Design optimization of a freight car wheel

Design optimization of a freight car wheel was performed employing statistical techniques. A three-step process was developed to arrive quickly at an optimum solution that provided lower stresses. At all stages weight reduction and the ability to manufacture were considered. The initial criteria were established by creating and analyzing several designs in which significant dimensional attributes were varied. During the second stage, we concentrated on those variables that resulted in reduced thermal stresses. The third stage involved final optimization wherein the combined effects of thermal and mechanical loads were evaluated. ANSYS 5.6.1 Finite Element software was used