Objective Currently, the contradiction between train operational energy consumption and operational benefits has become increasingly prominent, making it a primary issue in achieving energy-saving and environmental protection targets at various development stages. Therefore, it is necessary to study train lightweighting solutions to achieve the goal of reducing train weight.

Method Based on traditional materials for car body structures (austenitic stainless steel, low-alloy high-strength steel, weathering steel) and in combination with the requirements for train performance and functions (energy consumption, transport capacity, strength, appearance, system interfaces, etc.), an analysis is conducted on metro car body structures suitable for low axle load, large passenger capacity, constant-section straight car bodies with multiple openings, and methods to further improve the lightweight level of the car body structure are proposed. On the basis of traditional materials, the existing manufacturing tooling systems and equipment, an optimized car body structure model is built using finite element analysis software, and verification is carried out for the model through car body strength tests.

Result & Conclusion  Under the framework of the standard EN12663-1:2010+A1:2014 Railway applications - Structural requirements of railway vehicle bodies - Part 1: Locomotives and passenger rolling stock (and alternative method for freight wagons), the proposed car body structure optimization model can reduce the total mass by approximately 9.5% compared with similar car body structures, thus achieving the goal of passing the diagonal jacking test in one attempt.