JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 52

USERS’ PLATFORM Application Composite aerodynamic front-end cabs for passenger trains About four years ago, Kineco developed India’s first front-end cab for a DEMU train, including a driver’s desk and cab interior panelling. Based on the satisfactory field performance of this cab, Indian Railway decided to introduce composite aerodynamic front-end cabs with modern looks and enhanced driver comfort in other trains. (Diesel Electric Multiple Unit) passenger trains. The project included the product & engineering design, CFD validation of the engineering design, prototyping, mass manufacturing and installation. An entire structural front-end cab was designed along with the driver’s desk and interior components, in line with the following design criteria specified by the customer: - Maximum train speed: 140 km/h - Maximum wind speed: 100 km/h when the train is moving and 250 km/h when stationary - Minimum natural frequency: 1 Hz - Distributed load of 61 tonnes across 305 mm (height from centre line of buffer) and full width due to overriding of buffers - Distributed load of 31 tonnes on the front surface due to buffer failure RAVI SHRIVASTAVA GENERAL MANAGER, MARKETING & PROJECTS, KINECO U nlike conventional materials such as metals, composite materials are easy to mould into complex shapes, which gives the designer more freedom to design the front end with desirable aerodynamic curves. These materials also have a high strength-to-weight ratio, i.e. low density ( 100 MPa) and rigidity (E~10,000 MPa). This combination produces a lightweight construction which reduces the tare weight of driver coaches. Composites also reduce the drag force of train fronts by improving their aerodynamic shape, while demonstrating high corrosion resistance, which minimizes maintenance in such applications. Finally, large composite parts are easy to process and offer component integration opportunities together with improved aesthetic appeal. Cab interior - Distributed load of 2.165 tonnes per meter of the coach’s cab flooring The whole cab was designed in a single-piece construction with a separate back panel. A stiffened structure was used, consisting of a glass fibre composite skin supported by composite stiffeners with a solid rectangular cross section. The composite front-end cab was designed by Kineco and the structural design was vetted by an external engineering company. A detailed Composite aerodynamic front-end cab for DEMU trains As its first ever developmental project, Kineco was awarded a turnkey contract by Indian Railway for an all-composite front-end cab for short distance DEMU DEMU train with allcomposite cab in operation JEC Composites Magazine / No42 July-August 2008

JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008

Cover
- Applications Composite aerodynamic front-end cabs for passenger trains
- Citadel Plastics acquires BMC Inc.
- Niche market Durable concrete formwork system
- Cool radiators for hot trucks
BUSINESS - Market survey Hexcel anniversary in 2008 marked by investment
- Raw material Corrosion resistance of High-Performance Glass fibres
USERS’ PLATFORM KNOW-HOW Composites in the world Carbon fibre iPhone case
- New generation of hydrogen cars
- Architecture Composites and architecture: the perfect couple
- EEE enclosures
- Thermoplastics Reinforced thermoplastics enable affordable storm-resistant structures
- Gurit signs 4-year supply agreement with EADS
Innovations
- TechnoCompound expands its production
- SGL Group opens central technology and innovation centre
Agenda of events
FEATURE - Partnership Smart composite materials project DECID2 for structural applications
- Hankuk Fiber Group, one man’s determination
- Process Rapid processing of tubular parts made of thermoplastic composites ......................................
- Process Polydicyclopentadiene winning over construction professionals
- Trenchless pipes’ installation
- Corrosion Composite linings for corrosion protection
- Unmanned aircraft made of high-temperature prepreg
- High impact-strength spokes
NEWS WORLDWIDE - Companies GKN Aerospace creates repair facility for metallic and composite structures
- Raw material SMC/BMC compounds for building and construction
- Trends Coatema expertise: coating and materials handling technologies for prepregs
- The world’s largest offshore wind farm project
- Subsea structures
- Design “Eco-characterisation” of composite materials
- Special JEC Composite Asia
- Hitco to supply components for the B787
- Sandwich structure Polypropylene honeycombs for a variety of uses
- Head restraint system
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - Cover
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - NEWS WORLDWIDE - Companies GKN Aerospace creates repair facility for metallic and composite structures
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Hitco to supply components for the B787
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Hankuk Fiber Group, one man’s determination
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - Agenda of events
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - Innovations
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - BUSINESS - Market survey Hexcel anniversary in 2008 marked by investment
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Niche market Durable concrete formwork system
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Trends Coatema expertise: coating and materials handling technologies for prepregs
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - FEATURE - Partnership Smart composite materials project DECID2 for structural applications
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Architecture Composites and architecture: the perfect couple
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 32
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Raw material SMC/BMC compounds for building and construction
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 34
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Process Polydicyclopentadiene winning over construction professionals
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Thermoplastics Reinforced thermoplastics enable affordable storm-resistant structures
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 41
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 42
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Sandwich structure Polypropylene honeycombs for a variety of uses
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 44
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 45
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Corrosion Composite linings for corrosion protection
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 47
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - High impact-strength spokes
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Head restraint system
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Applications Composite aerodynamic front-end cabs for passenger trains
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 53
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Trenchless pipes’ installation
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Unmanned aircraft made of high-temperature prepreg
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Subsea structures
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 57
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Design “Eco-characterisation” of composite materials
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Raw material Corrosion resistance of High-Performance Glass fibres
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Process Rapid processing of tubular parts made of thermoplastic composites ......................................
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Special JEC Composite Asia
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