Rail Engineering

Engineering Excellence That Drives Results

At SIM-engineer, we We provide end-to-end engineering CAE solutions tailored to rolling stock manufacturers and subsystem suppliers. Our scope covers CAD, FEA, CFD, DEM and MBD analyses mapped to relevant EN, GOST and UIC standards to support design validation, certification and operational readiness.

Our expertise covers the full structural verification chain, from caonceptual load definition and detailed finite element modeling to fatigue, fracture, and certification-level documentation. All analyses are performed according to the applicable EN and UIC standards, with strict adherence to boundary conditions, material characterisation, and validation procedures.

Why SIM-engineer?

Risk Reduction

Validated numerical models supporting confident engineering decisions and regulatory compliance.

Cost Optimisation

Minimised prototyping and improved design efficiency through advanced simulation workflows.

Accelerated Development

Faster time-to-market enabled by integrated multiphysics and digital engineering tools.

Structural & Strength Assessment

Monoblock Wheels & Wheelsets:

Stress and fatigue life assessment under operational and exceptional load cases (traction, braking,curving, vertical/lateral loads, wheel flats)
Thermo-mechanical coupling for braking scenarios, thermal gradient–induced stress and residual stress field validation
Verification of geometrical and dimensional conformity per EN 13262 and UIC 510-2.
Wheelset structural integrity including press-fit interface modelling between wheel and axle
Modal and harmonic response for noise and vibration compliance per EN 13979-1+A2:2011
Standards referenced: EN 13262+A2:2011, EN 13979-1+A2:2011, EN 13260+A1:2011,EN 13261+A1:2011,EN 14033 series, UIC 510-2, UIC 510-5, UIC 511

Bogies & Running Gear:

Load case definition based on EN 13749:2011 and UIC 510-3 (vertical, lateral, and longitudinal loads, emergency braking, derailment scenarios).
FEA modelling with local mesh refinement in highly stressed regions (suspension mounts, welds, axlebox interfaces).
Fatigue analysis based on stress-life (S–N) and strain-life (ε–N) approaches per EN 13749 Annex E.
Modal and vibration analysis for ride stability, suspension tuning, and resonance avoidance.
Verification of bogie frame stiffness and strength according to UIC 515-0, 515-1, 515-4.
Validation of connection integrity (bolted/welded joints, damping elements, elastomeric bushings).
Standards referenced: EN 14033 series, EN 13749:2011, UIC 510-3, UIC 515-0, UIC 515-1, UIC 515-4, UIC 517, UIC 615-0, UIC 615-1, UIC 615-4.

Carbody Structures:

Primary and secondary load paths verification under service and exceptional load conditions (coupling, lifting, buffing, crash, jack lifting).
Global stiffness and deflection control to ensure structural integrity and passenger comfort.
Crashworthiness evaluation using explicit FEA for frontal and side impact per EN 15227.
Ultimate and yield strength verification under load cases defined in EN 12663-1+A1:2015-01 and EN 12663-2:2010.
Fatigue evaluation of welded joints using hot-spot or structural stress methodologies.
Modal validation of eigenfrequencies to prevent coupling with bogie-induced vibration.
Standards referenced: EN 12663-1+A1:2015-01, EN 12663-2:2010, EN 14033 series, UIC 566, UIC 577, UIC 625-7, UIC 651.

Attached Equipment: Tanks, Piping, and Mounting Systems:

Structural interface verification (welded and bolted joints) under static and vibration loads.
Dynamic load mapping from carbody accelerations and modal shapes.
Pressure and sloshing analysis for fluid-containing systems using CFD–FEA coupling.
Vibration fatigue assessment for support brackets and connection interfaces.
Thermal stress analysis for hot fluid or exhaust components.
Durability under environmental and service conditions per EN 12663-1+A1:2015-01.
Standards referenced: EN 12663-1+A1:2015-01, EN 12663-2:2010, EN 14033 series, UIC 566, UIC 577, UIC 625-7.

Welded Joints and Local Detail Assessment:

Local hot-spot and structural stress methods (per DVS 1612 and IIW recommendations).
Stress gradient analysis for welded and bolted joints with non-standard geometry.
Fracture mechanics analysis of pre-existing or detected cracks (LEFM).
Weld toe and root fatigue verification using nominal stress and notch stress approaches.
Assessment of attachments, reinforcements, and penetrations in high-stress regions..
Standards referenced: DVS 1612, EN 14033 series, EN 15273-2+A1:2017-03, UIC 505-1, UIC 505-6, UIC 506.

Dynamic, Load & Safety Analyses (Advanced Engineering Scope)

Our multidisciplinary team provides full-spectrum dynamic, load, and safety verification for rolling stock, from wheel-rail interaction to vehicle-level stability, including both static and transient analyses.

Load States & Mass Distribution:

Operational and exceptional load cases mapped to EN 14033 series and EN 15654/15663.
Center of gravity (CG) and inertia tensor calculation for each vehicle configuration (empty, partially loaded, full load).
Distribution of vertical, longitudinal, and lateral forces across bogies, axles, and carbody.
Dynamic amplification factors for acceleration, braking, cornering, and track irregularities.
Jack and lifting load validation to ensure structural safety during maintenance and emergency handling.
Standards referenced: EN 14033 series, EN 15654-2:2019-07, EN 15663+A1:2019-02, EN 12663 series, UIC 566, UIC 581.

Vehicle Dynamics & Ride Stability (MBD):

Multibody dynamic simulations of bogies, wheelsets, suspensions, and complete train sets.
Hunting and lateral stability evaluation at various speeds, including critical velocity identification.
Wheel-rail contact modelling using Hertzian contact theory and nonlinear compliance, integrated with track irregularities.
Suspension kinematics & damping optimisation for ride comfort, vibration isolation, and hunting mitigation.
Brake and traction force application under dynamic conditions, including emergency braking and adhesion-limited scenarios.
Coupled MBD–FEA simulations for flexible bodies, including carbody bending and torsion under dynamic loads.
Standards referenced: EN 14363, UIC 518, EN 14033 series

Ballast & Track Interaction (DEM):

Discrete Element Method simulations of ballast particle mechanics under cyclic and transient loads.
Settlement, degradation, and particle breakage analysis over operational lifetime.
Sleeper–ballast–rail interaction for accurate prediction of load transfer and support stiffness.
Fouling effects and tamping validation to support track maintenance planning.
Standards referenced: UIC 518, EN 14033 series.

Crashworthiness & Exceptional Events:

Buffing and draft loads assessment under coupling/uncoupling and collision scenarios.
Explicit FEA for frontal, side, and end-of-train impact conditions.
Progressive failure modelling of carbody structures, bogie frames, and critical joints.
Passenger safety envelope evaluation, including deformation of interior panels and mounted equipment.
Validation against homologation criteria per EN 12663, EN 15227, and UIC 566/577.

Vibration & Modal Analysis:

Modal decomposition for natural frequencies, mode shapes, and damping ratios of carbody and bogies.
Harmonic response for traction, braking, and auxiliary equipment-induced vibrations.
Ride comfort indices calculation according to EN 13129 and EN 14750.
Coupled vibration analysis with track irregularities, wind, and aerodynamic loads.

Lifting, Jacking & Maintenance Safety:

Structural verification for lifting points under distributed and concentrated load cases.
Emergency jack lifting scenarios to ensure compliance with UIC 581 and EN 12663 requirements.
Integration with mass distribution and inertia data to guarantee stability during maintenance operations.

Thermal & Fluid Systems (Advanced Engineering Scope)

Our thermal and fluid simulation services address the complete spectrum of aerodynamics, HVAC, environmental systems, and fluid–structure interaction in rolling stock. Analyses are performed using advanced CFD, conjugate heat transfer (CHT), and coupled FEA-CFD techniques.

External Aerodynamics & Crosswind Stability:

Aerodynamic drag and pressure distribution for vehicle bodies, pantographs, bogies, and underbody assemblies.
Crosswind and side-force evaluation, including lateral stability margins at operational and exceptional speeds.
Tunnel transient effects – pressure waves and slipstream analysis for passenger comfort and equipment safety.
Pantograph–catenary interaction and aerodynamic load simulation.
CFD turbulence modelling (RANS, LES, DES) for high-speed and regional trains.
Standards referenced: EN 14067, EN 14033 series.