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Open Access

ARTICLE

An Integrated Simulation Framework for Reliability Assessment of Bolted Joints in Lightweight High-Speed Train Battery Housings

Lin Zang1, Muhammad Fadhil Marsani2,*, Caiyan Long1,2,*, Yongping Yu3
1 School of Integrated Circuits and New Energy, Guangzhou College of Technology and Business, Guangzhou, China
2 School of Mathematical Sciences, Universiti Sains Malaysia, Penang, Malaysia
3 School of Construction Engineering, Jilin University, Changchun, China
* Corresponding Author: Muhammad Fadhil Marsani. Email: email; Caiyan Long. Email: email

Structural Durability & Health Monitoring https://doi.org/10.32604/sdhm.2026.080465

Received 10 February 2026; Accepted 17 April 2026; Published online 22 May 2026

Abstract

To bridge the gap between isolated structural and connection analyses in lightweight rail vehicle design, this study establishes an integrated modelling-simulation-verification framework. This integrated framework, developed via parametric FE modelling, multi-axial load simulation (per DIN EN 12663 & BS 7608), and standards-based verification, was applied to a specific housing design. Key results: (1) Under vertical ±3 g static loads, the tray experiences the maximum equivalent stress of 186.6 MPa, yielding a safety factor of 1.1 against the yield strength, which satisfies the minimum requirement (s1 ≥ 1.15) of the DIN EN 12663 standard. (2) Under fatigue spectrum, critical stress amplitudes are 39.38 MPa (lifting seat) and 37.87 MPa (frame), yielding fatigue safety factors of 2.54 and 2.64 (BS 7608 Class B). For the reliability assessment of similar rail transit equipment. The demonstrated framework effectively bridges the gap between isolated structural and connection analyses, providing a systematic tool for lightweight, reliable design. The framework provides validated design data and a reusable methodology for lightweight rail equipment.

Keywords

High-speed train; battery housing; finite element analysis; structural reliability; bolted connection; fatigue life; lightweight structure; dynamic load; safety factor

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