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Lightweight Design and Cost Potentials of Carbon Composites for Rail Vehicle ManufacturingFeasibility Study by Order of CFK Valley e.V.

CFK Valley Belgium - Innovation Day Composites and Railway Brussels, Belgium, 29 June 2016

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Prof. Dr.-Ing. Christian HühneDipl.-Ing. Jörg NickelDipl.-Ing. Jens KönigDr.-Ing. Hardy KökeDipl.-Ing. Johannes Wolff

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Feasibility StudyCarbon Composite Technologies for Rail Vehicle Manufacturing

Contents:1. Motivation, focus and methodology of the study

2. Principles of lightweight design in rail vehicle manufacturing

3. Application of composites in rail vehicles –state of the art

4. Opinions and statements towards the use of composites in rail vehicles

5. Boundary conditions essential for composite applications in rail vehicles

6. Analysis of lightweight potentials of a specific composite component

7. Cost analysis of a specific composite component

8. Conclusions, outlook, and recommendations

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Feasibility StudyCarbon Composite Technologies for Rail Vehicle Manufacturing

Executed by order of

Participants and contributors

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Feasibility Study1. Motivation, Focus

and Methodology

The objective of this feasibility study is to better understand and evaluate the opportunities, threats and total cost regarding the use of carbon composite technologies in rail vehicle manufacturing.

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Feasibility Study2. Principles of Lightweight Design in Rail Vehicle Manufacturing

Chapter 2 illustrates the principles of lightweight designin rail vehicle manufacturing.2

Source: Sch2006

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Feasibility Study2. Principles of Lightweight Design in Rail Vehicle Manufacturing

Source: Kop2013a

ConceptAssembly

Joining

Manufacturing processProduction

Component geometrycomponent shape

Material

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Feasibility Study2. Principles of Lightweight Design in Rail Vehicle Manufacturing

Evolution of Rail Vehicle Construction

Source: Ger2002

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Feasibility Study2. Principles of Lightweight Design in Rail Vehicle Manufacturing

Energy Cost Savings mass reduction regarding entire life cycle (30 years)

Source: Dit2013

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Feasibility Study2. Principles of Lightweight Design in Rail Vehicle Manufacturing

Affordable Cost for Lightweight Design per [kg] mass reduction and modes of transportation

Source: Kop2011

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Weight Distribution of Main Sub-assembliesMain sub-assemblies according to DIN EN 15380-2

Source (summarised): DMG2011, DIN_EN15380-2_2006

Feasibility Study2. Principles of Lightweight Design in Rail Vehicle Manufacturing

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Chapter 3 displays the state of the art with respect to research and application.3

Feasibility Study3. Composite Applications in Rail Vehicles – State of the Art

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Chapter 3 displays the state of the art with respect to research and application.3

Feasibility Study3. Composite Applications in Rail Vehicles – State of the Art

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Feasibility Study3. Composite Applications in Rail Vehicles – State of the Art

Source: SCI2012

Manufacturers worldwide – Sales Volume and Distribut ion:Top ten producers of rail vehicles in terms of new vehicle sales revenues 2010 [Mio. €]

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Feasibility Study3. Composite Applications in Rail Vehicles – State of the Art

Composite Applications in Rail Vehicles and Typical Manufacturing Methods

Sheet MouldingCompound (SMC)

Hand Lay-up Pultrusion Resin Transfer Moulding (RTM)

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Composites in Other Sectors Especially effective at uni-directional, effective at bi-directional load cases.

Feasibility Study3. Composite Applications in Rail Vehicles – State of the Art

Source: Airbus GroupSource: Airbus Group Source: Saab Kockums

Source: hanseyachts.com

Source: stromonline.ch

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Feasibility Study4. Opinions and Statements towards the Use of Composites

Chapter 4 documents the results of the enquiry carried-out in order to evaluate opinions and statements towards the use of composites in rail vehicles.

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Feasibility Study4. Opinions and Statements towards the Use of Composites

Sample Questions: What about increasing the use of composites? Where?

Benefits of Composites:• Complex 3D geometries

easier and more cost-efficient

• Weight reduction• Non-corrosiveness• Favourable also with small

production lots

What kind of benefits are being expected?

Source: Wen2013Source: Kla2009

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Feasibility Studie5. Boundary Conditions Essential for Composites in Rail Vehicles

Chapter 5 describes specificboundary conditions essential for composite applications in rail vehicles.

5Boundary Conditions: NVH, Loads, Repair, etc.

Load-bearingshell

Differentstiffness

Detectorlayer

Soft core

Acousticabsorbers

Damping layer

Decoupledinner panelling

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Feasibility Study5. Boundary Conditions Essential for Composites in Rail Vehicles

Boundary Conditions: Recycling

Source: Jec2014

Source: vAc2009

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Feasibility Study5. Boundary Conditions Essential for Composites in Rail Vehicles

Boundary Conditions: Life Cycle

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Feasibility Study5. Boundary Conditions Essential for Composites in Rail Vehicles

Boundary Conditions: Fire Protection

Source: Fla2014

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Feasibility Study6. Lightweight Potential of a Concrete Carbon Composite Component

Chapter 6 identifies the light-weight potential of a specific composite component6

Flat roof sections:Steel construction

Barrel-shaped roof sections:Fibre composite construction

Screening, investigation, analysis of the lightweight construction potentials within this chapter

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Feasibility Study6. Lightweight Potential of a Concrete Carbon Composite Component

The Results are a detailed design concept and the total mass of the carbon composite component.

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Chapter 7 reveals the total cost of the specific carbon composite component.6

Feasibility Study7. Cost Analysis of a Concrete Carbon Composite Component

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Feasibility Study7. Cost Analysis of a Concrete Carbon Composite Component

The outcome is a manufacturing concept and the resulting total cost of the specific carbon composite component.

Layer stacking table (1D)

Stacking unit: Gantry, automatically proceeding,including roll sections

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Feasibility Study8. Conclusion, Outlook and Recommendations (I)

Objective: • Current opportunities, risk, and cost of carbon composite applications

in structural components of rail vehicles.

Motivation: • Increasing environmental constraints.• Compensation of added weight from safety and comfort equipment.

Outcome:• Economical and ecological benefits of lightweight composite

structures in rail vehicles successfully proven by multitudinous analyses and studies.

• Numerous studies on composite applications in rail vehicles and developed composite constructions published.

• Significant weight savings predicted or proven by various studies. • Detailed analyses of composite rail vehicle structures considering

achievable weight savings and related total cost not available today .

Ch. 1

Ch. 1

CH. 2

CH. 3

CH. 3

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Feasibility Study8. Conclusion, Outlook and Recommendations (II)

Outcome (continued):• Enquiry carried out regarding the application of composites in rail

vehicles:• High expectations (savings of weight, operating costs, …)• High challenges as well (manufacturing costs, dimensioning, …)• Detailed investigation required for comprehensive evaluation of current

lightweight design and cost potentials regarding concrete components.• Multifarious constraints with respect to the use of fibre composites in rail

vehicles.• Detailed design concept of composite ICx roof segment elaborated:

• 32% weight savings by composite versus steel construction.• Applicable manufacturing concept generated:

• 12 € extra costs per reduced kilogram weight.• Currently only study with respect to the use of composites in rail

vehicles considering both detailed weight and cost evaluation of a concrete structural component.

Ch. 5

Ch. 4

Ch. 6

Ch. 7

Ch. 8

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Feasibility Study8. Conclusion, Outlook and Recommendations (III)

Outlook:• Further weight (and cost) saving potentials by:

• Considering overall car body system.• Development of pro-composite designs for rail vehicles.• Avoiding cost-intensive interfaces.• Uniform composite standards � approaches by EU-REFRESCO.

Recommendations:• Dealing with challenges beyond:

• Composite design philosophies for overall car body system.• Design and sizing.• Manufacturing and operation.• …

Ch. 8

Ch. 8

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References

[DINEN15380-2_2006] N.N.: DIN EN 15380-2: Bahnanwendungen – Kennzeichnungssystematik für Schienenfahrzeuge – Teil 2: Produktgruppen; Deutsche Fassung EN 15380-2:2006

[Dit2013] Dittus, H.; Pagenkopf, J.: Lightweight Design in Railway Vehicles – Energy and CostPotential, DLR Institut für Fahrzeugkonzepte, Vortrag beim DMG-Ausschuss Leichtbau, Frankfurt, 20.03.2013

[DMG2011] Bernicke, S.; Schwickert, M., Dellmann, T.; Schindler, Ch.: Leichtbau bei Schienenfahrzeugen – Bestandsaufnahme und Potentiale, Teilprojekt A: Vollbahnen, Teilprojekt B: Straßen- und Stadtbahn-Fahrzeugen, Abschlussbericht, IFS RWTH Aachen, TU Kaiserslautern, 2011

[Fla2014] flameretardants-online, http://www.flameretardants-online.com/web/de/106/84575cb4764b9030e1338c8cfd52c9a2.htm, abgefragt am 11.04.2014

[Ger2002] Gerhard, T.; Meyer, G.; Altenburg, K.: Revolution oder Evolution? – Betrachtung zu Werkstoff- und Bauweisenentwicklung für Schienenfahrzeuge, Eisenbahntechnische Rundschau ETR 51, 1 – 2/2002

[JEC2014] http://www.jeccomposites.com/sites/default/files/content/JECM17_BUSINESS_UNIVERSITYOF-NOTTINGHAM_the-mechanical-recycling_composites.jpg, abgefragt am 08.04.2014

[Kla2009] Klammer, J.: Strukturmechanik und Vibroakustik von CFK-Flugzeugrümpfen. Dissertation, Lehrstuhl für Leichtbau, Technische Universität München, 2009

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References

[Kop2011] Kopp, Gu.; Burkardt, N.; Maji´c, N.: Teil1, Kapitel 3: Leichtbaustrategien und Bauweisen, in: Henning, F. (Hrsg.); Moeller, E. (Hrsg.): Handbuch Leichtbau, München, Hanser Verlag, 2011

[Kop2013a] Kopp, Ge.; Friedrich, H; Kuppinger, J.; Schön, M.: Design of Sandwich Structures for a selfsupporting Containment for a Rail Vehicle, in: Tagungsband 13th Stuttgart International Symposium, Volume 2, Stuttgart, Springer Vieweg, 26.-27. Februar 2013, S. 369 – 383 und Präsentation

[SCI2012] N.N.: Hersteller von Schienenfahrzeugen und Standorten weltweit, Daten und Fakten zu 170 Unternehmen und Standorten, SCI MultiClientSthttp://www.sci.de/uploads/tx_edcuments/120427_Werbeflyer_MC_Hersteller.pdf, abgefragt am 26.07.2013

[Sch2006] Schindler, C.: Leichtbau im SPNV aus Sicht der Konstruktionsmethodik, ZEVrail – Glasers Annalen 130, Nr. 4, 2006, S. 158 – 163

[vAc2009] Van Acker, K.; Verpoest, I.: Lightweight materials for the automotive: environmental impact analysis of the use of composites, Revue de Métallurgie vol. 106, issue 12, S. 541 – 546

[Wen2013] Wennberg, D.: Multi-Funktional Composite Design Concepts for Rail Vehicle Car Bodies, Doctoral Thesis, KTH Stockholm, Vehicle and Maritime Engineering, 2013

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Contact:

Prof. Dr.-Ing. Christian Hühne

Deutsches Zentrum für Luft- und Raumfahrt e.V. (DLR)

German Aerospace Center

Institute of Composite Structures and Adaptive Systems

Lilienthalplatz 7

D-38108 Braunschweig

Phone: +49 531 295 2310

E-Mail: christian.huehne@dlr.de

Thank you!