Optimization of a roller coaster bogie considering fatigue life

This study explores the effectiveness of fatigue-life constrained topology optimization in roller coaster engineering, a previously unexplored field. Emphasizing the importance of fatigue life considerations, the research focuses on key components of roller coasters: the wheel assemblies. By integrating stress–life fatigue constraints, such an approach can lead to longer lasting and more efficiently designed roller coaster components. Multiaxial fatigue topology optimization using the method of moving asymptotes gradient-based optimization is examined to address the complex loading experienced by these bogies given a substantial load-time history in the high-cycle fatigue region. Using a validated optimization methodology, this study aims to reduce the bogie volume in selected domains while ensuring structural integrity and potentially extending service life. The optimization process successfully reduces the number of designable elements, resulting in decreased global volume and mass, and the results quantifiably demonstrate the impact of applying high-cycle fatigue constraints on the bogie’s performance.