Rail systems form the backbone of critical transportation infrastructure such as metros, trams, commuter trains, and freight railways. In these systems, safety is not limited to structural strength alone; it also requires the integrated evaluation of ride comfort, vibration behavior, wheel–rail compatibility, dynamic clearance (gauge), crashworthiness, aerodynamic effects, HVAC performance, and weld durability.
To address these multidimensional engineering challenges, Finite Element Method (FEM), Multi-Body Dynamics (MBD), and advanced fatigue assessment techniques have become indispensable tools in modern rail vehicle design and validation.
Rail vehicles and infrastructure components are continuously exposed to demanding operational conditions:
High static and dynamic loads
Continuous vibrations and shock effects
Acceleration, braking, and curving motions
Irregular forces caused by track roughness
Environmental effects (temperature variation, humidity, corrosion)
Fatigue due to millions of load cycles
Over time, these effects may lead to cracks, deformations, and performance degradation in car bodies, bogies, welded joints, and connection elements.
FEM-based engineering analyses make it possible to predict these risks digitally long before physical production begins.
Used to verify the structural integrity of rail system components under maximum loading conditions.
Car body primary load-carrying members
Bogie frames
Couplers and connection elements
Suspension mounting points
Objective:
To ensure that stresses do not exceed material yield limits and that safety factors comply with design requirements.
Performed to identify vibration modes and natural frequencies of structures.
Detection of resonance-prone frequency ranges
Optimization of suspension and bogie design
Reduction of noise- and vibration-related comfort issues
Objective:
To prevent operational frequencies from coinciding with the system’s natural frequencies.
Used to simulate vibration loads under real operational conditions.
Track roughness effects
Wheel–rail interaction forces
Continuous speed variations
Objective:
To predict vibration-induced damage and long-term fatigue risks.
Passenger comfort is one of the most critical quality criteria in modern rail projects.
Body acceleration levels (m/s²)
Vertical and lateral vibration spectra
Compliance with ISO 2631 and similar standards
Optimization of suspension parameters
Objective:
To keep vibration and shock levels within acceptable passenger comfort limits.
Conducted to ensure that vehicles do not collide with surrounding structures during curving, suspension travel, and track irregularities.
Vehicle sway motions
Maximum lateral and vertical displacements
Tunnel, platform, and infrastructure clearances
Objective:
To verify safe vehicle–infrastructure distances and eliminate collision risks.
The contact behavior between wheel and rail profiles is vital for both safety and ride quality.
Contact stress distribution
Slip and friction behavior
Wear prediction
Stability and derailment risk assessment
Objective:
To extend wheel and rail life, reduce maintenance costs, and improve running stability.
Crashworthiness is a critical regulatory requirement, especially for urban rail systems.
Collision scenarios in accordance with EN 15227
Low- and medium-speed impact simulations
Energy absorption mechanisms
Structural deformation zones
Passenger safety performance criteria
Objective:
To preserve structural integrity, control energy dissipation, and protect passenger survival spaces during collisions.
Compliance with international standards is mandatory in rail projects.
VDV 152: Structural loading and strength requirements for bogies
EN 12663: Load cases and safety factors for rail vehicle bodies
EN 13749: Bogie frame design and structural validation criteria
Objective:
To validate regulatory compliance and accelerate certification processes.
Welded joints are among the most critical weak points in rail vehicles.
Modeling of weld seam geometry
Stress concentration analysis
Determination of fatigue class (FAT class)
Weld life estimation
Compliance with DVS 1612
Verification of weld integrity under crash loads (EN 15227)
Objective:
To prevent early crack initiation in weld zones and ensure long-term service life.
Dynamic performance analyses are carried out to ensure safe and stable vehicle operation.
Lateral and vertical acceleration measurements
Derailment risk assessments
Running stability and ride comfort criteria
Suspension behavior optimization
Objective:
To ensure that vehicles operate safely and stably in compliance with EN 14363.
Aerodynamic effects become critical at higher speeds.
External airflow analysis around the vehicle (CFD)
Pressure fluctuations and tunnel effects
Crosswind stability
Aerodynamic drag forces
Noise and acoustic effects
Compliance with EN 14067
Objective:
To improve aerodynamic stability, reduce energy consumption, and validate vehicle safety under high-speed conditions.
HVAC system performance for rail vehicles is validated according to standards.
Cooling and heating capacity tests
Cabin temperature distribution
Humidity and air quality measurements
Performance evaluation under different ambient conditions
Thermal comfort simulations (CFD)
Compliance with EN 14750
Objective:
To guarantee passenger comfort and verify HVAC system efficiency under all operating conditions.
FEM alone is often insufficient for capturing real operating behavior.
Therefore, rail projects increasingly rely on an integrated Multi-Body Dynamics (MBD) approach (e.g., RecurDyn):
Vehicle motions → calculated via MBD
Resulting loads → transferred into FEM models
Structural responses → solved under realistic boundary conditions
This workflow significantly improves correlation between simulation results, field data, and physical tests.
At FETECH Advanced Engineering, we provide end-to-end engineering solutions tailored specifically for the rail industry.
Using advanced simulation platforms such as ANSYS, LS-DYNA, RecurDyn, CivilFEM, and Endurica, we deliver:
Static and dynamic strength analyses
Modal, vibration, and ride comfort analyses
Dynamic clearance and wheel–rail compatibility studies
Crash and impact simulations (EN 15227)
Bogie and car body analyses (VDV 152, EN 12663, EN 13749)
Weld strength and fatigue calculations (DVS 1612)
Vehicle dynamics analyses (EN 14363)
Aerodynamic analyses (EN 14067)
HVAC analyses and performance tests (EN 14750)
In addition to project-based engineering services, we also offer software sales, installation, training, and technical consultancy under one roof.
Structural safety in rail systems can no longer rely solely on physical testing.
Modern rail projects must simultaneously address strength, vibration, comfort, clearance, crashworthiness, aerodynamic performance, HVAC efficiency, and weld durability.
With FEM-based digital engineering:
Safety risks are identified early
Designs become lighter and more optimized
Certification processes are accelerated
Maintenance costs are reduced
Time-to-market is shortened