Evaluation of the structural integrity of a sandwich composite train roof structure

Abstract

We have evaluated the structural integrity of a sandwich composite train roof which can find a lightweight, cost saving solution to large structural components for rail vehicles in design stages. The sandwich composite train roof was 11.45 meters long and 1.76 meters wide. The FE analysis was used to calculate the stresses, deflections and natural frequencies of the sandwich composite train roof against the weight of air-condition system. The 3D sandwich FE model was introduced to consider the hollow aluminum frames jointed to both sides of the sandwich train roof. The results shown that the structural performances of a sandwich composite train roof under the loading conditions specified were proven and the use of aluminum reinforced frame was beneficial with regard to weight saving in comparison to steel reinforced frame. Also, we have manufactured the prototype of sandwich composite train roof on the basis of analysis results.