A vision for a lightweight railway wheelset of the future

Rail vehicle lightweighting using fibre reinforced polymer composite materials is essential for the future of rail. This is recognised as a means of reducing carbon dioxide production through lower energy consumption, as well as reducing the impact on track degradation, thus delivering improved rail capacity and performance. This paper presents an overview of the work conducted within work package three of the NEXTGEAR project focused on the 'wheelset of the future'. Three concepts for a hybrid metallic-composite railway axle are proposed and their strengths and weaknesses are assessed. A finite element analysis on the selected concept was conducted, including a solution for the bonded joints of the metallic collars which provide the interface to the wheels and bearings. An axle mass reduction of over 63% was shown. An overview is also provided regarding the analysis of manufacturability of the axle, non-destructive methods for axle inspection/structural health monitoring and effects of impacts from ballast stones. Finally, a preliminary evaluation of the benefits arising from the reduction of the unsprung masses is provided, based on multibody simulations of vehicle dynamics.