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November '18 - December '18

This project provides a comprehensive report on the suspension system found under train wagons - also known as a railway car "bogie" - that I designed on SOLIDWORKS.


It contains a master CAD assembly, free-body calculations, finite element analysis of critical parts, optimization of under-performing parts, and detail part and assembly drawings.



The master bogie assembly consists of five sub-assemblies: a bolster system, brake system, wear plate system, wheel adapter system, and wheel system. In all, the assembly contains a total of 157 parts, 34 of which are unique. Each part is dimensioned as closely as possible to its real-world model, and of the same material.

Delegating Loads


This bogie assembly is designed to support up to a 65-ton load (this is a common maximum load for a bogie). Along with additional loads, when distributed to the rest of the system, they may result in component failure. Free-body calculations find the resulting loads on key components, to be used for finite element simulations that test for yield stress.

bogie fea.PNG

Simulations & Optimization

These simulations determine whether the parts' design, force distributions, and material properties are sufficient to prevent them from yielding in a high-stress application. They were conducted on 10 components I deemed most likely to fail, and I strove to provide a safety factor of at least 3 for each component.

An additional optimization step was performed on components that did not meet the factory of safety guideline I was looking for. The only component with a safety factor below 3 was the frame, due to its thin spring platform design. Edits on the part solved this performance issue.

Detail Drawings

main assembly.PNG

Technical Report:

Drawing sheets were produced for the 15 most complex non-COTS parts, as well as the assembly itself.

Additional drawings, as well as the full technical report, can be downloaded below.