Weight reduction of the train by applying a new construction and testing process of the train car bogie

The algorithms and procedures of the train car bogie design which have been used so far are mainly based on the iterative approach: theoretical modeling—experimental studies of entire structures, until the assumed life is achieved. Such approach usually results in over-designing of the structure and the need for numerous expensive laboratory tests. Depending on the scale and nature of the object, more or less complex research systems are used for that purpose, but in the case of primary structures of the means of transport, usually multi-axial stands are used to apply load variable in time corresponding to the input function adopted in the design process. This approach is very costly, which is mainly caused by a high cost of preparing test objects for fatigue tests and a high cost of fatigue tests performed by using multi-axial testing stands. It should be noted that because of the nature of the fatigue, drawing conclusion on the correctness of the developed structure based on individual trials is associated with a significant uncertainty. Therefore it is often necessary to perform at least a few repetitions of fatigue tests. Thus there is a need to develop the design and testing methodology for complex technical objects such as bogies of railway vehicles, in order to limit the costs of research. The paper presents the proposal of method by which it is possible to optimize weight of railway vehicle bogies while limiting of costs of research by reducing the costs of test objects and the complexity of the test stand.