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Structural Analysis and Optimization of the Doors on the Falns Freight Wagon

Modern global trends in freight transport demand removal of all unnecessary freight wagon components in order to reduce mass. Because of that, the idea of structural analysis and optimization of the doors on the Falns freight wagon was born. By removing unnecessary mechanism, the mass of the Falns 48 wagon could be reduced by 276 kg, but the maximum deformation of the doors lower edges would increase from 0.04 mm to 3.76 mm. This increase in the maximum deformation of the wagon doors lower edges can cause the cargo to leak out of the wagon and fall down on the rails, and that is strictly forbidden. Therefore, it is necessary to implement optimization to find a certain compromise, or find the optimal solution. The deformations and stresses of the initial constructional solution of the wagon doors, with and without using the additional door holding mechanism, were analysed by using the finite element method. After that, the optimization process was carried out. The aim of the optimization is to reduce the maximum deformation of the doors lower edges at the expense of mass increase. In addition, a new constructional solution for the wagon doors was proposed and optimization of the proposed constructional solution was carried out. By analyzing the results, it was concluded that the use of the additional door holding mechanism on Falns 48 freight wagon, in the case of transporting iron ore, is not justified.

Structural analysis, optimization, Falns 48, freight wagon doors, finite element method

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