Case Studies

Realistic Simulation Makes a Safe Impact on Train Design
Abaqus Finite Element Analysis Software Simulates Collision on Anti-climb Crash Module

Swiss-based Stadler Rail Group produces about 700 light and commuter rail vehicles per year. All of its products meet stringent requirements governing safety equipment, strength of train units (cars and engines) and, above all, passenger and crew protection from the force of impacts.

But with a recent order from the Netherlands for 43 of the latest generation of Stadler’s GTW articulated rail cars, the company faced a new challenge: the train units had to meet as-yet unreleased crashworthiness standards that the country had adopted in advance of their approval by the European reviewing committee. Among the requirements was that the units provide passenger zone protection during a 36 km/h (22.4 mph) front-end collision between two units with a vertical offset of up to 40 millimeters.

Two developments drove the new requirement. First, head-on impacts could easily include a small offset because two train units had differing amounts of wheel wear or braking inclination. A second reason was more urgent: a recent numerical simulation of an offset collision indicated that the previous design of a crash module (a safety device on the front of the train car) might not prevent damage to the passenger zone of the train units during such an impact.

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