• 한국철도학회논문집
• /
• 제15권4호
• /
• pp.323-328
• /
• 2012

본 연구의 목적은 설계자 전용 알루미늄 압출재 철도차량 차체 구조물의 자동화 구조해석 지원프로그램을 개발하는 것이다. 본 연구에서 개발된 프로그램 명칭은 "AUTO-RAP"이며, 알루미늄 압출재 철도차량 설계 및 구조해석에 대해 전문적인 지식과 경험이 없는 엔지니어도 설계와 검증이 동시에 가능하도록 하였다. 설계자는 기존의 알루미늄 압출재의 데이터베이스를 활용하거나 사용자 정의에 의한 지식기반설계가 가능하도록 하였으며, 설계검증은 철도안전법과 도시철도차량 안전기준에 관한 규칙에 의거하여 철도차량 차체 구조 안전성을 자동으로 평가하도록 프로그래밍 하였다. 또한, 본 프로그램은 MFC(Microsoft Foundation Classes)를 사용하여 GUI 환경을 구축하였으며, ANSYS와 ABAQUS 같은 다양한 상용 유한요소해석 프로그램 및 CAD 프로그램과의 호환성을 위해 .stp, .iges 등의 파일 생성을 지원한다. 결론적으로, 본 프로그램을 통하여 알루미늄 압출재 철도차량 차체 구조물의 제품 설계 비용과 시간 단축에 기여할 것으로 판단된다.

• 대한기계학회논문집A
• /
• 제37권9호
• /
• pp.1099-1107
• /
• 2013

본 연구에서는 알루미늄 압출재로 구성된 한국형 표준전동차모델(K-EMU)의 차체를 대상으로 치수 최적설계와 구조체 소재 변경을 통한 경량화방안에 대해 연구하였다. 우선 K-EMU 차체의 하부구조, 측벽구조, 단부구조의 부재별 두께를 현재의 압출가능 두께를 적용하여 치수 최적화 기법으로 약 14.8% 경량화 하였다. 그리고 치수최적설계 된 K-EMU 차체에 유지보수성이 좋은 고장력강(SMA570)재질의 프레임타입 하부구조를 적용하여 초기 K-EMU 차체대비 약 3.8% 경량화 된 하이브리드 차체를 도출하였다. 마지막으로 샌드위치 복합재를 하부구조와 지붕구조에 적용하여 초기 K-EMU 차체대비 약 30% 경량화 된 초경량 하이브리드 차체를 도출하였다. 도출된 차체 모델들은 모두 전동차 구조체 하중시험법을 만족하였다.

• 한국철도학회:학술대회논문집
• /
• 한국철도학회 2002년도 춘계학술대회 논문집
• /
• pp.364-369
• /
• 2002

The purpose of this paper is to introduce the concept design and the structural strength of the double-deck rolling stock vehicle. Aluminum is very useful material for the carbody structure due to its characteristic of light weight. Large alumillum extrusion profiles(panels) have toe of merits such as easy production of complicated shapes, reduction of welding and cutting lines, and cutting down the labor cost. AED type is being applied to the standard EMUs and the EMUs Kwangju subway in Korea. Light material recommended the double-deck rolling stock vehicle because the center of gravity of the train is higher and its weight is heavier than those of the normal vehicle. So we applied the technology of the large aluminum extrusion profiles(panels) to the double-deck vehicle. We performed the structural strength analysis and examined its safety.

• Composites Research
• /
• 제32권1호
• /
• pp.29-36
• /
• 2019

본 논문의 목적은 소재대체법과 치수최적화 기법을 이용한 2층 고속열차 알루미늄 압출재 차체의 경량 설계를 제시하는 것이다. 소재대체법을 수행하기 위해 위상최적화 기법을 이용하여 차체 구조물의 샌드위치 복합재 적용 부위를 결정하였다. 해석결과, 루프와 2층 언더프레임에 샌드위치 복합재가 적용 가능함을 보여주었다. 치수최적화는 알루미늄 압출재와 카본/에폭시 복합재의 두께를 결정하는데 사용되었다. 치수최적화를 수행하기 위해, 설계변수, 제약조건, 목적함수를 정식화 하였으며 이러한 조건에 의해 유효설계를 도출하였다. 경량 설계의 결과로 2층 고속열차 하이브리드 차체의 무게를 2.18 ton(17.70%)까지 줄일 수 있음을 보여주었다.

• 한국철도학회:학술대회논문집
• /
• 한국철도학회 2008년도 춘계학술대회 논문집
• /
• pp.980-985
• /
• 2008

Since its invention at TWI in 1991, Friction Stir Welding (FSW) has become a major joining process in the aerospace, railway and ship building industries especially in the fabrication of aluminium alloys. In an attempt to optimize the friction stir welding process of Al alloys for extrusion Aluminium carbody of HEMU-400X (Extrusion Aluminum 6xxx series), effects of joining parameters such as tool rotating speed, plunging depth and dwelling time on the weld joints properties were evaluated. Experimental tests were carried out for butt joined Al plates. A wide range of joining conditions could be applied to join Al alloys for Extrusion Aluminum 6xxx series without defects in the weld zone except for certain welding conditions with an insufficient heat input. The microstructures of welds have dynamic-recrystallized grain similar to stir zone in FSW weld. For sound joints without defects, at the rotation speed of 700 rpm with different welding speeds, the tensile strengths of the Stir Zone(SZ) were almost the same, 80% of those of the base metal. (JIS Z 2201)

• 대한기계학회논문집A
• /
• 제30권11호
• /
• pp.1472-1478
• /
• 2006

Double-deck train has been attracted growing attention as next generation transportation around metropolis because of high passenger carrying capacity. To develop high-speed double-deck train with low operational costs, the carbody must be designed as light as possible. In addition, the carbody must be strong enough to ensure the safety of passengers. To meet these design requirements, we perform systematically weight minimization that determines thickness of aluminum extruded panels of the carbody. First, to reduce the design variables, we carry out the screening process that select sensitive or/and important design variables through design exploration. Then, weight minimization is accomplished under multi-loading condition such as vertical, compressive and torsional loads, while satisfying strength constraints of the design regulations. Finally, the result of design optimization is discussed by comparison with its initial design.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 춘계학술대회 논문집
• /
• pp.387-392
• /
• 2005

Double-deck train have studied in the next generation train in KRRI. Double-deck train have more seat capacities compared with single deck vehicles and is a efficient, reliable and comfortable alternative train. Because of heavy weight, weight minimization of double-deck train carbody is imperative to reduce cost and extend life-time of train. Weight minimization problem of the double-deck train car-body is required to decide 66 design variables of thicknesses for large aluminum extruded panel while satisfying stress constraints. Design variables are too many and one execution of structural analysis of double-deck train carbody is time-consuming. Therefore, we adopt approximation technique to save computational cost of optimization process. Metamodels such as response surface model (RSM) and kriging model are used to approximate model-based optimization is described. RSM is easy to obtain and expressed explicit function, but this is not suitable for highly nonlinear and large scaled problems. Kriging model employs an interpolation scheme and is developed in the fields of spatial statistics and geostatistics. Target of this design is to find optimum thickness of AEP to minimize weight of doulbe-deck train carbody. In this study, meta model techniques are introduced to carry out weight minimization of a double-deck train car-body.

• 한국철도학회:학술대회논문집
• /
• 한국철도학회 2002년도 추계학술대회 논문집(II)
• /
• pp.870-875
• /
• 2002

The weight saving that results from the substitution of aluminum alloy for steel may be used to provide reduced energy consumption and labor cost due to simplified manufacturing process and improved vehicle performance. Because of these advantages, foreign advanced rolling stock manufacturing companies have been using aluminum alloy for bodyshell manufacturing. In this research, the comparison between FE analysis and actual load test results is performed for aluminum extrusion bodyshell, which is manufactured by Rotem Company. And the results show that the aluminum carbody structure satisfies the strength and stiffness requirements. Commercial FE analysis code and specially designed test equipment are utilized for the structural analysis and the static load test of bodyshell respectively.

• 한국철도학회:학술대회논문집
• /
• 한국철도학회 1998년도 창립기념 춘계학술대회 논문집
• /
• pp.401-407
• /
• 1998

Recently, as the railway vehicles become speedy and massive, the collision is being regarded as an important factor for the assessment of safety for passenger. And the study of collision is being in progress more actively in advanced nations. In this study, the collision analysis is performed by using non-linear dynamic finite element program PAM-CRASH. The carbody used in analysis is made of Aluminum AL6005A to realize lightweight, and designed and manufactured by DHI (Daewoo Heavy Industry) lately. For the accuracy of the result in the practical collision, the experiment of material properties has been performed. The result of the analysis shows the underframe of rolling stock is the most important part as a collision energy absorbing structure. Further study is needed for optimal design which enables the carbody shell structure to disperse absorbing energy adequately.

• 한국철도학회:학술대회논문집
• /
• 한국철도학회 2000년도 춘계학술대회 논문집
• /
• pp.660-668
• /
• 2000

The stress of connection points between railway vehicle equipment and carbody is considered as one of the important railway safety factor under the vehicle service condition. If any material or equipment drop in to the rail during the service condition, the vehicle call be lose its control as well as run off the rail. The be]t safety evaluation method by using hand calculation is broadly used by manufacturer is introduced in this paper. Two different kinds of the bolt, such as regular bolt and the bolt aluminum extruded carbody use, are tested based on U.I.C according to equipment fixed. The effect of holder and base to bolt under tile loading condition is analyzed on this paper.