Finite Element-Based Optimization of Weld Joint Locations in Passenger Train Carbodies

This study aims to determine the optimal placement of welding joints on a passenger train carbody using Finite Element Method (FEM) analysis. The carbody was modeled in detail and analyzed under two primary loading scenarios: a 1000 kN compressive load and a uniformly distributed vertical load. The simulation revealed that the highest von Mises stress values occur near the center pivot and midspan regions, reaching approximately 246.91 MPa and 164 MPa, respectively. Maximum deformation was observed at the midspan, around 34.161 mm. In contrast, regions between the bolster and midspan showed significantly lower stress levels (0–82.3 MPa) and minimal deformation, indicating these areas are suitable for weld joint placement. By avoiding high-stress and high-deformation zones, the proposed approach contributes to improving fatigue resistance and extending the service life of the carbody structure.