A multiscale finite element method is used to develop a model of a carbon fibre-reinforced plastic (CFRP) bogie with variable cross-sections and ultra-thick laminates. The model is applied to examine how CFRP influences the dynamic performance of the vehicle. The complex geometry of the bogie side beam is represented through micromechanical parameter prediction, mesoscale laminate reconstruction and macroscale structural mapping, which together form a system of 416 CFRP plies. A stepped lay-up method with a ply thickness of 0.193 mm is applied to reproduce the geometry of the variable-section beam and to describe the anisotropic behaviour of the CFRP material and the coupling between the laminate layers. A modal test is carried out on the CFRP side beam. Comparison of the first eight natural frequencies and mode shapes shows that the simulation errors remain within 5 per cent. The Craig-Bampton reduction method is then used to build a rigid-flexible coupled (RFC) dynamic model of the CFRP bogie. By comparing the simulated acceleration responses with those measured in line tests, the validity of the model is confirmed. Further analysis of a conventional multi-rigid body (MRB) bogie model and the CFRP bogie shows that the CFRP bogie reduces the vibration amplitude of the side beam and the carbody, limits the transmission of high-frequency vibration, and improves both ride comfort and running safety at speeds up to 240 km/h.
GiossiRLPerssonRStichelS. Wheel wear reduction of a mechatronic two-axle vehicle: dynamic study including a carbon-fibre connection frame. Veh Syst Dyn2024; 62(4): 1037–1062. https://doi.org/10.1080/00423114.2023.2211182
5.
MistryPJJohnsonMSGalappaththiUIK. Selection and ranking of rail vehicle components for optimal lightweighting using composite materials. Proc Inst Mech Eng F J Rail Rapid Transit2021; 235(3): 390–402. https://doi.org/10.1177/0954409720925685
6.
BüchelerDKaiserAHenningF. Using thermogravimetric analysis to determine carbon fiber weight percentage of fiber-reinforced plastics. Compos Part B Eng2016; 106: 218–223. https://doi.org/10.1016/j.compositesb.2016.09.028
7.
BruniSMistryPJJohnsonMS, et al.A vision for a lightweight railway wheelset of the future. Proc Inst Mech Eng F J Rail Rapid Transit2022; 236(10): 1179–1197. https://doi.org/10.1177/09544097221080619
8.
MistryPJJohnsonMS. Lightweighting of railway axles for the reduction of unsprung mass and track access charges. Proc Inst Mech Eng F J Rail Rapid Transit2020; 234(9): 958–968. https://doi.org/10.1177/0954409719877774
9.
GeuenichWGuntherCLeoR. The dynamics of fiber composite bogies with creep-controlled wheelsets. Veh Syst Dyn1983; 12(1–3): 134–140. https://doi.org/10.1080/00423118308968739
10.
JeonKWShinKBKimJS. A study on fatigue life and strength of a GFRP composite bogie frame for urban subway trains. Procedia Eng2011; 10: 2405–2410. https://doi.org/10.1016/j.proeng.2011.04.396
11.
KimJSLeeWGKimIK, et al.Natural frequency evaluation of a lightweight GFRP composite bogie frame. Int J Precis Eng Manuf2015; 16(1): 105–111. https://doi.org/10.1007/s12541-015-0013-5
12.
LangDRadfordD. Cost, draping, material and partitioning optimization of a composite rail vehicle structure. Materials2022; 15(2): 449. https://doi.org/10.3390/ma15020449
13.
HanYWangRAllenP, et al.Analysis of failure mechanisms for CFRP laminated composite bogie frames of next-generation high-speed trains under service environment. Eng Fail Anal2025; 178: 109701. https://doi.org/10.1016/j.engfailanal.2025.109701
14.
MaQHQinXYGanXH, et al.Study on structural optimization of braid-and-lay integrated CFRP for metro bogie. Polym Compos2023; 44(10): 6419–6439. https://doi.org/10.1002/pc.27568
15.
ShunmugeshKRaphelAUnnikrishnanTG, et al.Finite element modelling of carbon fiber reinforced with vespel and honey-comb structure. Mater Today Proc2023; 72: 2163–2168. https://doi.org/10.1016/j.matpr.2022.08.301
16.
BaşoğluFYakarECBoraMO, et al.Comparison of low-velocity impact behavior of thick laminated composite structures: experimental and modelling. Polym Compos2023; 44(11): 7657–7673. https://doi.org/10.1002/pc.27654
17.
HoornNVKassapoglouCTurteltaubS, et al.Experimental damage tolerance evaluation of thick fabric carbon/epoxy laminates. J Compos Mater2022; 56(5): 761–778.
PeetersMSantoGDegrooteJ, et al.High-fidelity finite element models of composite wind turbine blades with shell and solid elements. Compos Struct2018; 200: 521–531. https://doi.org/10.1016/j.compstruct.2018.05.091
20.
GhinetSAtallaN. Modeling thick composite laminate and sandwich structures with linear viscoelastic damping. Comput Struct2011; 89(15–16): 1547–1561. https://doi.org/10.1016/j.compstruc.2010.09.008
21.
PereiraDAGuimarãesTAMResendeHB, et al.Numerical and experimental analyses of modal frequency and damping in tow-steered CFRP laminates. Compos Struct2020; 244: 112190. https://doi.org/10.1016/j.compstruct.2020.112190
22.
YanLLiSLiM, et al.Multiscale simulation and experimental studies on modal damping of ultra-thick CFRP laminates. Polym Compos2024; 45(12): 8214–8227. https://doi.org/10.1002/pc.28520
23.
DonoughMJPrustyBGVan DonselaarMJ, et al.In-plane and oblique edge-on impacts on thick glass-fibre/epoxy composite laminates. Int J Impact Eng2023; 171: 104373. https://doi.org/10.1016/j.ijimpeng.2022.104373
LingLZhangQXiaoX, et al.Integration of car-body flexibility into train–track coupling system dynamics analysis. Veh Syst Dyn2018; 56(4): 485–505. https://doi.org/10.1080/00423114.2017.1391397
27.
HanYTShiWDFengWJ. Dynamic damage detection and assessment on the bogie frame of high-speed train based on coupled elastic-multibody dynamics. Acta Mech Solida Sin2023; 36(5): 633–646. https://doi.org/10.1007/s10338-023-00410-2
28.
WangQSLiDDZengJ, et al.A diagnostic method of freight wagons hunting performance based on wayside hunting detection system. Measurement2024; 227: 114274. https://doi.org/10.1016/j.measurement.2024.114274
KirchhoffG. Über das Gleichgewicht und die Bewegung einer elastischen Scheibe. J für die Reine Angewandte Math (Crelle’s J)1850; 40: 51–88.
33.
CarreraE. Theories and finite elements for multilayered anisotropic composite plates and shells. Arch Comput Methods Eng2002; 9(2): 87–140. https://doi.org/10.1007/bf02736649
34.
ReddyJN. Mechanics of laminated composite plates and shells: theory and analysis. 2nd ed.CRC Press, 2004.
35.
YangBZhouSBertoF, et al.Static strength analysis of the composite bogie side beam using cohesive elements. Phys Mesomech2025; 28(5): 626–651. https://doi.org/10.1134/s1029959924601787
36.
CraigRRBamptonMCC. Coupling of substructures for dynamic analysis. AIAA J1968; 6(7): 1313–1319. https://doi.org/10.2514/3.4741
