Prediction of wheel wear in urban railway transport: comparison of existing models

One of the most important maintenance costs in tramway transport comes from wear of wheel profiles. In the highly competitive railway market, the prediction of wear is then a major concern of the constructors. In this article, we present and compare four models well adapted to tramway conditions, involving contacts on the rolling tread and on the flange with very different sliding and pressure conditions. Moreover, all models can be implemented from the natural outputs of the railway simulation packages classically used in industry for the dynamics design of the vehicles. The first one, proposed by Jendel, is based on the well-known Archard's wear model. Enblom continues Jendel's approach by taking into account the contribution of wheel deformation on the sliding velocity. The last two models, developed by Zobory, and Pearce and Sherratt, determine the wear from the energy dissipation in the contact area. The models are first compared on a theoretical basis and, for that purpose, are rewritten in a common form. Two cases are distinguished: mild wear as arising on the rolling tread and severe wear as arising on the flange. The models are also compared in the practical case of an urban transport vehicle running on circular tracks with different curve radii. Although the models show equivalent trends according to the theoretical study, important discrepancies appear between estimated wear depths. All models are actually dependent on experimental coefficients and it is likely that they were estimated in different conditions. On the other hand, a reasonable agreement can be found in some particular conditions. As an example, Zobory's, Enblom's and Jendel's models are very close to each other in severe wear conditions. This work shows that a general and reliable model could probably be developed from all positive aspects of the existing ones.     

A Theory of Wheelset Forces for Two Point Contact Between Wheel and Rail

This paper describes a quasistatic theory of wheelset forces for an important practical case of the wheelset rolling when one of the wheels touches the rail in two contact zones. One of these zones lies on the tread and the other on the wheel flange. For such contact the specific problem of finding the distribution of forces between the tread and flange arises. The simultaneous frictional rolling contact problems for both contact zones have been described with Kalker×apos;s non-linear theory and wheelset equilibrium equations.

The numerical results presented are for an individual wheelset on straight track, the distribution of forces being described for a wide range of loading conditions. The influence of steering on the distribution of forces has also been presented.

This theory can be easily extended for quasistatic curving of railway vehicles and may assist wear studies for vehicles with worn wheels.     

Rail vehicle wheel wear prediction: a comparison between analytical and experimental approaches

There are a number of theoretical and practical techniques to compute rail vehicle wheel wear. For instance, the Archard equation is a well-known tool to determine the worn volume in sliding contact, as a function of normal load, sliding distance and the surface hardness. Of course, the wear coefficient (called K) used in this equation to differentiate the wear models implicitly comprises the conditions that govern the contact surface. Two situations can be taken into account when considering a sliding contact in a rail vehicle wheels, particularly along a curved track: (i) when the radial force prevails the lateral tangential force, which is mainly the frictional force but before flanging and (ii) during flange contact. Also, the Archard equation is employed within the tread and flange regions separately, both the regions being of interest in this paper. A number of approaches are then used to find the distance slid. The authors compare the field test results and the outcome of the analytical approaches. When the wheel wear results acquired from the two test bogies on Iranian Railways, all technical (rigid frame bogies with new assemblies and components) and operational items were identical, except for changing the bogie orientation in the second test trial for a short period. Good agreement was found between the analytical and practical investigations.     

Wheel slide protection control using a command map and Smith predictor for the pneumatic brake system of a railway vehicle

In railway vehicles, excessive sliding or wheel locking can occur while braking because of a temporarily degraded adhesion between the wheel and the rail caused by the contaminated or wet surface of the rail. It can damage the wheel tread and affect the performance of the brake system and the safety of the railway vehicle. To safeguard the wheelset from these phenomena, almost all railway vehicles are equipped with wheel slide protection (WSP) systems. In this study, a new WSP algorithm is proposed. The features of the proposed algorithm are the use of the target sliding speed, the determination of a command for WSP valves using command maps, and compensation for the time delay in pneumatic brake systems using the Smith predictor. The proposed WSP algorithm was verified using experiments with a hardware-in-the-loop simulation system including the hardware of the pneumatic brake system.     

Wear rate estimation of train wheels using dynamic simulations and field measurements

Wheel–rail wear is one of the important problems in the railway industry, especially from the point of safety, maintenance, and replacement cost. To investigate this phenomenon, it is necessary to simulate the wheel–rail interaction. The simulation results and in particular the wear number is not tangible enough to explain the wear condition of the system. For one set of simulation performed on two different railway systems one could obtain the same wear numbers, of say 100, while having two completely different wear rates. In order to have a better understanding of the wear condition, it is proposed to convert the wear numbers to wear rates. In doing so by measuring the wear rate, one determines the rate at which the wheel flange thickness is reduced. In this research, a new approach has been proposed to determine the wheel wear rate through multi-body dynamic analysis and simulation and the field measurements carried out on the fleet of one of Tehran's subway lines. This procedure could also be expanded to determine a wear criterion for specific lines and their fleets. Having this wear criterion would provide a better understanding of the simulation results either prior to the construction of railway lines or for the presently used ones. In other words, designers can simulate a railway line, not being constructed yet, and with a good approximation determine the critical points along the line with high wear rates, and make necessary modifications to decrease the wear.     

Prediction procedure for wear distribution of transient rolling tire

As a research method, finite element analysis (FEA) with ABAQUS can help researchers to study throughout the whole process of abnormal tire wear. For precise tread wear simulation, this paper introduces a tire finite element model building method. Then, the model is verified by comparing its simulation results with experiment data. Based on the verified model, tire high-speed rolling procedure is presented by combining steady-state transport analysis and dynamic analysis. To predict the wear distribution, micro tread wear calculation method is described. Finally, the wear prediction procedure of tread mesh evolving is introduced and tire polygonal wear pattern is simulated by this procedure.     

Further study on the wheel–rail impact response induced by a single wheel flat: the coupling effect of strain rate and thermal stress

A comprehensive dynamic finite-element simulation method was proposed to study the wheel–rail impact response induced by a single wheel flat based on a 3-D rolling contact model, where the influences of the structural inertia, strain rate effect of wheel–rail materials and thermal stress due to the wheel–rail sliding friction were considered. Four different initial conditions (i.e. pure mechanical loading plus rate-independent, pure mechanical loading plus rate-dependent, thermo-mechanical loading plus rate-independent, and thermo-mechanical loading plus rate-dependent) were involved into explore the corresponding impact responses in term of the vertical impact force, von-Mises equivalent stress, equivalent plastic strain and shear stress. Influences of train speed, flat length and axle load on the flat-induced wheel–rail impact response were discussed, respectively. The results indicate that the maximum thermal stresses are occurred on the tread of the wheel and on the top surface of the middle rail; the strain rate hardening effect contributes to elevate the von-Mises equivalent stress and restrain the plastic deformation; and the initial thermal stress due to the sliding friction will aggravate the plastic deformation of wheel and rail. Besides, the wheel–rail impact responses (i.e. impact force, von-Mises equivalent stress, equivalent plastic strain, and XY shear stress) induced by a flat are sensitive to the train speed, flat length and axle load.     

Wheel life prediction model – an alternative to the FASTSIM algorithm for RCF

In this article, a wheel life prediction model considering wear and rolling contact fatigue (RCF) is developed and applied to a heavy-haul locomotive. For wear calculations, a methodology based on Archard's wear calculation theory is used. The simulated wear depth is compared with profile measurements within 100,000?km. For RCF, a shakedown-based theory is applied locally, using the FaStrip algorithm to estimate the tangential stresses instead of FASTSIM. The differences between the two algorithms on damage prediction models are studied. The running distance between the two reprofiling due to RCF is estimated based on a Wöhler-like relationship developed from laboratory test results from the literature and the Palmgren-Miner rule. The simulated crack locations and their angles are compared with a five-year field study. Calculations to study the effects of electro-dynamic braking, track gauge, harder wheel material and the increase of axle load on the wheel life are also carried out.     

Simulation of dynamic interaction between train and railway turnout

Dynamic train–track interaction is more complex in railway turnouts (switches and crossings) than that in ordinary tangent or curved tracks. Multiple contacts between wheel and rail are common, and severe impact loads with broad frequency contents are induced, when nominal wheel–rail contact conditions are disturbed because of the continuous variation in rail profiles and the discontinuities in the crossing panel. The absence of transition curves at the entry and exit of the turnout, and the cant deficiency, leads to large wheel–rail contact forces and passenger discomfort when the train is switching into the turnout track. Two alternative multibody system (MBS) models of dynamic interaction between train and a standard turnout design are developed. The first model is derived using a commercial MBS software. The second model is based on a multibody dynamics formulation, which may account for the structural flexibility of train and track components (based on finite element models and coordinate reduction methods). The variation in rail profile is accounted for by sampling the cross-section of each rail at several positions along the turnout. Contact between the back of the wheel flange and the check rail, when the wheelset is steered through the crossing, is considered. Good agreement in results from the two models is observed when the track model is taken as rigid.     

胎面轮廓形状优化技术研究--提高轮胎耐磨耗性能

胎面轮廓形状对轮胎的耐磨耗性能影响很大，因此对其进行优化很有意义。针对胎面轮廓形状比较复杂的特点，文中采用多个变量来定义胎面轮廓。同时，在现有磨耗理论的基础上，通过对胎面轮廓形状的优化初步给出了评价轮胎耐磨耗性能的指标。在此基础上，采用自编的多目标优化程序对胎面轮廓进行优化，并将计算结果与原胎数据进行了比较，结果表明，不论是从胎面的磨耗速度还是从胎面磨耗的均匀性来说优化胎都要优于原始。     

Simulation of dynamic interaction between train and railway turnout

Dynamic train-track interaction is more complex in railway turnouts (switches and crossings) than that in ordinary tangent or curved tracks. Multiple contacts between wheel and rail are common, and severe impact loads with broad frequency contents are induced, when nominal wheel-rail contact conditions are disturbed because of the continuous variation in rail profiles and the discontinuities in the crossing panel. The absence of transition curves at the entry and exit of the turnout, and the cant deficiency, leads to large wheel-rail contact forces and passenger discomfort when the train is switching into the turnout track. Two alternative multibody system (MBS) models of dynamic interaction between train and a standard turnout design are developed. The first model is derived using a commercial MBS software. The second model is based on a multibody dynamics formulation, which may account for the structural flexibility of train and track components (based on finite element models and coordinate reduction methods). The variation in rail profile is accounted for by sampling the cross-section of each rail at several positions along the turnout. Contact between the back of the wheel flange and the check rail, when the wheelset is steered through the crossing, is considered. Good agreement in results from the two models is observed when the track model is taken as rigid.     

Evaluation of odometry algorithm performances using a railway vehicle dynamic model

In modern railway Automatic Train Protection and Automatic Train Control systems, odometry is a safety relevant on-board subsystem which estimates the instantaneous speed and the travelled distance of the train; a high reliability of the odometry estimate is fundamental, since an error on the train position may lead to a potentially dangerous overestimation of the distance available for braking. To improve the odometry estimate accuracy, data fusion of different inputs coming from a redundant sensor layout may be used. Simplified two-dimensional models of railway vehicles have been usually used for Hardware in the Loop test rig testing of conventional odometry algorithms and of on-board safety relevant subsystems (like the Wheel Slide Protection braking system) in which the train speed is estimated from the measures of the wheel angular speed. Two-dimensional models are not suitable to develop solutions like the inertial type localisation algorithms (using 3D accelerometers and 3D gyroscopes) and the introduction of Global Positioning System (or similar) or the magnetometer. In order to test these algorithms correctly and increase odometry performances, a three-dimensional multibody model of a railway vehicle has been developed, using Matlab-Simulink?, including an efficient contact model which can simulate degraded adhesion conditions (the development and prototyping of odometry algorithms involve the simulation of realistic environmental conditions). In this paper, the authors show how a 3D railway vehicle model, able to simulate the complex interactions arising between different on-board subsystems, can be useful to evaluate the odometry algorithm and safety relevant to on-board subsystem performances.     

The effect of worn profile on wear progress of rail vehicle steel wheels over curved tracks

Dynamic performance, safety and maintenance costs of railway vehicles strongly depend on wheelset dynamics and particularly on the design of wheelset profile. This paper considers the effect of worn wheel profile on vehicle dynamics and the trend of wear in the wheels as a result of the vehicle movements. ADAMS/RAIL is used to build a multi-body system model of the vehicle. The track model is also configured as an elastic body. Measured new and worn wheel profiles are used to provide boundary conditions for the wheel/rail contacts. The fleet velocity profile taken during its normal braking is also used for the simulation. Wear numbers are calculated for different sets of wheels and the results compared with each other. Outcome of this research can be used for modifying dynamic performance of the vehicle, improving its suspension elements and increasing ride quality. It can also be further processed to reach to a modified wheel profile suitable for the fleet/track combination and for improved maintenance of the wheels. A major advantage of the computer models in this paper is the insertion of the wheel surface properties into the boundary conditions for dynamic modelling of the fleet. This is performed by regularly measuring the worn wheel profiles during their service life and by the calculation of the wear rate for individual wheels.     

Re-adhesion control for a railway single wheelset test rig based on the behaviour of the traction motor

A method for detecting wheel slip/slide and re-adhesion control of AC traction motors in railway applications is presented in this paper. This enables a better utilisation of available adhesion and could also reduce wheel wear by reducing high creep values. With this method, the wheel–rail (roller) creepage, creep force and friction coefficient can be indirectly detected and estimated by measuring the voltage, current and speed of the AC traction motor and using an extended Kalman filter. The re-adhesion controller is designed to regulate the motor torque command according to the maximum available adhesion based on the estimated results. Simulations under different friction coefficients are carried out to test the proposed method.     

Train-Track Interaction and Mechanisms of Irregular Wear on Wheel and Rail Surfaces

Summary High-frequency train-track interaction and mechanisms of wheel/rail wear that is non-uniform in magnitude around/along the running surface are surveyed. Causes, consequences and suggested remedies to relieve the problems are discussed for three types of irregular wheel/rail wear: (1) short-pitch rail corrugation on tangent tracks and large radius curves, (2) wheel corrugation as caused by tread braking, and (3) wheel polygonalisation. The state-of-the-art in modelling of dynamic train-track interaction in conjunction with prediction of irregular wear is reviewed.     

Study on the derailment behaviour of a railway wheelset with solid axles in a railway turnout

ABSTRACT

Dynamic wheel–rail interaction in railway turnouts is more complicated than on ordinary track. In order to evaluate the derailment behaviour of railway wheelsets in railway turnouts, this paper presents a study of dynamic wheel–rail interaction during a wheel flange climbs on the turnout rails, by applying the elasticity positioning wheelset model. A numerical model is established based on a coupled finite element method and multi-body dynamics, and applied to study the derailment behaviour of a railway wheelset in both the facing and trailing directions in a railway turnout, as well as dynamic wheel–turnout rail interaction during the wheel flange climbing on the turnout rails. The influence of the wheel–rail attack angle and the friction coefficient on the dynamic derailment behaviour is investigated through the proposed model. The results show that the derailment safety for a wheelset passing the railway turnout in facing direction is significantly lower than that for the trailing direction and the ordinary track. The possibility of derailment for the wheelset passing the railway turnout in facing and trailing directions at positive wheel–rail attack angles will increase with an increase in the attack angles, and the possibility of derailment can be reduced by decreasing the friction coefficient.     

Train-Track Interaction and Mechanisms of Irregular Wear on Wheel and Rail Surfaces

Summary High-frequency train-track interaction and mechanisms of wheel/rail wear that is non-uniform in magnitude around/along the running surface are surveyed. Causes, consequences and suggested remedies to relieve the problems are discussed for three types of irregular wheel/rail wear: (1) short-pitch rail corrugation on tangent tracks and large radius curves, (2) wheel corrugation as caused by tread braking, and (3) wheel polygonalisation. The state-of-the-art in modelling of dynamic train-track interaction in conjunction with prediction of irregular wear is reviewed.     

Switch Panel wear loading – a parametric study regarding governing train operational factors

The acting forces and resulting material degradation at the running surfaces of wheels and rail are determined by vehicle, track, interface and operational characteristics. To effectively manage the experienced wear, plastic deformation and crack development at wheels and rail, the interaction between vehicle and track demands a system approach both in maintenance and in design. This requires insight into the impact of train operational parameters on rail- and wheel degradation, in particular at switches and crossings due to the complex dynamic behaviour of a railway vehicle at a turnout. A parametric study was carried out by means of vehicle-track simulations within the VAMPIRE® multibody simulation software, performing a sensitivity analysis regarding operational factors and their impact on expected switch panel wear loading. Additionally, theoretical concepts were cross-checked with operational practices by means of a case study in response to a dramatic change in lateral rail wear development at specific switches in Dutch track. Data from train operation, track maintenance and track inspection were analysed, providing further insight into the operational dependencies. From the simulations performed in this study, it was found that switch rail lateral wear loading at the diverging route of a 1:9 type turnout is significantly influenced by the level of wheel–rail friction and to a lesser extent by the direction of travel (facing or trailing). The influence of other investigated parameters, being vehicle speed, traction, gauge widening and track layout is found to be small. Findings from the case study further confirm the simulation outcome. This research clearly demonstrates the contribution flange lubrication can have in preventing abnormal lateral wear at locations where the wheel–rail interface is heavily loaded.     

Railway Wheel and Automotive Tyre

In the present paper the theories of the railway wheel and the automotive tyre are discussed. After an introduction the paper opens with a discussion of the common ground, viz. the rolling motion of deformable bodies. Then the railway wheel is discussed, and it is shown that all aspects may be calculated numerically from the material constants Poisson's ratio, Young's modulus, and the coefficient of friction, and from the geometry of wheel and rail. Next the automotive wheel is considered. Such a wheel is very anisotropic, to the extent that the theory of the lateral motion (out-of-plane dynamics) is radically different from the longitudinal, or in-plane motion. Moreover, the analysis of the automotive wheel heavily relies on experiments. In the conclusion, the theories are compared.