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Design of a Lightweight Multifunctional Composite Railway Axle Utilising Coaxial Skins

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Design of a Lightweight Multifunctional Composite Railway Axle Utilising Coaxial Skins Article Design of a Lightweight Multifunctional Composite Railway Axle Utilising Coaxial Skins Preetum J. Mistry * , Michael S. Johnson , Charles A. McRobie and Ivor A. Jones Composites Research Group, Faculty of Engineering, Jubilee Campus, University of Nottingham, Advanced Manufacturing Building, Nottingham NG8 1BB, UK; [email protected] (M.S.J.); [email protected] (C.A.M.); [email protected] (I.A.J.) * Correspondence: [email protected] Abstract: The rising economic and environmental pressures associated with the generation and consumption of energy necessitates the need for lightweighting of railway vehicles. The railway axle is a prime candidate for lightweighting of the unsprung mass. The reduction of unsprung mass correlates to reduced track damage, energy consumption and total operating costs. This paper presents the design of a lightweight multifunctional hybrid metallic-composite railway axle utilising coaxial skins. The lightweight axle assembly comprises a carbon fibre reinforced polymer composite tube with steel stub axles bonded into either end. The structural hybrid metallic-composite railway axle is surrounded by coaxial skins each performing a specific function to meet the secondary requirements. A parametric sizing study is conducted to explore the sensitivity of the design parameters of the composite tube and the stub axle interaction through the adhesive joint. The optimised design parameters of the axle consist of a; composite tube outer diameter of 225 mm, composite tube thickness of 7 mm, steel stub axle extension thickness of 10 mm and a bond overlap length of 100 mm. The optimised hybrid metallic-composite railway axle design concept has a mass Citation: Mistry, P.J.; Johnson, M.S.; of 200 kg representing a reduction of 50% over the solid steel version. McRobie, C.A.; Jones, I.A. Design of a Lightweight Multifunctional Keywords: railway axle; lightweighting; composite material; multifunctional; unsprung mass; Composite Railway Axle Utilising coaxial skins Coaxial Skins. J. Compos. Sci. 2021, 5, 77. https://doi.org/10.3390/ jcs5030077 1. Introduction Academic Editor: Frédéric Jacquemin The worldwide imperative to reduce carbon dioxide (CO2) emissions poses a challenge to the transportation sector which accounts for approximately 25% of the total emissions Received: 4 February 2021 generated [1]. Vehicle lightweighting is a means of reducing CO emissions as a conse- Accepted: 5 March 2021 2 Published: 7 March 2021 quence of less energy being required for propulsion. This is recognised by the European Rail Sector Sustainable Mobility Strategy 2010 [2], which identifies fibre reinforced polymer Publisher’s Note: MDPI stays neutral (FRP) composites as a means of reducing the weight of rail vehicles. with regard to jurisdictional claims in While the structural carbody represents 24% of the rail vehicle mass, bogies are published maps and institutional affil- the single largest mass contributor accounting for 41% of the total tare weight [3]. A iations. bogie is a chassis containing the wheelsets while supporting the carbody through the primary suspension. The wheelset, comprising the axle and wheels, represents the majority of the unsprung mass. This mass gives rise to track impact damage. Renewal of the track represents a significant infrastructure maintenance cost, which contributes to service interruptions and travel downtime. Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. A railway axle typically is hot forged from EA1N grade steel [4]. Conventional This article is an open access article steel railway axles are solid. However, lightweighting is common by boring the centre distributed under the terms and of the solid axle with further mass savings being possible using alternative materials, conditions of the Creative Commons including FRP composites [5]. A FRP composite railway axle has yet to be put into service. Attribution (CC BY) license (https:// However, a prototype, filament wound, carbon fibre reinforced polymer (CFRP) tube axle creativecommons.org/licenses/by/ was manufactured for the British Rail Advanced Passenger Train [6]. This initial concept 4.0/). showed a mass savings of 70%. The behaviour of the composite axle was satisfactory in J. Compos. Sci. 2021, 5, 77. https://doi.org/10.3390/jcs5030077 https://www.mdpi.com/journal/jcs J. Compos. Sci. 2021, 5, x 2 of 12 J. Compos. Sci. 2021, 5, 77 2 of 12 conditions of the Creative Commons a mass savings of 70%. The behaviour of the composite axle was satisfactory in both static Attribution (CC BY) license and fatigue tests. However, the impact behaviour of the composite tube was found to be (http://creativecommons.org/licenses bothpoor. static Current and fatigueresearch tests. into However,a FRP composite the impact railway behaviour axle is of the the subject composite of the tube Horizon was /by/4.0/). found2020, toShift2Rail be poor. programme Current research entitled into NEXTGEAR a FRP composite [7]. Within railway this axle project, is the design subject concepts of the Horizonfor a hybrid 2020, metallic-composite Shift2Rail programme (HMC) entitled railway NEXTGEAR axle were [ 7proposed]. Within this[8]. These project, axles design em- conceptsbodied the for concept a hybrid of metallic-composite a multifunctional CFRP (HMC) railway railway axle. axle were proposed [8]. These axles embodiedThis paper the presents concept the of conceptual a multifunctional design CFRP of a multifunctional railway axle. HMC railway axle This paper presents the conceptual design of a multifunctional HMC railway axle which utilises coaxial skins to meet specific requirements with the overriding aim to min- which utilises coaxial skins to meet specific requirements with the overriding aim to imise mass. The relevant coaxial skins will be described followed by a parametric sizing minimise mass. The relevant coaxial skins will be described followed by a parametric study of the structural HMC railway axle assembly. sizing study of the structural HMC railway axle assembly. 2.2. RailwayRailway AxleAxle ConfigurationsConfigurations AA railway railway axle axle is is designed designed with with the the supporting supporting bearings bearings being being either either outboard outboard of of the the wheelswheels or or inboard. inboard. As As the the track track span span is is fixed, fixed, an an outboard outboard bearing bearing design design has has the the capacity capacity forfor the the greatest greatest mass mass reduction reduction as as it it features features a a longer, longer, plain plain shaft shaft region, region, suitable suitable for for CFRP CFRP replacement.replacement. As a a result, result, an an outboard outboard bearing bearing configuration configuration is isadopted adopted for for this this study. study. An Anaxle axle having having an inboard an inboard bearing bearing architecture architecture generally generally results results in a inlower a lower overall overall bogie bogie mass mass[9] and [9] would and would also alsobenefit benefit from from the themultifunctional multifunctional principles principles described described within within this this pa- paper.per. AA trailertrailer bogiebogie features features the the simplest simplest railway railway axle axle configuration configuration with with no no additional additional drivedrive elements elements mounted mounted onto onto the the shaft. shaft. Furthermore, Furthermore, brake brake discs discs can can be fitted be fitted either either to the to wheelthe wheel webs webs or outboard or outboard of the of wheels. the wheels. A typical, A ty solidpical, steel solid railway steel railway axle for axle a trailer for a bogie,trailer configuredbogie, configured for outboard for outboard bearings, bearings, is shown is in shown Figure in1. Figure The main 1. The features main of features the axle of are the theaxle wheel are the seats, wheel bearing seats, seatsbearing and seats the centraland the plain central shaft plain region. shaft Theregion. mass The of mass this axle of this is approximatelyaxle is approximately 400 kg. 400 kg. FigureFigure 1.1. AnAn outboardoutboard bearing bearing trailer trailer axle axle with with typical typical dimensions dimensions illustrating illustrating the the wheel wheel seat, seat, bearing seatbearing and seat plain and shaft plain region. shaft The region. global The coordinate global coordinate system shown system is shown in accordance is in accordance with EN 131031-1.with EN 131031-1. 3. Composite Railway Axle Design Incorporating Coaxial Skins 3. CompositeThe concept Railway design Axle of a multifunctional Design Incorporating composite Coaxial railway Skins axle utilising coaxial skins is shownThe inconcept Figure design2. The of design a multifunctional philosophy comp for thisosite axle railway concept axle was utilising derived coaxial from skins the constructionis shown in ofFigure high 2. voltage The design underground philosophy power for this cables. axle These concept cables was are derived comprised from the of severalconstruction layers of to protecthigh voltage the conductor underground and to po meetwer thecables. mechanical, These cables electrical are comprised and thermal of requirementsseveral layers [ 10to]. protect In a similar the conductor way, the structuraland to meet requirements the mechanical, of the electrical axle are and met thermal by the hollowrequirements HMC railway [10]. In axle a similar assembly way, comprising the structural a CFRP requirements
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