‘2 g g i ! 3 g i i ! g 2 E 3 DESIGN OF A LIGHT-WHOM AUTOMOBEL! CARRYING FRIIOHT CAR The!!! for the Dom. of I. S. MtcumAN STATE coma! John 8. Stevens, Jr. ' ' 1948 -~ooo—_., .- . - -' -..... -._ Design of a Lipht—keight Automobile Gerrying Freight Car 11 Theeiiz Swimmitted 1K) The Faculty of Michigan State College of (‘0 Aaricvlture and Applied ocience By John B. Stevens, Jr. Cenéiéste for the Degree of Bachelor of Science farch 1948 THESlS l' ”a '. .‘ .. [MM-u L \\\\\\‘s Acknowledeenents To Professor C. L. Allen and Mr. L. V. thhstine, of Civil Engineering at Hichigan State College, those help and interest has made this thesis possible. Also to Mr. V. L. Green, Mechanical Engineer of the Chicago, Milwau- kee, St. Paul and Pacific railroad, and Mr. T. M. Cannon, chief Engineer of Mount Vernon Car Annufacturine Company, who provided valuable infornatich. 5201399 Dedication To people, like nyself, vho really get a thrill out of vatching a train go by. Probably the most neglected subject by student engi- neers, here at Nichigen State College, is our greetest nesns of goods transportation, the Reilrords. In past years, railroading vas that aviation is to- dey; the top interest to nest young Ken as fer as a red- iun of travel. J *1 cilroete nsde great strides in inprcvenent until the first torld Yer. Since tiet tine, they have done little research or advancement until the end of the last war when rest of their equipment had gone beyond the maintenance point end rust be replaced. In viev of this fact, I have chosen this thesis title, "A Light Weight nutcrohile Ctrr3ing Freight Car." I chose to design this car due to the sdvsntsges this vculd hrve for the industry as a vhole. Railroeds are in their infancy as far as their de- velrprent. They are being forced to ccnpete yith var- ious nodes of transportation and shipping. When they drove the stsgecoach fron the road, they had a nonopoly on lend transportation until the automobile cane into existence. During this period, they had no reason to purchase net equipment except to enlarge their business and profits. Then, in the tventies, trucking companies began to infringe on their traffic, and in the Depression of 19?? through 1934, nany roads changed hands and failed. Through the later thirties, up until the last war, the railroads vere feeling the latest pinch of competition. This use the airplane, and it vas, in most pert, being used as a passenger carrier. new, hotever, the air- plane has also conuenced to carry freight and their speed, vhich means tine saving to the producer as vell as the consurer, is only the beginning of infringenent of air transportation on the revenue of the railroads. Railroads can beat the competition if they are mill- ing to give services to the traveller and the shipper that ere eaual or better than other methods of transpor- tation. Erny of the new passenger trains have improved their comfort and cleanliness and have instituted many new services to make travelling by train the most con- venient. movies, excellent diners, and playrooms for children are some of the inducements now available on' a.fev of the nev streamliners; yet, they have rore things to do that will help put the railroads ahead. The main thing to improve upon at present is speed. During.the last twenty to thirty years, little advance- nent in speed nes taken place. Trains in 1920 were travelling at approximately sixty miles an hour; today, the streenliners average about fifty-five to sirty-five miles an hour. Little or no change whatsoever has taken place. To increase their speed, there is the need for rail improverent; the use of heavier rail, straighter and eas- ier curves, and more gentle grades. All of these are slowly being done on the major roads. Before the war, I read an article stating that it would take one hundred thousand men, vorking five eight hour days for twenty years, to bring the standard of all railroads up to the present nost advanced system. That was before the war vhen the trains vere not being run around the clock se- ven days a meek as they have been doing for the last eight years. With the track and roadbed improvenent designed for travel at one hundred and fifty miles an hour, the trd.ns could actually conpete vith air travel and shipping, and outnode a great deal of the long distance trucking. The biggest asset a railroad has is convenience. It has, vith little eyception, its stations in the heart of the cities because railroads have been the main seals of transportation since our country began to enlarge. Airports are usually ten to tventy miles fron the city and an hour is lost on both ends of a trip. Travelling by air is also more expensive. Short hops by air are not economical to operate, and the present day railroads can easily conpete vitnin a radius of three hundred miles. If trains were travelling at 150 niles per hour, they could elininrte the airplane on short hauls becau- se of the convenience, safety, and cost. Faster trains need lighter cars, and along this line of thought, the aluninur-fabricated cars have developed. Liahtness means less dead load vhich is the rain item that rail- roads are interested in at present. The lovering of the dead load vould increase efficiency of the engine and vould lover operation costs. Railroad ten are, generally,keenly avare of the fact that the average pay load in freight cars tends to decrease steadily. If the pay load, the ancunt of weight carried as paying freight is going to continue to decrease, the veight of the dead load till also have to decrease accordingly. Car loads have decreased as follovs: 29.3 tons per car in 1920 25.6 tons per car in 1933 27.1 tons per car in l937 20.1 tons per car in 1946 This decrease can only nean that sore radical de- sign changes must be forthcoming and that they are com- ing soon. In general, cars that are in service today are nade of 16, 000 pound steel. This is 10v strength steel as conpared with the steels of today. During the last var, the steel industry was called upon to develops steels that vould vithstand as such as 150,000 pounds per square inch; hovever, at this time, the cost of this chrone steel CT! is ncuh too erpen ire to even consider for freight car construction. Ihe steel industry has developed a net high streng- th end corrosion resist 1t steel vith neny easy fabric- ating properties and low cost. This steel is called Mayari-R, and it has a nininun tensile strength of 70,000 pounds per Snuare inch and a yield point of 50,000 pounds per Square inch with an endurance limit eouel to the yield point. This res developed 1y the Bethlehem Steel Conpany. In this design, it vill he used for the vain undercarrizpe construction. Lnother veight saving device is to veld the nenbers together therely elininating the flrnges, laps, and the rivet heads. By using the Unionrelt co tinucus, an auto- netic process developed by Crfield Railroad Service Con- pany, vou hpve numerous adventzras. The joint is strong- y t ( er than the parent plates vhich eliminates one of the detrirental reasons thy velding has heor frcvned upon for so many years. For many years, velders vhc were not oualified to do uniform vork have held beck the use of velding in railroad construction. Now, with the develop- ment of machines to do the same vork, it is accepted practice. Another edvrntage of melding is the vater tightness feature. This not only eliminates a lot of corrosion, but it tends to lessen the chances of denage due to to moisture getting to the merchandise inside the oer. Railroads loose a greet deal of money due to tater da- rege cvused by loose joints. Still another is the advrntage of stresses being distributed over a greeter are? eliminating the concen- tration due to riveting. Welding can be used on most eny thickness and sec- tions of the panels can easily be removed and hand-melded nev ones put in their place. One thing rust be remembered in car construction, as in any other work vhere repair and replacement is necessary, and that is the ability to remove parts and replace or repair with the minimum cost. Frequently this is impossible and makes the vhole unit of no value or the cost of replacemen so expensive that it would have been cheaper to buy a nev unit. The first all aluninum freight cars vere built in 1951, by the Canton Car Connnor and vere placed in ser- vice in the aluninum industry in the middle vest. These cars are nov sixteen years old and have shown no evid- ence of wear or tear from service. However, there vas some evidence of electrolytic corrosion between dissimilar aluminum alloys vhioh was principrlly due to the use of steel rivets. A great deal of research has been done on aluminum freight cars by the Reynolds Car hanufacturing Company. For the design of freight cars, the engineer has a number of alloys to choose from, but he is rsuelly in doubt vhich alloy vill be best suited for a particular pert of the car. The alloys recommended for load carrying frsming are, in the crder of preference; 17 S-T, R SEl-T, and R SEl-W. Alloys 1? S-T and R Sdl-T have strength equal to that of Open Hearth Steel, and should be used wherever no severe offsetting or forming is required. R eel-w is reccrrended for parts requiring severe offsetting or forming. The strength of R selAW is about one half of the strength of R Sfil-T or 17 S-T, end if aluminum parts are designed to equal deflection of sim- ilar steel parts, usually, the stresses vill be low enough to use R ZEl-W. When the maximum strength is required, then the formed shapes can be age hardened to R 361-T. For outside sheething of cars, aluminum alloys that are recomrended are, in the order of preference: R 301—T, R EOI—W, R 301-0, R Sol-T, and R 361-0. Alloys in "T" temper should not be sed for perts without severe bends or flanges, end then only used when proper bend redii can be used. For parts reouiring flenging and some forning, "W" temper ellcys Should be used. For parts reouirine severe forming combined vith drew, "0" temper, \hich is in the annealed state, should be used. In all ceses, en CO aluminum service engineer should be consulted for infor- mation as to the exact types of netel to use. All this reduction of dead 109d leads to the main purpose of this thesis. Thvt is that one of the services thet is being oonpletley neglected by the railroads today is the problen of yessenger trananItrtion after the train destination hes been reached. In this complex life of ours, it is necessary that a traveller,nnor reaching the station nearest his destination to use public transporta- tion to continue on his way. Frequently upon re ching said station, it is necesssry to so neny rdditicnsl niles 1y bus or taxi. This inconvenience and expense could be easily elinineted py transporting the automobile on the save train with tne passenger. It is frcr this idea, that this thesis hes grovn. Eot altogether s nev idea to the world, I thought I had hit upon an untried thing, butthe Hungsrien Fttiouel Reilvsy hed a fev csrs converted to carry 3 Ctr in he hag- gage car for the ssre purpose; hovever, n1 ides deals with the carrying vI four eutcnobiles in one freight car. i—lo This car s designed to he .irply lcsded elininsting layover tire thicn tends to raise the cost of shipping. It is designed to Le‘ploced at the herd end of passenger trains, directly behind the engine, so thrt ease in un- loading can be utilized. Oh this ides, the end loading system has come. Instefd of the conventional type of side loading, the ends of the box oer o:n be tvo doors that swing to em;“ side vhich elinin tee the need of trrning dollys. During the tar, the army used to transport all of their larger eeuipnent on flat cars. This res done by running then fro; one flat car to the next nerely by placing planks betveen the decks of eech successive one. This idea is incorporated in my car vith the addition of e regular top end sides to conforv to the strnderd pess- enger designs. Side loading, or standard methods, are at this tine the only eccerted nethcd in general use; hovever, the end loading method has the advantage of driving right up a ranp to the deck of the oer end right on vithout the chance of danege through attenpting a treacherous turn. Also along this line, the railroad vould need attern- ents for end-loading to do the driving of the cers on and off the train. With sideloading also, it is nearly in- possible to use nore than the floor, but with the end loading, tro decks are easily accessible because of the ease of entry. Similar tc the sutoheuler trailei, this car can C'rry tto oers on each deck, slloving :rple roon for each autoncbile. Sirule chenrels are used as ramps and are easily carried with the freight csr. All of this leads to savings for the r ilread hat can be passed 10 on to the traveller. The cost of present freight car service, over a per- iod of a year, is from one to five riles per ton per rile. From this rate,vs can see that our car vill be sbcut half as heavy as standard oars. For convenience, re use one nil per tcn per mile. ihis vould Fan that the rail- roads are doing the service for cost, vhich is inpractioal, but ve can use this as an illustration. A trip from Detroit, Michigzn, to Buffalo, Nev York, 1‘) distance of 250 niles vill be us d as a corparison to shov the difference betveen driving and the use of this We are alloxing two tone for the stand:rd autono- bile. The veight of the freight car is 30,000# and 16,000# or tventy-three tons total; therefore, the cost to the railroad, to include the auto-carrier car in the trsin, vould be five dollzrs and seventy-five cents($5.75). If this were put in as a service to the passengers, it vould be about one dollar and tventy cents($l.20). From Highway Econonics, it is learned that you can not operate an automobile for less than seven cents a Nile. This includes all depreciation, cost of operation, tares, and insurance. This vould Kean a cost of seventeen dollars and fifty cents($l7.50). In comparison to the 11 ;,L cost of the cerrier cer, there vould be e saving cf ei1~ teen dollars end thirty cents($l6.30) vhich vomld be a great encoursscnent to drivers to use the service offer» ed by the trains. Besides e sevinp in monetary values, there is the safety valve 3 person gets by using rail trénsportetion. Railroads heve been sited for their record of safety for 3' cars; . All the facts presented are the reasons why this idea helped to convince me that there is not only a need for this car,bufi this service rcvld help increase passen- ger traffic and lessen traffic accidents by lusting traf- - q fic on the highveys. Zherscne vovld ce rcre relsped rp- cn arriving at their destination becavse of the lack of H driving fatigue. BPSides these esscns, the financial savings and tine savings would nore then rzke their pro- ject vorth trging. 4Q'-6" AUTO-CARRYING FREIGHT CAR e1 e e e1" es re @ e e e e 7% e e e e ‘e e t METHOD OF PLACEMENT OF CARS SPRIFIQTIOE general 91112921029 Diotanoo o/o of Body Bel-torn 30'-10" Height innido ll'-0" Height of Door Opening 11'-0" Height of Top or Rail to Cantor of Couploro 2510+" Total Height, top of Hall to Hoof 15'-OO" Height. top of Boil to Floor 3'-7 3/4" Length inside 4on6- Length inside to inside Coupler Knuckle- 44' .40 Length ovor end .111: 40'-10" Truck wheel)“. 5'-6" 'idth over side plate: 9'-10" 'idth innit. 9'-2' Iidth over roof oavoo 9'-4 3/8” gtogialg All material. covered by LLB. upooiti'cotiono shall con- form thereto. The following alumina: alloys shall be used: Outside ohoathing 3-3014 Shape. — _ 1'7 8-! rollover Block: R «303-! Rivets 15.17 8-1‘ Plates R-SOl-c 8c 11-301-: ‘3 W Tho nunbcr. diumionc, locations, and armor of application to be in accordanco with tho Intorotato Commerce Commiacion crdcra and A.A.R. roquircnonta. Holdings All wolding to bo automatic by tho OxWold Railroad 8on1 cc Company prccoac. Center Sillog Two 12 7/8' - 31.3} 36.000 poi Stool standard ccntor aill occtiono. opaccd 12 7/8" apart. cxtonding full longth of the car from ctrikor to otrikor. weldod. 81g; Billos Aluminu- angloo o“ 33*" x 5/16“ - 3.49! alloy 17‘ 8-1'. oxtcnding-fnll length of tho car and roinforcod at bolotcr with i" channel chapcd hont atocl plate. m Bill» o" 13*": 5/16“ - 3.4%} alloy 17 8-! aluminu- angloo oxtcnding full width of tho car and woldcd to center oill. ......r.......fl....u,...J - . ....£1.1«~ t. aclsurs: Built up typo of alloy stool platos. Top and Bot- tcl pans 5/16” alloy stool with odgoo Joined by continious wold and sscursd to contsr sill by wold- . ' ing. 5/16" alloy stool top cover plats oxtondo cror contor sills and is welded to tho bolstor pans. Bottom bolster pan roinforcod cwor sido boaring wit 4 3/4“ x 6/16' prossod alloy stool channel woldod in plsco as opocifiod by LLB. Standard roquirononto. W' . 3/16“ prossod alloy stool disphron flangod 2 3/4! all around and socuroly fastod to contor sill and aids 3111. ' Diggml Dragon ‘1' proosod alumina plats. alloy 3-3014 woldod to sido and end sill st cno cod and to 5/16“ prosood stool gnsoot woldod to contor sill. o 11 Dori : Standard A.LR. coupling. w ‘ Standard Vootinghouso Air 23on with braking pcwor to bo 75% of light weight of car based on fifty pounds por square inch cylindor prossuro. Bid: flan: 3/16' thick alumina plato woighing 2.69} por foot. alloy 17 S .1'. Side Posts: ihirty por car spocial aluminum. 1'! 8-1', 3" LOW per foot '8' section 5/16“ wob with flamos 7/16' 3M. 9/16. thick. gorge; Posts; Bpocial aluminum 1'7 3.2, '1' socticns with i' wob and 9/16“ flanges, woighing 4.06} por foot. 329; Channels: . Pour standard channels, 12" x 4" woighing 35.5} per foot. 40' long. 299k beams; A lino standard 4" x 2 5/8” '1' soction woighim 7.?! nor foot. M Doors: Pour hingod doors nado of i” thick aluminum plats alloy 17 8-1‘ weighing 3.591} per foot. Roof: lurphy aluminum (.072) welded root as manufactured by the Standard Railway manufacturing Compaq. Ileorigg; Tongue and groove 1 3/4" x 5 l/ld' race yellow A pine fastened to underframe with clips as manufact- ured by the lscLean-rogg company. a Sh ° Black Iron #18 gauge to be nailed to the bottom of the floor over wheels to meet Interstate Comoros Comission safety appliance rules that requires ear operating in passenger service to have. TRACK CHANNEL 25:0 # 3*: ~ a: 5’- 1" .J r 4 1 P: 2500fiper whee‘ Mot-Momen+ .- E5!- = 2500 (460'T§>= 38000 "1. ”D. Encode-4 : ‘3 I2"X4" Channe‘ NE\GHT - 35.5 ‘53 lgl'. Ans ‘”‘ Amsz-Z I = 2MB me E = 35.5 4.8 I *1- ” H ‘l 2 it - " x J \ 21 ¥ , 7’". 12" ' —zr— Dr DECK BEAM 2500* 2500* 2 l " 2 I" no“ __1r_[)_l Auow 2500* P...- Wham Foc+or of 30!?ch To give 215 ‘h'mes The ouc'l'uql loud 1‘s 1'qu in+o Consideva+ion ‘H’Ie Vibru'hon and ined'io effeci’ For “Hm \rouno‘ing curves. CR\T|CAL Secnou 2\ 2:111: esoo( ): 2b '95 20.000 ARCA ‘2.Z|;gin Ax‘sVI AxisZ'Z - .3. I: 6.0 0.77 Wemm - 7.7 /¢+. z: 3.0 0.58 Fag—i % ~—D * #*- Isl-J dwh‘v‘ f S\DE POST 3" a1 T ‘ I 1 - J E K I :f" I 4 m. M as} $4 I .“l ALUMINUM l7S-T AREA -. 3.35 59.... WEIGHT -= 4.os*/rt I = 4.45 2 = 3.02 SIDE SlLL 8 :-——3.9a"—~L- 492“——- 3. 2 ALUMINUM ITS-T ‘- ‘ AREA = 2.885%."1. ‘5‘ WEIGHT = 3.49“/€I. \9 l6 Axis |-| Axns 2‘2 " ' I I064 2.70 .5 {’4' Z 2.64 0.93 —.‘ /~ f 1 -.‘I+- 2.1e——-Jv- 43%”___J 1‘: :I :: cur-OFF E' 1 ' AREA = I076 2.3.... ‘~ . I (—4 I = 55.40 ‘ . c.0c.('o., NOTE-Q AREA OF STEEL To AREA OF ALUMINUM -329 BY RATIO .03 CORNER POST SEOT. ‘J q. I“. ‘3" AREA= L325u‘m. an) I ‘ [.4‘4 22 N" V l.— L348" # 2.52" a Is ._ In" , 3.|3——| ‘ga I L] * ALUMINUM I7s-‘r e3.“ | “I, 1 AREA = 3.35 sq.in. 3 w Io r- o *m 4 _‘ J: M E H 4. e / 4. a) I stI ' / An: N AmsZ-Z I . “Ta . I -— 1.98 7.45 . 1 [in ‘_ z = 3.07 2.39 ' O 1'.‘ .s 3."- ‘°- 2 = 3.33 3.99 1 I6 I w -—3 CORNER POST I 2- e W a 3‘.- | " moo II P’ 5 q: TJ LIuo " 2. 7-1" ' Z 'AREA = 5.27 sam- A“: \‘l Ans 2'?— I : [5-52. 20' 64' z = 3.54- 4-‘5 SIDE PLATE ”\Wnlz" “\Q~ 2 r- ilf N 6) ‘1'- u, 4 "e— 1 9% t ‘ \——‘= ‘I ‘ é-a)‘ ’o 3- _, n.— 3 ._ v = “I” 8 5-. <- q- I-——— 2.97"__—4_ L78" .5... ALUMINUM l73-T AREA 2.96 $3.... WEIGHT 3.597“ Axw H Asa: 2-2 I - “.29 6,94 Z= 270 234 ‘° ° ...‘1 BlbllCéIaQflY Forrcki, R. 3., End Sibp, 3.A., "height EECrciicn-Frcirht Cars Construction," delivered bcfcre A.9.N.E. arnurl heating, Atlantic City, Decerber 4, 1947. Green, V.L., end Drinka, J.J. ., Cciober, 194E, pp. 561-5FV in Slin 9tressed Boxcar S Trensrortation, v. 67, no.7 , "Critic 1 Shearing Stress ides ." Green, V.L., Railvey ire, v. 105 no. 25, Decerber 17, 1938 pp. 979-873,"Chic"ro, "ilvaikea, St. Prul Ind Pacific REilroad Evilds Ligl wt Cight CEIE .” fEEtror, F.F., F iJYFy LEE, v. 10‘, nc.£2, Ikverhcr, 1938, PP. 770-772, "Why Light-WEight Freig t CErE." RE), R.L., ”91cm 14, v. 2F,1o. 11, “bvcztEr194E, pr. 1043~ 1048,”E1d666 F eight e r Conbtrtctic Tnur, Ernest E., Fetal Progress, v. 35, no. 1, pp. 36-49, "Light-weight Freight Core." Railway Age, v. 105, no. P“, PP- 795, "Iotor Cars b? Effil in Hungary." Railvay Age, v. 107, rr. 929, "Union FEcific Provides FEE Merchandise Service." R iIVEy nge, v. 105, no. 19, movenber 5, 1938, pp. 654-658, ""eldec Box and Refriger°tor CErs." R: ilvzy Age, v. 107, no. 9, [Urns t 96, 19? 9, "pn. 307-308, "Use of Layari-R Steel in Freirht 08 re Rrilvev V cch"nicf1 Engineer, v. 119, no.2, Feer‘ry,1945, pp..I :4, "F astice for CEr Building." Railva v yechanical Enrineer, v. 119, no.4, Aprjl, 1943, pp 0 A 4 [1"- 4/1 7 , " 'l‘nrep R0? 6 S 8113.? 11113Fj 1711,11}? A211 037’ “(‘3' Cg rs . I. "Leverieticn Threatens to Brnkrvp Sone RCEOE Notional quety ZEVE, v. 53, no. 1, Jennnry, 1946, pp. F2, 04, 99, "Freig_ht CEr Doors.” RE—ilvey lMech nical Engineer, v. 119, no. 4, April, 194? pp. 143-146, "Aluminum Freight Car Building.” Steel, v. 104, no. 26, June 26, 1939, pp.44-45,63, "Light Weight Box Cars." 2 . .‘I ",1 . .“|. .\ Steel, v. 10?, no. 1, July 3, 1939, pp. 61,62,64,73, "Use of Light, High, Tensile Steel for Box Cars." A Yearbook of Epilroad Information, 1947. A'Yeerbcok of Rsilrosd Informaton, 1945, by Committée on Public Relations of Eastern Railroads. Great Lakes Steel Corporetion, penphlet, "The All Purpose Freight Car Floor." Popular Science, February, 1948, pp. 158, Design of Auto: Loader. A 1 \L 1 V r , ”/ ’ SECTKDN OF AUTO-CARRYING FRElGHT CAR I . .tzi ll 0. .?00‘3,|VH.1.310 11""! D:‘-'.'IO.O:€I};‘¥!¥.OOo‘lY‘Ot O..."(’\.. 61 Ly. .