Structural optimization design of a bolster based on a simulation-driven design method

Abstract A simulation-driven design method which uses multiple optimization methods can effectively promote innovative structural design and reduce the product development cycle. Meanwhile, the sub-model technology which has more detailed simulation and optimization analysis can enormously improve the efficiency of modelling and solving. This study establishes a general workflow of structural optimization for a stainless-steel metro bolster by combining the simulation-driven design method and sub-model technology. In the sub-model definition phase, the end underframe sub-model which contains the bolster is obtained based on the whole car body finite element (FE) model, and the effectiveness of the end underframe sub-model is also proved. In the conceptual design phase, the topology path inside the bolster is obtained by the topology method and the optimized structure of the inner ribs inside the bolster is determined according to manufacturing processes and design experiences. In the detailed design phase, the thickness of each part of the bolster is determined by size optimization. The simulation analyses indicate that the requirements of static strength and fatigue strength are fulfilled by the optimized bolster structure. Besides, the weight can be reduced by 11.18% and the weld length can be decreased by 17.79% compared with the original bolster structure, which means that not only the lightweight design goal is achieved, but also the welding quantity and manufacturing difficulty are greatly reduced. The results show the effectiveness of the simulation-driven design method based on the sub-model technology in the structural optimization for key parts of rail transit vehicles.