Development of a Design Procedure Combining Topological Optimization and a Multibody Environment: Application to a Tram Motor Bogie Frame

Abstract

Nowadays, it is essential to find increasingly rapid and efficient design strategies. This approach becomes crucial in the railway industry, where components must be verified according to multiple reference standards, both structurally and dynamically. In this context, the present research activity aims to develop a fast and effective desin procedure based on European reference standards. The goal was to develop the geometry of a motor bogie frame for a tram vehicle, integrating three fundamental tools for development: finite element simulations and topological structural optimization, a Write Computer Aided Design (CAD) environment, and a multibody environment. Their integration could enhance design accuracy, streamline the traditional design workflow, and support innovation. The optimization process involved the introduction of complex technological constraints, directing the geometry toward production by casting. A tool was developed to automate running dynamics simulations and the output of results for immediate verification of the entire vehicle performance. Finally, the new geometry was tested both structurally and dynamically. The mass was reduced by approximately 7% while ensuring satisfactory mechanical performance. The maximum value of stress was reduced by about 16%. The dynamic performance showed negligible variation, confirming the encouraging outcomes to make this procedure increasingly effective and reliable.