On the Application of HyperWorks for the Design of Bi-Level Trains

The new Stadler bi-Level Train KISS has been designed by using HyperWorks. In order to perform a large spectrum of analyses a FE-model has been created with more than three million elements. HyperMesh has been applied to generate a detailed FE model for different Analysis types: Global linear static analyses, explicit crash analyses and structural optimizations have been performed including material-, geometric- or contact-nonlinearities. The evaluation of the welded seams has been performed with FEMFAT according to the standard EN 15085 and DVS 1608, respectively to the IIW recommendations. The design of the bi-level train bases on aluminium extrusions, which have been modelled using linear shell elements. In areas with concentrated loads a small number of milled parts have been applied. The element density as well as the mesh quality has been especially considered for an optimized capture of the stress gradients. In the structural homogeneous areas an isometric mesh has been generated to guarantee rapid model changes during the vehicle development. The number of triangular elements (for shells) and tetrahedra (solids) has been kept as low as possible. OptiStruct has been applied to optimize the transition Zone from the high floor to the low floor section close to the wide passenger door. The Performance of the car Body structure and of the bogie structure is demonstrated with respect to structural and crashworthiness requirements.


The Author

Dr. Alois Starlinger
Head of Structural Analysis and Testing
Stadler Rail