Impact damage behavior of lightweight CFRP protection suspender on railway vehicles

Jiang, Jian; Zhang, Zhifang; Fu, Jiyang; Ramakrishnan, Karthik Ram; Wang, Caizheng; Wang, Hongxu · 2022 · DOAJ

DOI: 10.1016/j.matdes.2021.110332

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Summary

This study investigates the impact damage behavior of lightweight carbon fiber reinforced polymer (CFRP) protection suspenders used in railway vehicles. These components are critical safety devices designed to prevent falling bolsters from contacting rails, thereby avoiding train derailments. The research is motivated by the industry shift toward lightweight designs using fiber reinforced polymers to replace traditional steel components for energy savings and environmental protection. However, composite structures are susceptible to impact damage, and there is a lack of specific studies on the impact response of protection suspenders, particularly regarding the influence of bolt preloads and lay-up configurations. The researchers developed a three-dimensional finite element model in ABAQUS/Explicit to simulate low-velocity impact scenarios. The damage analysis employed Continuum Damage Mechanics (CDM) models to govern both intra-laminar and inter-laminar damage. Intra-laminar damage initiation was determined using the three-dimensional Hashin criterion in strain form, while damage evolution was modeled using energy release rates and characteristic lengths to mitigate mesh dependency. Inter-laminar delamination was simulated using a Cohesive Zone Model (CZM) with a quadratic stress failure criterion and the B-K criterion for propagation. Bolt preloads, which are essential for realistic boundary conditions, were applied using a virtual thermal deformation method, as the standard bolt tool was unavailable in the explicit solver. The model was validated against experimental data from Shi et al., showing good agreement in impact force-time curves, force-displacement responses, and delamination morphology. The study analyzed two lay-up configurations, [0]10 and [0/90/0/90/0]S, under bolt preloads of 0, 5, and 20 kN. Results identified vulnerable positions under impact as the contact edge between the suspender and impactor, the curved corners, and areas surrounding bolt holes. The [0]10 lay-up demonstrated superior impact resistance compared to the [0/90/0/90/0]S configuration. Furthermore, increasing bolt preloads significantly improved structural safety by preventing crack damage around the installation holes. The findings provide valuable insights for the lightweight design and structural optimization of railway vehicle components. By demonstrating that specific lay-ups and adequate bolt preloads enhance impact resistance, the study offers a validated simulation framework that can reduce development time and costs compared to extensive experimental campaigns. This work supports the safe integration of CFRP materials in critical railway safety components, ensuring they can withstand sudden impact loads during service.

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