OPTIMIZATION AND DESIGN OF THE 2ND GENERATION OF AN INNOVATIVE CHASSIS FOR HIGH-SPEED PASSENGER TRAIN

Abstract

As part of the Next Generation Train (NGT) project of the German Aerospace Center (DLR), an innovative single wheel-unit bogie with independently rotating wheels (IRW) is being developed for a high-speed passenger train (HST). The train design emphasizes on lightweight design methods to conceive an energy-efficient, high performance vehicle concept. The work presented in this thesis focuses on the optimization of the second-generation innovative bogie of NGT HST in terms of lightweight design, complexity, cost, and maintenance. Following a systematic product development method, potentials for optimization were identified, and corresponding solutions were proposed. The design requirements called for a complete redesign of the axle bridge. Topology optimization was performed on a methodically developed design space to create a high-stiffness material distribution. Through a series of iterations, a manufacturable design for the axle bridge was developed from the topology layout, and structural analyses employing the finite element method were performed to ensure the structural adequacy and safety of the proposed axle bridge design. The developed axle bridge design was able to fulfill the design requirements and was optimized for lightweight design, complexity, cost, and maintenance. The design presented in this thesis serves as a demonstrator for a conceptual design and is not intended for immediate or mass production.