Development of a Methodology for Railway Bolster Beam Design Enhancement Using Topological Optimization and Manufacturing Constraints

Rolling stock manufacturers are finding innovative structural solutions to improve the quality and reliability of railway vehicle components. Structural optimization processes represent an effective strategy for reducing manufacturing costs, resulting in geometries that are easier to design and produce combined with innovative materials. In this framework, the present paper proposes the development of a design methodology to innovate a railway bolster beam using topological optimization techniques, assessing the effect of different manufacturing constraints oriented to the casting process. A comprehensive numerical testing campaign was conducted to establish an effective testing procedure. Two different designs were obtained and compared, statically and dynamically, evaluating the difference in terms of mass, mechanical performance and manufacturability. Reductions in stress values up to 70% were observed, along with an 8% increase in the first natural frequency of the component, leading to beneficial effects in terms of stiffness. The methodology shows encouraging results to streamline the design of complex casting components, moving to a new generation of structural railway components.