JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 45

Moderni ation of lndian rolling stock

composites could be used for the following
components: locomotive gear cases, axle box
covers, composite brake blocks and brake
gear bushes, berth and chair backings, coach
panelling, roof water tanks, toilet modules,
lavatory chutes, window guides, doors (main
entrance, sliding doors for first class AC compartment, inter-communication doors in AC
coaches, sliding doors for electrical multiple
units (EMU)/diesel multiple units (DMU),
sliding/flush doors for toilets, vestibule doors,
etc.), canopy ends for EMU/DMU coaches,
toilet cabinets, folding tables, fuel injection
pump covers, luggage racks and more.

Semi-high-speed trains
Indian Railways aims to improve the speed
of passenger trains to 160-200 km/h on
dedicated conventional tracks. To this end,
the company invited global bidders for the
$0.3 Bn trainset project.
While several companies did not submit
bids as quantities were less, several trials
were conducted with the Talgo trains to
demonstrate higher speeds on existing tracks.
Coupled with the WDP4 or WAP5 Indian
locomotives, various trials were conducted
on the busiest Indian routes. Compared to

the bogie-mounted Linke Hofmann Busch
(LHB) coaches of Indian Railways, the Talgo
uses direct roof suspended integrated coaches
that make it much lighter, efficient and stable.
However, as the company considers leasing
or buying through an open tender, there are
serious limitations for direct adaption of the
existing coaches. Indian Railways mostly
operates sleeper, non-AC coaches while
Talgo only offers AC chair car options as it is
the most commonly used format across the
globe. Moreover, an integrated coach without
separate bogies has a much lower height,
which may be difficult with Indian stations.
The environmental conditions in India are
also quite diverse.
India may have to look for custom-built
coaches with lower weight and greater stability to accomplish its semi-high-speed dreams
on conventional tracks.
High-speed trains
Indian Railways also aims to operate highspeed trains on new tracks with improved
technology. The Ministry of Railways set up
the National High-Speed Rail Corporation
Limited (HSRC) to promote high-speed rail
corridors under a public-private partnership
model.
As approved in the 2014 rail budget, India
aims to build the "Diamond Quadrilateral",
a quadrilateral-shaped network that will
connect the four metro cities in India by highspeed rail. The foundation stone for a 500-km
high-speed rail network was recently laid in
western India with Shinkansen as the partner
of SPV. The development of high-speed rail
will require a widespread use of composites in
the upcoming rolling stock.
Dedicated freight corridors
Under its plan to expand and modernize its
freight operating capabilities, the Ministry of
Railways established the Dedicated Freight
Corridor Corporation of India Limited
(DFCCIL). It aims to have separate tracks
for freight transfer, thus freeing up passenger
tracks - allowing higher speeds and higher
maintenance times on passenger tracks - and
regularizing freight transfer, which is currently
at less than 20 km/h of average speed.
DFCCIL received approval to build two
routes - the Eastern and Western freight
corridors - over an estimated 3,360 km. The
N°117 November - December 2017

routes are planned to operate freight trains
1.5 km in length and 7.1 m in height, using
electric locomotives with a trailing load of
15,000 tons and 400 containers - a world
first in this sector. The project's bridges and
infrastructures will support a 32.5-ton axle
load. It will operate 800 electric locomotives
with 12,000 HP and aim to attain a freight
speed of 100 km/h.
The mammoth project will generate great
strides in technology development and foster
the deployment of composites in many areas.
Growth of urban rail transit systems
The urban rail transit system in India mainly
consists of suburban rail systems, rapid transit
systems (known as metros), monorail and
trams.
Suburban rail is the oldest urban rail transit
system in India. Established in 1853, the
country's suburban rail network uses a very
ancient infrastructure and India has the
highest ridership per length with a whopping
ridership of 13 million over a 2,853 km length.
The suburban rail runs EMUs on mainlines,
thus getting a higher utilization of the capital
invested in tracks.
The rolling stock used in Indian suburban
rail was modernized in recent years. As part
of the Mumbai Urban Transport Project
(MUTP) phase III, the Mumbai Rail Vikas
Corporation (MRVC) decided to purchase
565 EMU coaches to increase speed and
comfort. The old rakes were capable of
attaining a maximum speed of 85 km/h. The
new rakes supplied by MRVC Siemens can
reach a maximum speed of 100 km/h and the
Bombardier coaches built by ICF can even
reach 120 km/h.
The Bombardier rakes use aluminium
composite panelling for the inside walls and
roof. However, the sidewalls, fluted panels,
poles and interiors are still made of stainless
steel. Despite this, the rakes are lighter than
the existing ones. The trials at 80 km/h are
already over and MRVC plans to conduct the
same at 110 km/h.
Metro constructions have seen a surge in
India since the last decade. Out of 24 metros
inaugurated across the world between 2013
and 2017, 19 (79%) where located in India
and China. Similarly, out of 43 metros under
construction, 11 (26%) are located in India
and 14 (33%) in China. The graphs show

/ jec composites magazine

Feature Land Transportation

A global scenario
Around the world, manufacturers of semihigh-speed and high-speed trains make a
widespread use of composite materials in
their products.
For instance, the exterior nose of Korea's
TGV trains (maximum speed 300 km/h)
is made of glass-reinforced polyester-matrix
composites with a varying thickness (5 to 10
mm). At a number of locations, higher thickness with additional layers of glass or metal
inserts provides higher strength. Secondary
parts like toilet interiors, sidewall interiors
and driver's desks also use glass-polyester
composites, mostly processed by the HLU
(hand lay-up) technique. Moreover, a few
SMC (Sheet Moulding Compound) and
RTM (Resin Transfer Moulding) components are reportedly used for some parts. The
388 m-long Korean TGV is transforming the
Korean Railroad Corporation (KORAIL).
Similar uses of composites can be quoted
in the American Acela, the Siemens
Velaro, China's CRH380A, and the N700
Shinkansen, among others.

A elcome signal for composites

45



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017

Cover
Edito
Opinion: Today, DAS Energy offers flexible, lightweight PV modules, designed and made in Austria
Contents
NEWS
In brief
Investments - Composite materials in the heart of the Augsburg science park
Agenda
BUSINESS
North America - Steady growth for North america
Pultrusion - EPTA report reveals vast opportunities for pultruded composites in residential housing
Strategy - China’s road to innovation: the German way
MANUFACTURING
Process - Fibre Patch Placement: expanding the scope of additive manufacturing
Automation - Flexibility in automated composites lamination
Fibre placement - Automated manufacturing of stiffened composite shells using dry fibre material
Industry 4.0 - lndustry 4.0 materials handling components and innovative LFT pellets
Feature Land transportation - A sector to conquer
Innovation - Composite innovations boost transport technologies
Body - Out-of-autoclave train body using a new curable prepreg
Floor - Enough to cover three soccer fields – Germany’s ICE train fleet’s composite floor
Market - Steady growth for the railway market
India - Modernization of Indian rolling stock - A welcome signal for composites
Mobility - lntegrated urban solutions are the core driver of user-oriented ad-hoc mobility
Materials - Composites hit a snag in railway
Truck - A large-volume, lightweight CFRP container
The future of inner-city freight is coming closer
SOLUTIONS
Medical - Composite wheelchair casters reduce weight and provide a smoother ride
Pressure vessel - Novel materials solution for high-pressure composite tanks for hydrogen storage
Aeronautics - Aircraft interior modules based on thermoplastic honeycomb
In the World
TECHNOLOGY
NDT - Health monitoring of CFRP using printed circuits
Software - Building a case for automated composite lay-up
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 68
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Opinion: Today, DAS Energy offers flexible, lightweight PV modules, designed and made in Austria
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Investments - Composite materials in the heart of the Augsburg science park
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 11
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 12
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 14
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 16
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 18
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - North America - Steady growth for North america
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Pultrusion - EPTA report reveals vast opportunities for pultruded composites in residential housing
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 21
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 22
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Strategy - China’s road to innovation: the German way
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 24
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 25
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Process - Fibre Patch Placement: expanding the scope of additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Automation - Flexibility in automated composites lamination
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 29
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 30
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Fibre placement - Automated manufacturing of stiffened composite shells using dry fibre material
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 32
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 33
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Industry 4.0 - lndustry 4.0 materials handling components and innovative LFT pellets
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 36
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Innovation - Composite innovations boost transport technologies
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 38
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 39
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Body - Out-of-autoclave train body using a new curable prepreg
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Floor - Enough to cover three soccer fields – Germany’s ICE train fleet’s composite floor
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Market - Steady growth for the railway market
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 43
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - India - Modernization of Indian rolling stock - A welcome signal for composites
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 45
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 46
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 47
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Mobility - lntegrated urban solutions are the core driver of user-oriented ad-hoc mobility
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 49
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Materials - Composites hit a snag in railway
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 51
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Truck - A large-volume, lightweight CFRP container
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - The future of inner-city freight is coming closer
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 54
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Medical - Composite wheelchair casters reduce weight and provide a smoother ride
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 56
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Pressure vessel - Novel materials solution for high-pressure composite tanks for hydrogen storage
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Aeronautics - Aircraft interior modules based on thermoplastic honeycomb
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - In the World
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 60
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - NDT - Health monitoring of CFRP using printed circuits
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 62
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 63
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Software - Building a case for automated composite lay-up
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 65
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 67
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