RAILWAY

RAILWAY OPTIMISED LIGHTWEIGHT CARBON FIBRE BOGIE FRAME

ELG Carbon Fibre Ltd (UK) and partners Alstom Transport (UK), Magma Structures (UK), University of Birmingham (UK), University of Huddersfield (UK)

This project will deliver a composite bogie frame concept, addressing the barriers that have prevented commercial adoption. It will be the first project to develop a carbon fibre bogie frame and the first to include recycled material.

​

The project aimed to deliver at least 50% weight saving over metal frames through the use of carbon fibre materials; the current design delivers at least 70% weight saving. The mechanical properties of the materials are tailored to provide integrated suspension and steering functionality, reducing the lateral forces on rail tracks by up to 40%, and also providing a 20% reduction in overall train fuel consumption.

​

This tailoring is achieved by using a combination of approximately 80% recycled carbon fibre and 20% prime carbon fibre. By achieving this tailored flexibility using a lightweight composite construction, vertical loading will be reduced as a consequence of lower axle weight, which will further reduce track damage.

The potential affordability issues associated with the use of composites are addressed through the use of low-cost recycled carbon fibre materials and a cost-effective processing technique suitable for the manufacture of components of this size and complexity.