This was our Thesis Project at IIT Roorkee and the aim was to design and simulate the crash-worthy (energy absorbing) element for a LHB type passenger coaches running at a speed greater than 60KMPH. We scored an Outstanding A+ (10/10) in the project, which was also presented at RDSO (Research Designs and Standards Organization), Ministry of Railways, Lucknow.

1. CRASHWORTHINESS
OF RAILWAY
COACHES
AKASH BEHL DR. SATISH C. SHARMA
RAVI BHUSHAN PANDEY DR. S.P. HARSHA
YASH RANE

2. AIM
To design and simulate the crash worthy
(energy absorbing) element for a LHB type
passenger coaches running at a speed
greater than 60KMPH.
Target: To design a crashworthy element with energy
absorbing capacity of 3MJ.
(40 KMPH is achieved by RDSO Lucknow)

3. MODEL OF LINKE HAUFMAN BAUCH
COACHES
• AAR ‘H’ type center buffer
coupler is used in LHB
coaches
• Y frame fiat bogie is used.
• Better than screw coupling
previously used in ICF.

4. MODEL OF COUPLER
RDSO performed crashworthy
analysis at 40KMPH. Modifications
for crashworthiness:
- Provision of pocket for
honeycomb.
- Buckle initiators have been
provided in longitudinal
members.
- Thickness of door stiffening collar
at middle and end doors,

5. CRASH SCENARIO
BEFORE CRASH
AFTER CRASH

6. DRAFT GEAR
 Draft gear with the absorbing capacity of 45KJ was introduced for
first time and was revised as 35 KJ.
 Balanced Draft Gear was preferred over Single and Twin Draft Gear
Single Pack Draft Gear TWIN Pack Draft Gear

7. ENERGY ABSORBED BY DRAFT GEAR
 Minimum energy
absorption – 35 KJ
 Energy absorbed by
draft gear (J) = 19.25 x
WL x WV x VL
2 / (WL+WV)
WL = weight of locomotive
=112 ton
WV = weight of wagon =
60 ton
VL = velocity of locomotive

8. ADDITIONAL ENERGY ABSORBER
 A coach is designed to take a minimum 2000 kN buff load without
any permanent deformation.
 The coach can store elastic energy equal to (Energy Stored =
1/2XForce2/Stiffness) 13 kJ when a buff load of 2000 kN is applied at
one end and buff stopper at the other end is restrained.
 Side buffer has equivalent energy of 20 kJ per coach end.
Coach
No.
Coach
End
Energy Absorption in MJ
Coach
Body
Honeycom
b
Coach
End
Coach
1 Front 1.48 2.09 3.57 6.02
Rear 1.22 1.23 2.45
2 Front 1.02 1.20 2.22 3.79
Rear 0.69 0.88 1.57
3 Front 0.41 0.70 1.11 2.50
Rear 0.60 0.79 1.39
RDSO: Results of test performed at 42.7 KMPH

9. HONEYCOMB
• Approximately 66 % of internal
energy is dissipated in energy
absorbing elements
• Figure shows that the coach
buckles at approximately 5 MN and
the honeycomb crushes at an
average force of 1.5 MN.

10. HONEYCOMB - Disadvantages
 Energy Absorption is limited
to 2 MJ.
 Force is ultimately
transferred to passenger
with short reaction time.

11. MAGNETO-RHEOLOGICAL FLUID
 Magnetic particles consist of sub-domains.
 Sub-domains have dipole moments.
 Orientation is achieved by the application of magnetic field.
 Formation of real chain of particles takes place.
 Column-like structures arise.
 Motion of the fluid is thus, impeded.

12. PROPERTIES
 Yield Strength
 Activation Time
 Power Requirements
 Fail-Safe Operation
 Response time

13. DISADVANTAGES
 Sedimentation
 Use of permanent magnets

14. Lord MRF-336AG
Lord MRF-336AG offers the following beneficial characteristics:
 Fast Response Time
 High Dynamic Yield Stress
 Low Off-State Viscosity
 Broad Operating Temperature Range
 High Resistance to Hard Settling
 Easy Remixing
 Non Abrasive

15. Formation of Magnetic circuit

16. MR Fluid Cylinder
Pneumatic Reservoir
PISTON ROD

17. Floating Piston

18. Space for
electromagnetic coil
Piston Head

19. FUTURE PLANS
 Simulation of modeled design to achieve the target of 3 MJ energy
absorption capacity.
 Verify the performance of the design by Real time simulation at
RDSO Lucknow. The crashworthy element will be simulated with
complete model of 24 LHB passenger train in LS-DYNA.

20. Thank You!