Durability Evaluation of a Hybrid Composite Train Carbody for the Korean Tilting Train

(1)

This paper explains the fatigue test for a composite train carbody. The composite carbody with

length of 23m was manufactured as a sandwich structure composed of a aluminium honeycomb core

and woven fabric carbon/epoxy face. In order to evaluate fatigue strength of the composite

carbody, the carbody was excited by two 50-ton capacity hydraulic actuators. The excitation

frequency was determined by natural frequency evaluation test under full weight condition. The

test was conducted for 2x10 ⁶ cycles. During the fatigue test, fatigue cracks of the composite

carbody and steel underframe were inspected by the nondestructive tests using X-ray and liquid

penetrant. From test tests, no fatigue crack was detected.

(2)

23030mm 15900mm

3690mm

2970mm

HVAC system Observation window

Side entrance door

Stainless steel underframe Window Area

Roof

Inner frame Aluminum honeycomb

sandwich with carbon/epoxy face

Inner frame of sidewalls Inner frame of roof structure

Joining area between composite bodyshell and

underframe CF1263

carbon/epoxy

CF1263 carbon/epoxy Aluminum

honeycomb

(a) Dimension of the tilting train. (b) Cross sectional view of the composite carbody.

Fig. 1 Hybrid composite carbody for Korean tilting train.

Fig. 2 Installation of the composite carbody for fatigue test. Fig. 3 Hydraulic actuator for excitation.

(3)

: 변형률 게이지(53개소, 100채널) : 변위 게이지 (17개소, 17채널) : 가속도계 (6개소, 6채널)

Fig. 4 Schematic diagram of the installation locations of each sensor.

Fig. 5 The installed sensors on the

carbody.

(4)

Frequency (Hz)

1 2 3 4 5

Load (kN)

-60 -40 -20 0 20 40 60

3.4 Hz Actuator #1

Fig. 6 Dynamic signal of the hydraulic actuator.

Table 1 Strain and deflections according to the displacement of actuator.

Fig. 7 Locations inspected by X-ray. Fig. 8 X-ray device.

(5)

Load (kgf)

0 5000 10000 15000 20000 25000 30000

St ra in ( με )

-1000 -500 0 500 1000

LOR10-1 LOR10-2 LOR10-3 LOR11-1 LOR11-2 LOR11-3 LOR12-1 LOR12-2 LOR12-3 LOR13-1 LOR13-2 LOR13-3 Applied air-con. weight

Fig. 9 The measured strains according to the applied load.

Load (kgf)

0 5000 10000 15000 20000 25000 30000

D e fle c tio n ( m m )

-40 -20 0 20 40

D#1 D#2 D#3 D#4 D#5 D#6 D#7 D#8 D#9 D#10 D#11 D#12 D#13 D#14 D#15 D#16 D#17 Applied air-con. weight

Durability Evaluation of a Hybrid Composite Train Carbody for the Korean Tilting Train

This paper explains the fatigue test for a composite train carbody. The composite carbody with

length of 23m was manufactured as a sandwich structure composed of a aluminium honeycomb core

and woven fabric carbon/epoxy face. In order to evaluate fatigue strength of the composite

carbody, the carbody was excited by two 50-ton capacity hydraulic actuators. The excitation

frequency was determined by natural frequency evaluation test under full weight condition. The

test was conducted for 2x10 ⁶ cycles. During the fatigue test, fatigue cracks of the composite

carbody and steel underframe were inspected by the nondestructive tests using X-ray and liquid

penetrant. From test tests, no fatigue crack was detected.

Stainless steel underframe Window Area

Roof

Inner frame Aluminum honeycomb

sandwich with carbon/epoxy face

Inner frame of sidewalls Inner frame of roof structure

Joining area between composite bodyshell and

underframe CF1263

carbon/epoxy

CF1263 carbon/epoxy Aluminum

honeycomb

(a) Dimension of the tilting train. (b) Cross sectional view of the composite carbody.

Fig. 1 Hybrid composite carbody for Korean tilting train.

Fig. 2 Installation of the composite carbody for fatigue test. Fig. 3 Hydraulic actuator for excitation.

: 변형률 게이지(53개소, 100채널) : 변위 게이지 (17개소, 17채널) : 가속도계 (6개소, 6채널)

Fig. 4 Schematic diagram of the installation locations of each sensor.

Fig. 5 The installed sensors on the

carbody.

Fig. 6 Dynamic signal of the hydraulic actuator.

Table 1 Strain and deflections according to the displacement of actuator.

Fig. 7 Locations inspected by X-ray. Fig. 8 X-ray device.

Load (kgf)

St ra in ( με )

Fig. 9 The measured strains according to the applied load.

Load (kgf)

D e fle c tio n ( m m )

Fig. 10 The measured displacements according to the applied load.

Fig. 11 Peak/valley values of strain measured during fatigue test.

Fig. 12 X-ray radiograph for the composite carbody

and PT test result for the underframe.

Durability Evaluation of a Hybrid Composite Train Carbody for the Korean Tilting Train

This paper explains the fatigue test for a composite train carbody. The composite carbody with

length of 23m was manufactured as a sandwich structure composed of a aluminium honeycomb core

and woven fabric carbon/epoxy face. In order to evaluate fatigue strength of the composite

carbody, the carbody was excited by two 50-ton capacity hydraulic actuators. The excitation

frequency was determined by natural frequency evaluation test under full weight condition. The

test was conducted for 2x10 6 cycles. During the fatigue test, fatigue cracks of the composite

carbody and steel underframe were inspected by the nondestructive tests using X-ray and liquid

penetrant. From test tests, no fatigue crack was detected.

Stainless steel underframe Window Area

Roof

Inner frame Aluminum honeycomb

sandwich with carbon/epoxy face

Inner frame of sidewalls Inner frame of roof structure

Joining area between composite bodyshell and

underframe CF1263

carbon/epoxy

CF1263 carbon/epoxy Aluminum

honeycomb

(a) Dimension of the tilting train. (b) Cross sectional view of the composite carbody.

Fig. 1 Hybrid composite carbody for Korean tilting train.

Fig. 2 Installation of the composite carbody for fatigue test. Fig. 3 Hydraulic actuator for excitation.

: 변형률 게이지(53개소, 100채널) : 변위 게이지 (17개소, 17채널) : 가속도계 (6개소, 6채널)

Fig. 4 Schematic diagram of the installation locations of each sensor.

Fig. 5 The installed sensors on the

carbody.

Fig. 6 Dynamic signal of the hydraulic actuator.

Table 1 Strain and deflections according to the displacement of actuator.

Fig. 7 Locations inspected by X-ray. Fig. 8 X-ray device.

Load (kgf)

St ra in ( με )

Fig. 9 The measured strains according to the applied load.

Load (kgf)

D e fle c tio n ( m m )

Fig. 10 The measured displacements according to the applied load.

Fig. 11 Peak/valley values of strain measured during fatigue test.

Fig. 12 X-ray radiograph for the composite carbody

and PT test result for the underframe.

test was conducted for 2x10 ⁶ cycles. During the fatigue test, fatigue cracks of the composite