Development of a hybrid composite bodyshell for tilting trains

Abstract

In this study, a concept of a hybrid bodyshell for a tilting train is proposed and a prototype model has been developed. Tilting trains require lightweight structure and stability on curves. To satisfy these requirements, the upper bodyshell of the prototype model was made of composite honeycomb panels and the lower underframe of stainless steel. The composite honeycomb panel was composed of carbon fiber reinforced skins and an aluminum honeycomb core. The hybrid structure made it possible to reduce the carbody weight by almost 30 per cent. The hybrid bodyshell was tested for the static and fatigue strength and fire safety was also verified by testing. The hybrid bodyshell was proved to be good enough for commercial use. As a result, the conventional manufacturing process for the rolling stock could be changed by introduction of this new structure.