SAMES Copyright 2014 • [email protected] • +49 (0) 9128 9253-300 reliable - flexible - .innovative SAMES .innovative Project task Process SAMES was contracted by ASTRA Vagoane Calatori S.A. to design and to manage structural strength assessment of carbody shells for 2842 and 3100 mm width. ASTRA Vagoane Calatori S.A. is a well-known rolling-stock manufacturer situated in the City of Arad in Romania. ASTRA decided to SAMES engineers help to meet the challenge of a tight project timeschedule. Based on the technical 3D- design of carbody shell structure by ASTRA Vagoane, a company with decades of experience in carbody shell design and production, SAMES created a defeatured FEM conform 3D-model. A second target was to adapt existing passenger coach design to a generator coach design for high loads. The generator car is equipped with two generators, technical equipment and a large fuel tank. The main goal is to achieve exact modelling while having small model size to realize good analysis performance. SAMES sought to keep as much parts of passenger coach in the new generator design to simplify the production process and to reduce costs. Both generator and passenger coach carbody shell design and structural strength, modal and linear buckling analysis were done for 2842 and 3100mm width. The design process has been done in compliance with EN 15085 and EN 12663. Futhermore all necessary gauging analysis (UIC 505) and driving dynamic analysis in combination with the adapted bogies were done according to APTA and documentation and accompanying documents. The reliable and innovative engineering process of SAMES in combination with the technological professionals of ASTRA and the experienced production process enables ASTRA to produce all carbody shells in time and to highest quality. Result AAR standards. Finally four carbody shells were created with similar production process and optimized weight distribution and structural strength. SAMES prepared all documents necessary for the local production of bogies in Romania. In cooperation with Astra it was defined, 3D-models and simulation work to be created by SAMES, while Astra prepares 2D-production Documentation .i Carbody shell characteristics Width: 2842/3100 mm Length: 23200 mm Height (from TOR): 4190 mm Floor height (from TOR): 1120 mm Weight (vehicle design mass): 41.000 kg Capacity: 80 seats Material: S355/S235 Standards (e.g.): EN 12663, EN 15085, UIC 505, EN 15663 passenger coach (production) passenger coach (FEM-analysis) Customer Operator Scope Status of project Project size Project duration Astra Vagoane Calatori S.A. n.n. Structural strength assessment and design completed n.n. 2013 Contact SAMES Rad-Schiene Systemtechnik GmbH Gsteinacher Str. 41 # 90537 Feucht # Germany Internet: www.sames.org Technical data is subject to change Carbody shell design & structural analysis Engineering for Romania Doc. RS140312-008 SAMES .innovative project fact sheet

Carbody shell design & structural analysis Engineering · PDF fileS.A. to design and to manage structural strength ... of passenger coach in the new generator design to simplify the

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Page 1: Carbody shell design & structural analysis Engineering · PDF fileS.A. to design and to manage structural strength ... of passenger coach in the new generator design to simplify the

reliable - flexible - .innovative

SAMES.innovative

Project task

Process

SAMES was contracted by ASTRA Vagoane Calatori S.A. to design and to manage structural strength assessment of carbody shells for 2842 and 3100 mm width. ASTRA Vagoane Calatori S.A. is a well-known rolling-stock manufacturer situated in the City of Arad in Romania. ASTRA decided to SAMES engineers help to meet the challenge of a tight project timeschedule.

Based on the technical 3D- design of carbody shell structure by ASTRA Vagoane, a company with decades of experience in carbody shell design and production, SAMES created a defeatured FEM conform 3D-model. A second target was to adapt existing passenger coach design to a generator coach design for high loads. The generator car is equipped with two generators, technical equipment and a large fuel tank. The main goal is to achieve exact modelling while having small model size to realize good analysis performance. SAMES sought to keep as much parts of passenger coach in the new generator design to simplify the production process and to reduce costs. Both generator and passenger coach carbody shell design and structural strength, modal and linear buckling analysis were done for 2842 and 3100mm width. The design process has been done in compliance with EN 15085 and EN 12663. Futhermore all necessary gauging analysis (UIC 505) and driving dynamic analysis in combination with the adapted bogies were done according to APTA and

documentation and accompanying documents.

The reliable and innovative engineering process of SAMES in combination with the technological professionals of ASTRA and the experienced production process enables ASTRA to produce all carbody shells in time and to highest quality.

Result

AAR standards. Finally four carbody shells were created with similar production process and optimized weight distribution and structural strength.

SAMES prepared all documents necessary for the local production of bogies in Romania. In cooperation with Astra it was defined, 3D-models and simulation work to be created by SAMES, while Astra prepares 2D-production

Documentation

Carbody shell characteristicsWidth: 2842/3100 mmLength: 23200 mmHeight (from TOR): 4190 mmFloor height (from TOR): 1120 mmWeight (vehicle design mass): 41.000 kg Capacity: 80 seats

Material: S355/S235

Standards (e.g.):EN 12663, EN 15085, UIC 505, EN 15663

passenger coach (production)

passenger coach (FEM-analysis)

Customer

Operator

Scope

Status of project

Project size

Project duration

Astra Vagoane Calatori S.A.

n.n.