This paper aims to offer a novel viewpoint for improving performance and reliability by developing and optimizing suspension components in a Y25 bogie through material optimization based on wheel-rail interactions under variable load and track conditions.

The suspension system, a critical component ensuring adaptation to road and load conditions in all vehicle types, is especially vital in heavy freight and passenger trains. In this context, the suspension set of the Y25 bogie - commonly used in Türkiye and Europe - was modelled using CATIAV5, and stress analyses have been performed by way of ANSYS using the finite element analysis (FEA) method. E300-520-M cast steel was selected for the bogie frame, while two different spring steels, 61SiCr7 and 51CrV4, were considered for the suspension springs. The modeled system was subjected to numerical analysis under loading conditions. The resulting stresses and displacements were compared with the mechanical properties of the selected materials to validate the design.

The results demonstrate that the mechanical strength and deformation characteristics of the suspension components vary according to the applied external loads. The stress and displacement responses of the system were found to be within the allowable limits of the selected materials, confirming the structural integrity and reliability of the design. The suspension set is deemed suitable for the prescribed material and environmental conditions, suggesting potential for practical application in real-world rail systems.

This research contributes to the design and optimization of bogie suspension systems using advanced CAD/CAE tools. It thinks that the material selection and numerical validation approach presented here can guide future designs in heavy load rail applications and potentially improve both safety and performance.