Centre for Railway Research Newcastle University

1. Centre for Railway ResearchNewcastle University Professor Mark Robinson Director of Newrail RESEARCH FOR A SUSTAINABLE METRO

2. Europe’s Leading University Railway Research Centre

3. Mission Statement Maintain and enhance our position as the leading University based Railway Research Centre in Europe ‘To be globally recognised and respected as a Rail Research Centre through our innovation, quality and engineering excellence

4. 1990 1994 2004

5. Key Focus Areas Strategic Research Academia Consult

6. Key Strategic Areas Transport Policy European Commission ERRAC RSSB ERA BSI CEN IRSG DfT transport Newcastle TSB Rail Research UK ESPRC UK Testing Facilities

7. Research Rail Vehicles Rail Systems Rail Freight & Logistics Rail Infrastructure

8. Two Key Areas of Importance for a Sustainable Metro: Energy Savings and Environmental Impacts Safety & Security

9. Dr Stephen Ingleton Technical Director stephen.ingleton@ncl.ac.uk

10. Inherently Secure Blast Resistant & Fire Safe Metro Vehicles (3 Year Project) Grant Agreement No. 234148

11. PARTNERS

12. PROJECT AIMS • To increase metro vehicle resilience to terrorist bomb blast through selection of vehicle materials and structural design • To increase security against a firebomb attack through design of fire barriers and fire suppression technology • To increase the resilience of vehicles to blasts in order to speed up recovery following attackto return to normal operation • To reduce the attractiveness of metro systems as a target for attack by reducing deaths and injuries and increased resilience

13. APPROACH • Review of previous blast and incendiary attacks on metro systems • Analysis of potential future threats, risks and potential trends • Threat and attack scenario’s to provide design approach

14. SCENARIO DEFINITION Vehicle Setting Device Infrastructure Response Damage

15. BLAST SIMULATION & TESTING • Finite element modelling and simulation of blast conditions • Study of blast mechanics related to rail metro vehicles and systems • Small/large scale blast testing (correlation) components and vehicle • Evaluation of range of potential vehicle design improvements

16. FIRE SIMULATION & TESTING • Fire reaction modelling of incendiary attacks • Small and large scale blast testing (correlation) • Review of fire suppression technologies (e.g. water mist) • Evaluation of range of potential design improvements

17. AREAS OF INTEREST – Reduce Damage and Injury • Glass fragmentation • Door retention • Structural deformation • Equipment retention • Vehicle derailment • Interior components (floor) • Critical system protection • Driver Protection • Evacuation & egress • Recovery (injured & system)

18. RESEARCH OUTPUT • Appraisal of State-of-Art design practices (techniques) • Specification of the desired vehicle performance • Design specification for blast and firebomb mitigation • Recommendations for future international standards

19. SPV 400 PATROL VEHICLE

20. “Delivering Safety & Security” We gratefully acknowledge support from the EC Grant Agreement No. 234148

21. Lightweight Metro Vehicles Dr. Joe Carruthers

22. MODURBAN: “Removing Constraints on the Use of Lightweight Materials” “ … to provide engineers in urban vehicle production with lightweight materials, concepts and designs in order to provide affordable vehicles with reduced weight” (and reduced energy consumption)

23. Material selection for lightweighting • The rail vehicle designers within the project team identified the lack of reliable, comparable material property data as one of the current constraints to the use of lightweight materials. • What they requested was: • A large (customisable) database that provides a global population of possible material options. • A means of sorting through that database in a systematic and rational manner in order to identify and compare only those materials that fulfil the requirements and constraints of the application considered. CES Selector / Constructor

24. The benchmark vehicle • Six car metro vehicle. • Tare mass approximately 190 tonnes. • Aluminium bodyshell.

25. Mass breakdown

26. Four case studies Gear-box casing Grab rail Floor panel External door leaf

27. Case studies

28. Example – grab rails • Consider metro vehicle interior grab rails. • Currently, these are typically made from stainless steel, steel or aluminium. • Grab rails typically add more than half a tonne to the mass of a metro vehicle. • Is there a material that could provide a lighter solution at similar cost and performance levels?

29. Problem definition • Function: • Stiff beam to add the stability of standing passengers. • Objective: • Minimise mass.

30. Problem definition (continued) • Constraints: • Length and radius fixed. • Must be sufficiently stiff to support passengers. • Must not fail by fatigue in bending. • Must have a natural frequency above 30 Hz to avoid vibration issues. • Must have adequate fire performance. • Must be cost comparable to existing solutions.

31. Lightweight grab rail: prototyping • The lightweight carbon fibre reinforced polymer grab rail was prototyped in collaboration with Exel Composites UK. • Real (measured) mass saving = 57%. • The prototypes were produced using a continuous manufacturing process known as pullwinding. • In sufficient volumes, the resulting tubes are less costly than the equivalent stainless steel.

32. Lightweight grab rail: demonstration

33. Summary of mass saving benefits • Using the MODURBAN energy model it has been estimated that a 10% saving in metro vehicle mass would provide: • A 7% saving in energy consumption. • A 100,000€ annual cost saving per vehicle due to reduced energy consumption.