved crashworthiness

In this paper, the authors present a crashworthiness assessment and suggestions for modification of a conventionally designed rail vehicle with a driving cab (cab car). The analytical approach, based on numerical analysis, consisted of two stages. Firstly, the crashworthiness of the cab car was assessed by simulating a collision between the cab car and a rigid wall. Then, after analysing structural weaknesses, the design of the cab car was modified and simulated again in the same scenario. It was found that downward bending is an intrinsic weakness in conventional rail vehicles and that jackknifing is a main form of failures in conventional rail vehicle components. The cab car, as modified by the authors, overcomes the original weaknesses and shows the desired progressive collapse behaviour in simulation. The conclusions have general relevance for other studies but more importantly, point to the need for a rethink of some aspects of rail vehicle design.

Fracture prediction in 4-point bending of an extruded aluminum panel

Currently, the ICE cab cars in Europe are of all-aluminum construction for durability and low weight. Several serious train collisions involving this type of train raised questions about their integrity under accidental loads. A typical aluminum cab car is assembled from extruded aluminum panels, which are MIG welded, forming long seam lines. In this work, crushing characteristics of full scale sandwich panels under a 4-point bending load configuration were studied experimentally and numerically. Tests were run all the way to first fracture which occurred inside buckling induced dimples on the compressive side. The force–deflection response and fracture initiation were predicted by the finite element method and compared with experimental results. The location of the first fracture and the corresponding load was predicted with great accuracy using a newly developed fracture criterion. Based on a simplified beam model, a closed form analytical solution of the force–deflection response for the pre-fracture stage was also developed.