Russian Federation
Joint Stock Company “Scientific and Innovation Center “Cars” (Chief Designer)
Russian Federation
UDC 629.
Objective: to evaluate the potential for reducing the tare weight of a solid-bottom gondola car by lightening the floor-supporting welded beams through the application of the topology optimization method. Methods: a concise review of established parametric optimization approaches is presented. Topology optimization of the floor-supporting welded beam design was performed using the Evolutionary Structural Optimization (ESO) method. With an applied compressive force of 2.5 MN, the strength of the optimized supporting beam configuration was verified under the design load combined designated as mode 1b in GOST 33211. Results: implementing topology optimization on the welded beams of freight car frames, while constraining permissible sheet thickness variations, enables targeted modification of the beam cross-section. After technological refinement of the optimization outcomes, a beam design with less mass has been produced. Comparing the example to the original design, the mass has been lowered by a factor of 2.4 or 58%. Practical significance: this research demonstrates the applicability of topology optimization techniques to engineering design issues for metal freight vehicle structures. A supporting beam configuration that reduces mass while preserving the strength properties of the beam has been proposed. It consists of vertical sheets with trapezoidal cutouts and a lower sheet of variable width.
gondola car, gondola car frame, strength, topology optimization
1. Boronenko Yu. P., Filippova I. O. Ispol'zovanie vysokoprochnyh staley v vagono- stroenii // Transport Rossiyskoy Federacii. 2015. № 3 (58). S. 16–19. EDN UCCVOP
2. Boronenko Yu. P., Komaydanov A. A., Drobzhev S. M. Effektivnost' primeneniya alyuminievyh splavov v konstrukciyah gruzovyh vagonov // Podvizhnoy sostav XXI veka: idei, trebovaniya, proekty: materialy HVII Mezhdunarodnoy nauchno-tehnicheskoy konferencii (Sankt- Peterburg, 21–24 avgusta 2023 goda). SPb.: PGUPS, 2024. S. 7–13. EDN HDAJWL
3. Boronenko Yu. P., Drobzhev S. M., Rahimov R. V. Problemy konstruirovaniya vagonov iz alyuminievyh splavov // Zheleznodorozhnyy podvizhnoy sostav: problemy, resheniya, perspektivy: materialy III Mezhdunarodnoy nauchno-tehnicheskoy konferencii (Tashkent, 17–20 aprelya 2024 goda). Tashkent: Tashkentskiy gosudarstvennyy transportnyy universitet, 2024. S. 42–48. EDN KPRNZD
4. Orlova A. M., Demin K. P., Popesku R. V. Primenenie vysokoprochnoy stali dlya sozdaniya poluvagonov povyshennoy gruzopod'emnosti // Byulleten' rezul'tatov nauchnyh issledovaniy. 2024. № 3. S. 7–23.
5. Orlova A. M., Demin K. P., Popesku R. V. Kak povysit' effektivnost' poluvagona: napravleniya snizheniya tehnicheskogo koefficienta tary // Transport Rossiyskoy Federacii. 2023. № 3–4 (106–107). S. 33–38.
6. GOST 33211-2014. Vagony gruzovye. Trebovaniya k prochnosti i dinamicheskim kachestvam (s popravkoy, s izmeneniem № 1): utv. prikazom Rosstandarta ot 05.06.2015 № 565-st. M.: Standartinform, 2020. 54 s.
7. Bulychev M. A., Beyn D. G. Matematicheskoe modelirovanie i optimizaciya kuzovov poluvagonov s nesuschim polom. Bryansk: Bryanskiy gosudarstvennyy tehnicheskiy universitet, 2014. 183 s.
8. Lozbinev V. P. Proektirovanie i optimizaciya nesuschih sistem kuzovov vagonov. Bryansk: Bryanskiy gosudarstvennyy tehnicheskiy universitet, 1997. 88 s.
9. Lozbinev F. Yu. Ekonomiya material'nyh resursov v sfere proizvodstva i ekspluatacii nesuschih kuzovov vagonov. Bryansk: Centr nauchno-tehnicheskoy informacii, 2000. 131 s.
10. Evolyucionnoe modelirovanie v proektirovanii nesuschih sistem vagonov / I. N. Serpik [i dr.] // Vestnik Vserossiyskogo nauchno-issledovatel'skogo instituta zheleznodorozhnogo transporta. 2008. № 5. S. 21–25.
11. Krotov S. V., Kononov D. P., Buynosov A. P. Optimizaciya elementarnoy detali podvizhnogo sostava // Transport Urala. 2023. № 1 (76). S. 65–69.
12. Optimizacii topologii konstrukciy s ispol'zovaniem PK ANSYS / N. I. Marchuk [i dr.] // Tendencii razvitiya nauki i obrazovaniya. 2019. № 47–46. S. 58–61.
13. Marchuk N. I., Prasolenko E. V. Reshenie zadach topologicheskoy optimizacii konstrukciy s ispol'zovaniem programmy ANSYS // Novaya nauka: Opyt, tradicii, innovacii. 2017. T. 2, № 4. S. 196–199.
14. Beyn D. G. Analiz napryazhennogo sostoyaniya nesuschego nastila pola chetyrehosnogo poluvagona s gluhim kuzovom // Vestnik Bryanskogo gosudarstvennogo tehnicheskogo universiteta. 2011. № 1 (29). S. 47–51.
15. Normy dlya rascheta i proektirovaniya vagonov zheleznyh dorog MPS kolei 1520 mm (nesamohodnyh). M.: GosNIIV-VNIIZhT, 1996. 320 s.
16. Beyn D. G., Ispolova E. A. Ocenka prochnosti i razrabotka konstrukciy usilennyh uvyazochnyh ustroystv poluvagonov // Vestnik Rostovskogo gosudarstvennogo universiteta putey soobscheniya. 2015. № 1 (57). S. 30–35.
17. Poluvagon: patent na poleznuyu model' № 169635 U1 Rossiyskaya Federaciya, MPK B61D 3/00, B61D 17/06, B61F 1/00. № 2016138777 / Boronenko Yu. P., Cyganskaya L. V., Bondarenko K. V.; zayavl. 30.09.2016; opubl. 28.03.2017; zayavitel' AO «Nauchno-vnedrencheskiy centr “Vagony”».
18. Kuzov poluvagona: patent na poleznuyu model' № 179519 U1 Rossiyskaya Federaciya, MPK B61D 3/00. № 2016152340 / Boronenko Yu. P., Beyn D. G., Tret'yakov A. V.; zayavl. 29.12.2016; opubl. 17.05.2018; zayavitel' AO «Nauchno-vnedrencheskiy centr “Vagony”».
19. Kuzov poluvagona: patent na poleznuyu model' № 177170 U1 Rossiyskaya Federaciya, MPK B61D 17/06, B61D 23/00. № 2017119246 / Tret'yakov A. V., Beyn D. G.; zayavl. 02.06.2017; opubl. 12.02.2018; zayavitel' AO «Nauchno-vnedrencheskiy centr “Vagony”».
20. Poluvagon: patent na poleznuyu model' № 224505 U1 Rossiyskaya Federaciya, MPK B61D 3/20, B60P 7/13. № 2023122034 / Boronenko Yu. P., Cyganskaya L. V., Beyn D. G.; zayavl. 23.08.2023; opubl. 28.03.2024; zayavitel' AO «Nauchno-vnedrencheskiy centr “Vagony”».
