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HP MULTI JET FUSION HELPS STRENGTHEN TRAIN DOOR STRUCTURES
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CAF is multinational group with more than 100 years of experience in the supply of comprehensive transit solutions. CAF is
positioned at the forefront of technology for high
value added and sustainable mobility.
The company is a leader of the railway industry
offering one of the most comprehensive and
flexible arrays of products in railway-related
markets, such as rolling stock, components,
infrastructure, signaling, and services
(maintenance, refurbishing, and financial
services).
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SOLUTION
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CAF identified current metallic parts in their train systems that are suitable to replace with plastic parts made with HP Multi Jet Fusion technology. One of these parts is the support of the train’s door cover structure.
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The parts were virtually tested and simulated under their current mechanical requirements using finite element analysis (FEA). The FEA structural static analysis of the part identified the areas that should be reinforced using the new design.
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CAF engineers began an iterative process of redesign and digital simulation by reinforcing or stiffening weak areas with fillers or other geometries to improve robustness.
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INDUSTRY
Mobility and transportation
SECTOR
Rail Solutions
SIZES
X: 9.9 in / 25.15 cm
Y: 3.9 in / 10 cm
Z: 4.1 in / 10.5 cm
VOLUME
15.9 in3 / 260.9 cm3
MATERIAL
HP 3D High Reusability PA 12
POST-PROCESSING
Bead blasting
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RESULTS
The validated design was 3D printed using HP 3D HR PA 12 and produced to substitute the metallic model in new train system assemblies with the following mechanical improvements:
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- Part performance: The results of the FEA show an acceptable part performance that met mechanical requirements.
- Enhanced strength: The second iteration integrates a nerve instead of the internal filler in order to strengthen the weaker area.
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ORIGINAL METALLIC PART
The initial part identified as suitable to be changed from a metallic part to a 3D printed part produced with HP Multi Jet Fusion technology and HP 3D HR PA 12 material.
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ORIGINAL PART FATIGUE ANALYSIS
This step involves analyzing the original part without modifying the geometry or shape. The part did not meet the mechanical expectations, so new solutions were proposed to change the geometry.
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FIRST ITERATION PART FATIGUE ANALYSIS
The first suggested geometry modification, which includes an internal lattice structure to strengthen the part. The FEA shows that this solution is not adequate and another solution must be found.
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SECOND ITERATION PART FATIGUE ANALYSIS
The second iteration integrates a nerve instead of the internal filler in order to strengthen the weaker area. The results of the FEA show an acceptable part performance that meets mechanical requirements. This will be the final design to enable the transition from metal parts to parts produced by HP 3D HR PA 12.
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