Design Optimization of a Composite Rail Vehicle Anchor Bracket

The rail transportation sector is currently seeking to decrease greenhouse gas emissions by incorporating composite materials that can reduce the mass of vehicles. During early adoption of composites in the rail transportation industry, these materials have predominantly been applied to simple design geometries and lightly loaded structures, have been optimized only through modification of composite thickness and composite layer shape, and have only been constrained with respect to a single mechanical performance metric. This study investigates the use of finite element analysis software in the simulation of fiber-reinforced composite materials applied to, and optimized for, a complex and heavily loaded rail vehicle anchor bracket. The research assesses the applicability of optimization methodologies to a complex and heavily loaded structure and advances established practices by constraining the solution with respect to multiple design requirements: manufacturing, compliance, and failure criterion. The optimization process successfully developed a composite structure with a predicted mass reduction of 33% compared to an existing steel design, and simultaneously met compliance, manufacturing, and failure criteria constraints.