European project Run2Rail is investigating whether frames with carbon fibre and 3D printing critical parts can make rail vehicles lighter, quieter, more comfortable and reliable.
The project is being carried out by the Institute for Rail Research (IRR) at the University of Huddersfield in the UK. The aim is to investigate the potential - and shortcomings - of new materials. The benefits are sought in a reduction of the of the mass of wheel sets, simple design and a reduction in lifetime costs.
Layer by layer
IRR is collaborating with the Politecnico di Milano, Rina and Italian engineering and design firm Blue Group. At the launch meeting, it was decided to explore the use of carbon fibre composites, which would allow the bogie frames to be produced layer by layer with robots. "You can have any number of curves and shapes, building the shape you really want, whereas with a steel frame in particular, only a certain number of shapes are possible," said IRR director Professor Simon Iwnicki. "Moreover, carbon fibre is much lighter and you can put material where you want it, making it even lighter."
Composite wheels?
Another track in the research is the use of 3D printing with lasers and steel powders. The technology is maturing and components such as axle boxes and brake brackets are now being considered for the process. Although one company has already created a bogie engineering with carbon fibre-reinforced leaf springs, the Run2Rail project could lead to unprecedented use of new materials in rolling stock. But wheels are still likely to be made of conventional steel. "We have considered alternative materials for wheel hubs and axles, but the failure modes and risks are not yet fully understood. But we are looking into it," Iwnicki said.
By: Kelly Bakker
Source: The Engineer/Run2Rail
