• Proceedings of the Korean Society For Composite Materials Conference
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• 2004.04a
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• pp.47-50
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• 2004

Weight reduction of the carbody is of great concern in developing high speed tilting train. Currently the composite materials are widely applied to the carbody structure due to their excellent material properties such as high specific strength and stiffness characteristics. In this paper, finite element analysis was conducted to design sandwich structures of composite carbody of the Korean Tilting Train eXpress(TTX). Several load tests on the carbody according to JIS E 7105, such as static vertical, compressive and torsional load tests was performed by finite element analysis, and the structural safety of composite carbody structure was verified.

• Journal of the Korean Society for Railway
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• v.3 no.2
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• pp.92-99
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• 2000

Composites are very useful material for light train carbody due to its high specific strength and lightweight characteristics. The composites, called 3-D board, are developed with a special stitching method. In this process, the glass fiber fabrics of skin material and foam core material are stitched together with glass fiber thread. The glass thread in Z-axis turns into FRP form. The conventional delamination problem can be solved with 3-D sandwich structure. In addition, with the lower density of foam, the weight of the panel and the operation expenses can be highly reduced. To evaluate the usefulness of the 3-D board, the double-deck light train carbody is studied. The stress analyses are carried out under various loads and boundary conditions with FEM Code, ANSYS. On comparing with the aluminum carbody, 3-D board carbody can be reduced by about 2 ton for the total weight of carbody.

• Proceedings of the KSR Conference
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• 2003.10c
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• pp.98-102
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• 2003

The use of composite materials for the carbody structures of tilting train has many advantages because of manufacturing variety, specific high-strength & stiffness characteristics, and long-life durability, but the strongest advantage is the possibility of lightweight product. In the leading countries, the composite materials are used for the material for drivers' cabs, interior/exterior equipments for railway train, and it is now developing the composite materials applied for the train carbody structure. In this paper, we conducted the evaluation of structural stability for the all aluminum carbody, all composite carbody and hybrid carbody structures of the Korean Tilting Train eXpress(TTX) with the service speed of 180km/h.

• Proceedings of the KSR Conference
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• 2002.10a
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• pp.156-161
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• 2002

This paper describes the result of carbody load test. The purpose of the test is to evaluate an safety which carbody structure shall be considered fully sufficient rigidity so as to satisfy proper system function under maximum load and operating condition. Carbody material applied a stainless steel and an aluminum alloy, The stainless steel model is the carbody of a motor car which is delivering to KNR line 1 in 2002 and the aluminum alloy model is the carbody of a motor car which is delivering to GWANGJU line 1 in 2003. This strength test is based on "performance test standard for Electrical Multiple Unit, noticed by Ministry of Construction ＆ Transportation, in 2000" and reference code is UIC 566 and JIS E 7105.

• Journal of the Korean Society for Railway
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• v.7 no.1
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• pp.32-36
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• 2004

Aluminum carbody for rolling stocks is light and perfectly recycled, but includes severe defects which are very dangerous to fatigue strength. Static load test has been performed up to date to assess structural safety of the carbody. However, static load test is not sufficient to evaluate fatigue strength of the carbody, because fatigue failure is caused by dynamic load. In this study, the established load test methods for carbody are described and the characteristics of the methods are discussed. Also, a testing method to simulate dynamic loading condition is proposed for evaluation of fatigue strength of the carbody. The results by the proposed testing method are compared with the results by the static load test and new findings are discussed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.9
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• pp.1099-1107
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• 2013

This study proposes a weight reduction design for urban transit, specifically, a Korean EMU carbody made of aluminum extrusion profiles, according to size optimization and useful material changes. First, the thickness of the under-frame, side-panels, and end-panels were optimized by the size optimization process, and then, the weight of the Korean EMU carbody could be reduced to approximately 14.8%. Second, the under-frame of the optimized carbody was substituted with a frame-type structure made of SMA 570, and then, the weight of the hybrid-type carbody was 3.8% lighter than that of the initial K-EMU. Finally, the under-frame and the roof-panel were substituted with a composite material sandwich to obtain an ultralight hybrid-type carbody. The weight of the ultralight hybrid-type carbody was 30% lighter than that of the initial K-EMU. All the resulting carbody models satisfied the design regulations of the domestic Performance Test Standard for Electrical Multiple Unit.

• Proceedings of the KSR Conference
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• 2007.11a
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• pp.30-34
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• 2007

Structural integrity of railway vehicles should last for a long period against various and continuous fatigue loadings, and the carbody structures of railway vehicle are manufactured by applying multiform welding types for each material. Since the most of cracks are occurred and proceeded at the vicinity of welding area during the lifetime of carbody structure, the fatigue strength evaluation for welding area of carbody structure should have been carried out. Rotem Company has evaluated lifetime and fatigue strength of carbody structure according to the fatigue analysis based on the international standard and/or inner-official regulation. This study introduces the fatigue analysis method that we have evaluated and calculated the damages for the welding areas of carbody structure under various fatigue loading conditions using cumulative fatigue damage rule(Miner's rule) to verify whether the cumulative damage does exceed unity. This study contains the fatigue test of specimens to derive stress-life relations(S-N curve), sub-modeling analysis and the calculation of cumulative damages under fatigue loading. The fatigue analysis verifies the welding area shall be capable of withstanding under fatigue loading, identifies how critical area shall be selected and presents the principles to be used for design verification.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.1051-1055
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• 2003

Aluminum carbody for rolling stocks is light and perfectly recycled, but includes severe defects which are very dangerous to fatigue strength. Structural integrity assessment for the carbody by static load test has been performed up to date. In this study, to evaluate fatigue strength of the aluminum carbody of urban transit unit. a testing method to simulate dynamic loading condition was proposed and the fatigue strength of the carbody was evaluated. The dynamic load test results showed that the alternating stress ranges were different from the estimated ranges based on the static test results. Excessive stress ranges at the center are thought to come from the flexible motion of the carbody. published fatigue test data for aluminum components, but variation of alternating acceleration along the length due to flexibility of carbody yielded unexpected results. Because fatigue strength based on the static test results may be overestimated at the center, modification of testing method is necessary.

• Proceedings of the KSR Conference
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• 2004.06a
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• pp.754-760
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• 2004

Structural analysis and tests were conducted for a carbody manufactured by aluminum alloy. The results were compared, and structural safety was evaluated based on the results. Aluminum carbody in Kwangju turned out safe in terms of structural Strength.

• Proceedings of the KWS Conference
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• 2004.05a
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• pp.290-292
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• 2004

In this paper, static and fatigue load tests for the specimens, components and carbody were carried out to investigate the strength of welded joints in aluminum rolling stock. Tensile load test results showed that the static strength of welded joint for heat-treated alloys is reduced significantly and fatigue strengths are scattered by the welding imperfections. Component and whole carbody fatigue test results showed agreements with the design fatigue strength standards for specimens of same joint detail. Test results revealed that full penetration welding and strict management of welding procedure are crucial for securing strength of welded joint in aluminum carbody.