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By

Sunil Saini
Varun Chugh
Contents
 Why Composites
 Light Weight
 Fire Safety
 Crashworthiness
 Applications
 Bodywork
 Seats
 Driver’s Cabin
 Stabilization of Ballasted Rail Tracks
 Doors
 JuteGlass
 JuteCoir
 Sleepers for Railway Girder Bridges
 Gear Case
Why Composites?
Light Weight

 Lighter vehicles would benefit in two


ways:
 Yield capacity increases by:
 Providing increased payload (e.g. the full-
utilisation of double-deck capacity without
exceeding axle load limits)
 Reducing the detrimental effect of an
increased service on the existing railway
 Lighter vehicles would reduce
running costs
 Weight savings of around 20%
Fire Safety

 Thermosetting polymer resins on


which the majority of rail vehicle
composites are based are organic
and hence burn
 Aluminium hydroxide- filled polyester
resin
 Phenolic resins
 CNTs as reinforments
Crashworthiness

 Composite vehicle structures ought


to be capable of dissipating more of
the kinetic energy associated with a
collision than a conventional metallic
design
 Honeycomb crushes under load in a
uniform way, preventing damage to
the
supporting structure
 energy absorption can be as
Applications
FRP Pultruded Profiles
•Windows, ladders, Doors,
luggage racks
Bodywork

 Fibrocom
 surface laminates are connected to each
other by intermediate wall laminates,
 forming a rigid three-dimensional
structure with load carrying capacity
 The channels can be filled with foam
to provide thermal and sound
isolation.
 Fire safety is ensured by a suitable
selection of resins and fire retardants
Seats

 Three‐dimensional tailored textile


preforms
 Allows
 Fast
 Automatic
 Low cost production
 Moulding processes such as
RTM are used
Driver’s Cabin

 Vibration dampening
 Noise attenuation
 Heat insulation
Stabilization of Ballasted
Rail Tracks
 Bonded geo grids geotextiles are
used
 Functions as
 Drainage
 Separation of ballast
from sub-ballast
Doors

 FRP sliding doors


 Two different doors have been
fabricated
 One with 'compreg' inside & FRP skin on
either side of the door
 Other being sandwich construction with
FRP exterior skins & PU foam inside.
 The detailed testing carried out at RRL-
Bhopal and the results were very
encouraging
JuteGlass
Composite Components for
Railways
 Glass & louvre shutters for

 Windows,
 Lavatories
 Axle box covers
JuteCoir Composites An
Alternative to Wood Products
 Coir and jute impregnated with
phenolic resins
 Used for
 sleeper berth backing
 doors & windows
 as a backing material for seat &
backrest
Sleepers for Railway Girder
Bridges
 FRP Fabricate
 Good substitute for wooden sleepers
 Offers:
 Vibration damping
 High resistance against strength drop
and water resistance
Gear Case

 FRP gear-cases for the traction


motors for diesel & electric
locomotives as replacement of
existing steel gear-cases
 Prevents the leakage of lubricating
medium
 Safe from damages by stone ballast.
 Expected to last for 6 years in
service as against merely 2 to 3
years of conventional steel gear-case