Avanish et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

IJAET/Vol. IV/ Issue II/April-June., 2013/71-73

Research Paper

OPTIMIZATION OF A RAILWAY BOGIE M. Naveen, K. Jagadeshwar, M. Sai Satish Chandra, T. P. S. Avanish

Address for Correspondence Mechanical Department, K. L. University, Green Fields, Vaddeswaram, Guntur District, A.P INDIA.

ABSTARCT- Indian Railways plays a key role in transportation of goods and passengers across India. As part of our contribution we have

taken up a project related to Indian Railways i.e., to optimize the present bogie design. After completion of this project we

will be able to suggest some changes in the design so as to enhance the strength of the bogie and to optimize the material

usage in its production. This will reduce the cost of its production. In this regard we have used PRO-E and CATIA and the

analysis part is done using HYPERMESH. The main aim of this project is to optimize the design of the bogie of a goods

train in order to reduce the material costs without significant reduction in load bearing capacity.

I. INTRODUCTION

Indian Railways (reporting mark IR) is an Indian

state-owned railway company headquartered in New

Delhi, India. It is owned and operated by the

Government of India through the Ministry of

Railways. Indian Railways has 114,500 kilometers

(71,147 mi) of total track over a route of 65,000

kilometers (40,389 mi) and 7,500 stations. It has the

world's fourth largest railway network after those of

the United States, Russia and China. The Indian

railways are also proposing to build the highest

railway track in the world overtaking the current

record of the Beijing-Lhasa Railway line. The

railways carry over 30 million passengers and

2.8 million tons of freight daily. In 2011-2012

Railway earns an Rs 104278.79 core which consists

of Rs 69675.97 cores from freight and 28645.52

cores from passengers tickets. It is the world's fourth

largest commercial or utility employer, by number of

employees, with over 1.4 million employees. As for

rolling stock, IR owns over 240,000 (freight)

wagons, 60,000 coaches and 9,000 locomotives.

Railways were first introduced to India in 1853. By

1947, the year of India's independence, there were

forty-two rail systems. In 1951 the systems were

nationalized as one unit, the Indian Railways,

becoming one of the largest networks in the world.

IR operates both long distance and suburban rail

systems on a multi-gauge network of broad, meter

and narrow gauges. It also owns locomotive and

coach production facilities.

Indian Railways have always inspired us, so we

thought of working on the bogie and wagon. Thus

we came across many aspects such as manufacturing

and repair during our visit to the wagon work shop

of Guntupalli.

II. TYPES OF BOGIES

There are different types of bogies used all over

India but frequently used bogies for freight carrying

purpose are only few. They are:

1. Super service(ir) bradken

2. Barbar

3. Wegmann

4. Bradken

5. Linke hopmen

6. Aarpide control

7. Talbot

8. Feiguies bogie

9. Closed frieght wagon

10. Casnub bogie

11. Bogie covered type –BCNA

Broad Gauge Covered Type Wagon type 'BCNA' 8-

wheeler type, mounted on Cast Steel CASNUB 22

NLB Bogies, 1000 mm thread diameter, 22.9T Axle

Load Wheel sets, Cartridge Type Roller Bearings

with Adaptors and Single Pipe Air

Brake System. These wagons have two-doors on

each side of the wagons suitable for transportation of

all classes of goods, food grains and bagged cement

etc. requiring protection from weather and natural

hazards

III. CASNUB BOGIE

CASNUB Bogie is used in Freight wagons.

CASNUB bogie consists of two cast iron frames,

floating bolster, mild steel spring plank, nested

springs, and friction snubbers. Bolster is supported

on the side frames through two nested of

springs.Two cast iron steel frames are connected by

spring planks. Frictional snubber acts as a frictional

damper, which dampens the oscillations. Frictional

snubbers provide damping action proportional to

load.

Salient features of CASNUB bogie are given below:

Table.1 Feature Description

Gauge 1676 mm

Axle load 20.3 T

For CASNUB 22 HS-22.9 T

Wheel diameter 1000 mm

Wheel base 2000 mm

Type of axle bearing

used

(i) Cylindrical Roller Bearing

(ii) Standard AAR Tapered Cartridge

Bearing (Wide Jaws)

(iii) Standard AAR Tapered cartridge

bearing (narrow jaws)

Distance between

journal centers

2260 mm

Distance between

side bearers

1474 mm

Type of side bearer (I) Roller Type

(Ii) Constant Contact Type.

(Iii)Spring Loaded Constant Contact Type Side Bearer

Type of pivot (I) Top And Bottom Pivot Integrally Cast

With Bolster- CASNUB 22W IRS Type

(Ii) Spherical Type.

Anti-rotation

features

Anti-Rotation Lugs Have Been Provided

Between Bogie Bolster And Side Frame And

Brackets.

Type of brake beam (I) Unit Type Fabricated Brake Beam

Supported And Guided In The Brake Beam

Pockets.

(Ii) Unit Type Cast Steel Brake Beam Suspended By Hangers From Side Frame

Brackets.

Suspension system Long Travel Helical Spring.

Avanish et al., International Journal of Advanced Engineering Technology

IJAET/Vol. IV/ Issue II/April-June., 2013/71

Fig.1 Casnub Bogie

IV. DESIGNING OF WAGON AND

USING PRO-E AND CATIA

Our project deals with the material optimization of

the railway wagon. For those purpose we have

selected the most used type of wagons for freight

purpose i.e., Closed Type Goods Wagon. These

types of wagon are used to transport goods and

commodities that cannot be exposed to the

environment openly like Cement, Chemical and

Food Commodities etc.

Based on the design, the whole wagon can be

divided into 2 parts broadly

1. Upper Part( Shell) and

2. Lower Chassis(Bogies - Two in number)

The Shell part of the wagon is modeled in Pro

The Structure of the shell of the wagon is based on

its framework. This framework consists of channels

of different cross section which are welded together.

The Steel Sheets are riveted to these channels to

make up shell as a whole.

A. Steps Involved In Modeling the Wagon Shell

1. The sketch of the cross section was

sketched.

2. This sketched was extruded along the

length.

3. The bottom and top support C-Channels are

extruded.

4. The advantage of the symmetry of the

wagon design is used with mirror option.

5. The C-Channel at the front and back side

are extruded.

6. The L-Channels at the two sides of the shell

are extruded.

7. The C-Channels and L-Channels are used

to attach the top and bottom support

channels rigidly.

8. The channels extruded are arrayed al

the length.

9. Two doors are cut on the two sides

symmetrically.

10. All the channels are thickened with the

thickness measured earlier from the real

wagon.

11. The frame and the sheet work are colored

differently for better visualization.

Thus the shell part is modeled and it is saved in

IGES format which is the imported to Hyper Mesh

for further analysis on the structure.

B. Designing process of bogie in CATIA

As our project specifies about the optimization of the

design and material of a Wagon,

International Journal of Advanced Engineering Technology E-ISSN 0976

71-73

AND BOGIE

Our project deals with the material optimization of

the railway wagon. For those purpose we have

selected the most used type of wagons for freight

purpose i.e., Closed Type Goods Wagon. These

types of wagon are used to transport goods and

cannot be exposed to the

environment openly like Cement, Chemical and

Based on the design, the whole wagon can be

Two in number)

gon is modeled in Pro-E.

The Structure of the shell of the wagon is based on

its framework. This framework consists of channels

of different cross section which are welded together.

The Steel Sheets are riveted to these channels to

Steps Involved In Modeling the Wagon Shell:

The sketch of the cross section was

This sketched was extruded along the

Channels are

The advantage of the symmetry of the

or option.

Channel at the front and back side

Channels at the two sides of the shell

Channels are used

to attach the top and bottom support

The channels extruded are arrayed along

Two doors are cut on the two sides

All the channels are thickened with the

thickness measured earlier from the real

The frame and the sheet work are colored

differently for better visualization.

modeled and it is saved in

IGES format which is the imported to Hyper Mesh

CATIA

As our project specifies about the optimization of the

We have RE-DESIGNED the basic structure of the

bogie. We have removed the bulky parts of the bogie

and later we have developed the design using

CATIA software.

We have removed the parts of that play the

importance of housing the brake system.

The housing system cannot be optimized because the

system itself requires certain space and material for

it to sustain for longer period.

We have only designed the major parts which take in

huge amount of stresses when the bogie in motion.

Fig.2 Casnub Bogie modelled in

C. The design of axle system

The axle system does suffer from loading. So, we

have also designed the axle system.The axles are

also developed using the CATIA software.

Fig.3Axle system modelled in

V. ANALYSIS USING HYPER MESH

A. Meshing the bogie

The Bogie is meshed based on the different

parameters:

1. Conversion of the design into a solid

2. Using tetra mesh in 3D option. The

maximum and minimum values of the

element size are 30.000 and 20.000

respectively

B. Geometry clean up:

The meshed bogie thus formed must be checked for

free edges.

This is done by using the AUTOCLEAN UP option.

C. Quality of meshing of the bogie:

1. The bogie has generated approximately

some 5500000 nodes when the element

size is described as .80000

2. We have changed the option by keeping

the element size as 30.00000 and we have

generated approximately 70000 nodes.

3. The aspect ratio and war page is tested.

ISSN 0976-3945

D the basic structure of the

bogie. We have removed the bulky parts of the bogie

and later we have developed the design using

We have removed the parts of that play the

importance of housing the brake system.

ptimized because the

system itself requires certain space and material for

We have only designed the major parts which take in

huge amount of stresses when the bogie in motion.

Fig.2 Casnub Bogie modelled in CATIA

The axle system does suffer from loading. So, we

have also designed the axle system.The axles are

software.

Fig.3Axle system modelled in CATIA

MESH

The Bogie is meshed based on the different

Conversion of the design into a solid

Using tetra mesh in 3D option. The

maximum and minimum values of the

element size are 30.000 and 20.000

d must be checked for

This is done by using the AUTOCLEAN UP option.

g of the bogie:

The bogie has generated approximately

some 5500000 nodes when the element

size is described as .80000

We have changed the option by keeping

the element size as 30.00000 and we have

generated approximately 70000 nodes.

The aspect ratio and war page is tested.

Avanish et al., International Journal of Advanced Engineering Technology

IJAET/Vol. IV/ Issue II/April-June., 2013/71

VI. OUR RESULTS

Fig.4von-mises stresses of the Bogie

Fig.5Displacements values

A. ADVANTAGES

• Applying the loads at desired nodes.

• Design is a conceptual one, inspired from the

design by GM (General Motors)

• Removal of the bulky parts of the structure

and reducing the fillets radius in order to

reduce the stress flow line concentration.

• The bogie generated about 30,000 nodes

which resemble the accuracy with which we

have tried to get the results.

• The wagon was designed and meshed and the

results are assumed to be same as the results

done by reputed organizations.

B. DISADVANTAGES

• We have missed a section of the brake

housing in the design process, and with which

the analysis would have been clearer

International Journal of Advanced Engineering Technology E-ISSN 0976

71-73

mises stresses of the Bogie

Applying the loads at desired nodes.

is a conceptual one, inspired from the

Removal of the bulky parts of the structure

and reducing the fillets radius in order to

reduce the stress flow line concentration.

The bogie generated about 30,000 nodes

e accuracy with which we

The wagon was designed and meshed and the

results are assumed to be same as the results

We have missed a section of the brake

, and with which

the analysis would have been clearer

• At the housing of the chassis, a small fillet

section was missed this would have

contributed to reduce more stress lines.

VII. CONCLUSION

As per the topic chosen the complete design and

analysis of the bogie are performed and results are

obtainedThe design developed can be an alternative

to the present design. The material that we have used

is stainless steel, which will probably be used in

manufacture of wagons in the near future.

VIII. FUTURE SCOPE OF THIS

• The project can be further carried out to

optimize the material usage in the fabrication

of wagon.

• Design of the wagon based on stainless steel

can be studied as wagon made of Stainless

steel would reduce the maintenance cost

incurred for the ordinary steel wagons.

• Analysis of wagons fabricated with welding

rather than riveting can be done.

REFERENCES 1. IIT-K Students , ”Design and Optimization of a

Passenger Bogie”, Kanpur, journal

2. Railway Bogie, http://en.wikipedia.org/wiki/Bogie3. Casnub Bogie ,”Details and specifications of Casnub

Bogie”,http://wiki.iricen.gov.in/doku/doku.php?id=d

efects_in_rolling_stock:casnub_bogie4. Freight cars , “Freight cars used for carrying loads”,

http://en.wikipedia.org/wiki/Railroad_car#Freight_ca

rs 5. Wagon Work Shop , Guntapalli

6. ProE,“Tutorials”,http://bdml.stanford.edu/twiki/pub/

Manufacturing/ProETutorial/ProE_Wildfire_2_Tutorial-2006.pdf

7. CATIA Tutorials, “CATIA V5 help”

8. Hyper Mesh Tutorials ,”Hyper Mesh Help Online”Ramesg R Gopal , “Sustainable stainless steel for

wagons”, National workshop on stainless steel coach

and wagon manufacture,pdf

ISSN 0976-3945

At the housing of the chassis, a small fillet

section was missed this would have

contributed to reduce more stress lines.

As per the topic chosen the complete design and

bogie are performed and results are

obtainedThe design developed can be an alternative

to the present design. The material that we have used

is stainless steel, which will probably be used in

manufacture of wagons in the near future.

PROJECT

The project can be further carried out to

optimize the material usage in the fabrication

Design of the wagon based on stainless steel

can be studied as wagon made of Stainless

steel would reduce the maintenance cost

rdinary steel wagons.

Analysis of wagons fabricated with welding

rather than riveting can be done.

K Students , ”Design and Optimization of a , journal

http://en.wikipedia.org/wiki/Bogie Casnub Bogie ,”Details and specifications of Casnub

http://wiki.iricen.gov.in/doku/doku.php?id=d

:casnub_bogie Freight cars , “Freight cars used for carrying loads”,

http://en.wikipedia.org/wiki/Railroad_car#Freight_ca

stanford.edu/twiki/pub/

Manufacturing/ProETutorial/ProE_Wildfire_2_Tutor

V5 help”

Hyper Mesh Tutorials ,”Hyper Mesh Help Online” “Sustainable stainless steel for

wagons”, National workshop on stainless steel coach