Multi-Stage Topology Optimization for Structural Redesign of Railway Motor Bogie Frames

This study presents a comprehensive structural optimization workflow for a railway motor bogie frame, aimed at developing an innovative and lightweight design compliant with the reference European standards. The methodology integrates a two-stage topology optimization process, supported by an extensive numerical simulation campaign and a dedicated sensitivity analysis to identify the most critical load scenarios. In the first optimization stage, a global evaluation of the frame performance revealed that increasing the number of optimization parameters leads to a rise of approximately 50% in solver iterations. Symmetry constraints proved essential for simplifying both the optimization and the subsequent…