CASE STUDY - CAF
INDUSTRY SEGMENT : MOBILITY AND TRANSPORTATION | Rail Solutions
Viability studies Civil Work Electrification Signalling Maintenance and system operation
RANGE OF PRODUCTS
High speed trains Regional and commuter trains Metros Trams and LRV’s Locomotives
TRAIN DOOR SUPPORT PLACEMENT
TRAIN DOOR SUPPORT
CHALLENGE OF THE CUSTOMER
CAF identified a group of metallic parts currently applied and used in train systems, suitable to be changed to plastic parts by digital transformations using HP Multi Jet Fusion technology. One of those parts is the support of the train’s doors cover structure.
First, the parts are virtually tested and simulated the FEA (Finite Element Analysis) under their current mechanical requirements applying HP 3D High Reusability PA 12 material properties. As the parts were designed to be produced with metal, the part should be redesigned to adapt to the HP 3D High Reusability PA 12 material. However, a first FEA structural static analysis of the part was done in order to identify the areas that should be reinforced in this new design.
CAF engineers started an iterative process of redesign and digital simulation, reinforcing or stiffening weak areas with fillers or other geometries in order to improve its robustness. Finally, the validated design was printed and produced to substitute of the metallic model in new train system assemblies.
ORIGINAL METALLIC PART
Initial part identified as suitable to be transformed from metallic part to 3D printed with HP Multi Jet Fusion with HP 3D HR PA 12 material.
ORIGINAL PART FATIGUE ANALYSIS
Analysing the original part without modifying the geometry or the shape, the part did not meet the mechanical expectations. New solutions were proposed by changing its geometry.
1st. ITERATION PART FATIGUE ANALYSIS
The first geometry modification suggested is this design, which includes an internal lattice structure to its original geometry in order to strengthen the part. The FEA shows that this solution is not good enough, and another solution must be found.
2nd. ITERATION PART FATIGUE ANALYSIS
This second iteration integrates a nerve instead of the internal filler in order to strengthen specifically the weaker area. The results of the FEA show an acceptable part performance that meets the mechanical requirements. This is going to be the final design to enable the transformation and replacement of metal parts to the 3D printed HP 3D HR PA 12 parts.