Crashworthiness design and experimental validation of a novel collision post structure for subway cab cars

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Crashworthiness design and experimental validation of a novel collision post structure for subway cab cars XING Jie(邢杰)1, 2, XU Ping(许平)1, 2, ZHAO Hui(赵慧)1, 2, YAO Shu-guang(姚曙光)1, 2, WANG Qian-xuan(王前选)3, LI Ben-huai(李本怀)1, 2 1. Key Laboratory of Traffic Safety on Track, Ministry of Education, Central South University, Changsha 410083, China; 2. Joint International Research Laboratory of Key Technology for Rail Traffic Safety, Changsha 410083, China; 3. School of Railway Tracks and Transportation, Wuyi University, Jiangmen 529020, China; © Central South University Press and Springer-Verlag GmbH Germany, part of Springer Nature 2020 Abstract: This paper proposes a novel collision post structure designed to improve the crashworthiness of subway cab cars. The structure provides two innovative features: 1) a simpler connection between the post and the car roof, which gives a more reasonable load transfer path to reduce the stress concentration at the joint; and 2) a stiffness induction design that provides an ideal deformation model to protect the safe space of the cab cars. The novel collision post structure was evaluated with finite element analysis, and a prototype cab car was mechanically tested. The results demonstrate that the deformation response was stable and agreed well with the expected ideal mode. The maximum load was 874.17 kN and the responses remained well above the elastic design load of 334 kN as required by the design specification. In addition, there was no significant tearing failure during the whole test process. Therefore, the novel collision post structure proposed has met the requirements specified in new standard to improve the crashworthiness of subway cab cars. Finally, the energy absorption efficiency and light weight design highlights were also summarized and discussed. Key words: collision post structure; subway cab cars; crashworthiness; quasi-static test Cite this article as: XING Jie, XU Ping, ZHAO Hui, YAO Shu-guang, WANG Qian-xuan, LI Ben-huai. Crashworthiness design and experimental validation of a novel collision post structure for subway cab cars [J]. Journal of Central South University, 2020, 27(9): 2763−2775. DOI: https://doi.org/10.1007/s11771-020-4497-5.

1 Introduction The issue of crashworthiness requirements for subway cab cars has been a topic of discussion for some time. Cab cars are passenger-carrying vehicles located at the very end of the subway train. The operator is positioned at the end of the cab car where he or she can have a good visibility of the track. However, the proximity of the operator to the

very end of the car puts him or her at greater risk in the event of a collision condition. Generally, crashworthiness research focuses on the scenario that a leading cab car hits another train head on. In this scenario, the underframe and the superstructure of the cab car are loaded. The energy-absorbing component installed on the underframe dissipates the kinetic energy through various forms plastic deformation. Many literatures h a v e r e p o r t e d o n t h e des i