Railway ground vibrations induced by wheel and rail singular defects

Railway local irregularities are a growing source of ground-borne vibration and can cause negative environmental impacts, particularly in urban areas. Therefore, this paper analyses the effect of railway track singular defects (discontinuities) on ground vibration generation and propagation. A vehicle/track/soil numerical railway model is presented, capable of accurately predicting vibration levels. The prediction model is composed of a multibody vehicle model, a flexible track model and a finite/infinite element soil model. Firstly, analysis is undertaken to assess the ability of wheel/rail contact models to accurately simulate the force generation at the wheel/rail contact, in the presence of a singular defect. It is found that, although linear contact models are sufficient for modelling ground vibration on smooth tracks, when singular defects are present higher accuracy wheel/rail models are required. Furthermore, it is found that the variation in wheel/rail force during the singular defect contact depends on the track flexibility, and thus requires a fully coupled vehicle/track/foundation model. Next, a parametric study of ground vibrations generated by singular rail and wheel defects is undertaken. Six shapes of discontinuity are modelled, representing various defect types such as transition zones, switches, crossings, rail joints and wheel flats. The vehicle is modelled as an AM96 train set and it is found that ground vibration levels are highly sensitive to defect height, length and shape.     

Modelling of wheels and rail discontinuities in dynamic wheel–rail contact analysis

A classification of wheel–rail contact is given. Difference is made between modelling of a running wheel with continuous single-point-contact, as is common practice in wheel–rail contact analysis, and a wheel with transient double- or multi-point-contact, which may occur for rail irregularities with curvatures larger than that of the wheel circumference. It is shown that application of the first model for these irregularities will strongly underestimate the contact forces as it does not describe occurring mechanisms correctly. Further, it is shown that in principle it is not possible to describe the second type of contact fully correct with a lumped wheel model. Both wheel models are formulated mathematically for some basic contact cases. Afterwards, results are applied to a linear track model. Analytical closed-form solutions are found in the frequency domain for arbitrary type of contact and numerically transformed to the time domain. Finally, the necessity is shown to avoid situations where transient multiple-point-contact may occur (like rail joints) in practice.     

Modelling of wear and fatigue defect formation in wheel–rail contact

The model for analysing wear and fatigue defect formation is developed based on the approaches of contact and fracture mechanics. The model includes the solution of the contact problem for the wheel and rail to find the shape, size and position of the contact zones and the contact stresses and calculation of the surface wear and the function of damage accumulation in the rail and wheel. The wear rate and the worn-profile evolution of the wheel surface are calculated using both statistic and deterministic approaches to modelling of vehicle dynamics (tribo-dynamic modelling). The influence of the evolution of the wheel–rail profiles due to wear on the damage accumulation process is analysed. It is shown that for some values of the wear rate coefficient, the wear process can prevent the crack initiation under the wheel surface.     

Non-steady state modelling of wheel–rail contact problem

Among all the algorithms to solve the wheel–rail contact problem, Kalker's FastSim has become the most useful computation tool since it combines a low computational cost and enough precision for most of the typical railway dynamics problems. However, some types of dynamic problems require the use of a non-steady state analysis. Alonso and Giménez developed a non-stationary method based on FastSim, which provides both, sufficiently accurate results and a low computational cost. However, it presents some limitations; the method is developed for one time-dependent creepage and its accuracy for varying normal forces has not been checked. This article presents the required changes in order to deal with both problems and compares its results with those given by Kalker's Variational Method for rolling contact.     

An efficient approach to the analysis of rail surface irregularities accounting for dynamic train–track interaction and inelastic deformations

A two-dimensional computational model for assessment of rolling contact fatigue induced by discrete rail surface irregularities, especially in the context of so-called squats, is presented. Dynamic excitation in a wide frequency range is considered in computationally efficient time-domain simulations of high-frequency dynamic vehicle–track interaction accounting for transient non-Hertzian wheel–rail contact. Results from dynamic simulations are mapped onto a finite element model to resolve the cyclic, elastoplastic stress response in the rail. Ratcheting under multiple wheel passages is quantified. In addition, low cycle fatigue impact is quantified using the Jiang–Sehitoglu fatigue parameter. The functionality of the model is demonstrated by numerical examples.     

A dynamic wheel–rail impact analysis of railway track under wheel flat by finite element analysis

Wheel–rail interaction is one of the most important research topics in railway engineering. It involves track impact response, track vibration and track safety. Track structure failures caused by wheel–rail impact forces can lead to significant economic loss for track owners through damage to rails and to the sleepers beneath. Wheel–rail impact forces occur because of imperfections in the wheels or rails such as wheel flats, irregular wheel profiles, rail corrugations and differences in the heights of rails connected at a welded joint. A wheel flat can cause a large dynamic impact force as well as a forced vibration with a high frequency, which can cause damage to the track structure. In the present work, a three-dimensional finite element (FE) model for the impact analysis induced by the wheel flat is developed by the use of the FE analysis (FEA) software package ANSYS and validated by another validated simulation. The effect of wheel flats on impact forces is thoroughly investigated. It is found that the presence of a wheel flat will significantly increase the dynamic impact force on both rail and sleeper. The impact force will monotonically increase with the size of wheel flats. The relationships between the impact force and the wheel flat size are explored from this FEA and they are important for track engineers to improve their understanding of the design and maintenance of the track system.     

Influence of wheel–rail contact modelling on vehicle dynamic simulation

This paper presents a comparison of four models of rolling contact used for online contact force evaluation in rail vehicle dynamics. Until now only a few wheel–rail contact models have been used for online simulation in multibody software (MBS). Many more models exist and their behaviour has been studied offline, but a comparative study of the mutual influence between the calculation of the creep forces and the simulated vehicle dynamics seems to be missing. Such a comparison would help researchers with the assessment of accuracy and calculation time. The contact methods investigated in this paper are FASTSIM, Linder, Kik–Piotrowski and Stripes. They are compared through a coupling between an MBS for the vehicle simulation and Matlab for the contact models. This way the influence of the creep force calculation on the vehicle simulation is investigated. More specifically this study focuses on the influence of the contact model on the simulation of the hunting motion and on the curving behaviour.     

A robust non-Hertzian contact method for wheel–rail normal contact analysis

A modified Kik–Piotrowski (MKP) model is proposed in this paper for an accurate and robust calculation of wheel–rail normal contact problem. The presented method is able to consider the relationship between the elastic deformation of a line and the normal pressure distribution within the contact patch. A novel shape correction method is put forward to correctly describe the elastic deformation of the contact patch. Taking the results estimated by Kalker’s variational method and Kik–Piotrowski method as references, the proposed method is validated by three contact cases, including the assumed standardised non-Hertzian contact and the two-point contact, as well as the contact behaviours based on three actual wheel–rail profiles. The simulation results indicate that, compared with Kik–Piotrowski method, the proposed MKP method achieves better agreement with Kalker’s variational method. Moreover, the MKP method can avoid the abrupt change of wheel–rail normal force due to the sudden transfer of the contact point, which contributes to a better computational stability.     

Indirect method for wheel–rail force measurement and derailment evaluation

Wheel set flange derailment criteria for railway vehicles are derived and the influence of wheel–rail contact parameters is studied. An indirect method for wheel–rail force measurement based on these derailment evaluation criteria is proposed. Laboratory tests for the calibration of strain–force devices on the bearing box are carried out to determine the relationship between the applied force and the measured strain. The simulation package, SIMPACK, is used to develop a passenger car model to generate wheel–rail forces and vibration signals. Different cases are considered in this model to provide an accurate validation of the identified wheel–rail forces. A feasibility test is conducted in the Beijing Loop test line using a passenger car equipped with a set of strain gauges on the wheel set. The comparison of the force time history applied to the instrumented wheel set and that obtained using the indirect method is presented.     

Design and optimisation of wheel–rail profiles for adhesion improvement

This paper describes a study for the optimisation of the wheel profile in the wheel–rail system to increase the overall level of adhesion available at the contact interface, in particular to investigate how the wheel and rail profile combination may be designed to ensure the improved delivery of tractive/braking forces even in poor contact conditions. The research focuses on the geometric combination of both wheel and rail profiles to establish how the contact interface may be optimised to increase the adhesion level, but also to investigate how the change in the property of the contact mechanics at the wheel–rail interface may also lead to changes in the vehicle dynamic behaviour.     

Physical processes in wheel–rail contact and its implications on vehicle–track interaction

Friction within the wheel–rail contact highly influences all aspects of vehicle–track interaction. Models describing this frictional behaviour are of high relevance, for example, for reliable predictions on drive train dynamics. It has been shown by experiments, that the friction at a certain position on rail is not describable by only one number for the coefficient of friction. Beside the contact conditions (existence of liquids, solid third bodies, etc.) the vehicle speed, normal loading and contact geometry are further influencing factors. State-of-the-art models are not able to account for this sufficiently. Thus, an Extended-Creep-Force-Model was developed taking into account effects from third body layers. This model is able to describe all considered effects. In this way, a significant improvement of the prediction quality with respect to all aspects of vehicle–track interaction is expected.     

Methodology and verification of calculations for contact stresses in a wheel–rail system

The distribution of contact stresses in the wheel–rail system is a decisive factor for the wear of elements and the safety of rail transport. Analytical calculations of stresses based on the Hertz theory can only be applied to elastic deformation of materials. High dynamic loads leading to plastic deformation (not considered in the Hertz theory) are a predominant cause of problems in the contact vicinity. These problems can be successfully resolved by applying the finite-elements method. Two- and three-dimensional test models were generated to estimate an error in numerical calculations in the MSC.MARC program. We compared the results of numerical calculations with analytical calculations. Based on the obtained results we defined the effect of parameters describing the finite-elements mesh on the calculation error for contact stresses, and adjusted mesh parameters appropriately to achieve as low as possible error in numerical calculations. We also defined the effect of material characteristics on the value of contact stresses on the wheel–rail interface.     

Estimation of wheel–rail contact conditions and adhesion using the multiple model approach

This paper presents the development of a multiple model estimation approach for the identification of the adhesion limit to overcome the problem of the wheel slip/slide at the rail wheel-rail contact. The contact characteristics at the rail wheel-rail interface are both highly nonlinear and subject to changes due to exposure to external contaminations. The detection of adhesion and its changes is therefore scientifically challenging, but would provide a critical information in the control of trains to avoid undesirable wear of the wheels/track but also the safety compromise of rail operations. This study exploits the variations in the dynamic behaviour of the railway wheelset caused by the contact condition changes and applies a bank of Kalman filters designed at selected operation points for the adhesion estimation. A fuzzy logic system is then developed to identify the contact conditions by examining the residuals from the Kalman filters.     

Sensitivity of the wheel–rail contact interactions and Dang Van Fatigue Index in the rail with respect to irregularities of the track geometry

This paper investigates the effects of the track geometry irregularities on the wheel–rail dynamic interactions and the rail fatigue initiation through the application of the Dang Van criterion, that supposes an elastic shakedown of the structure. The irregularities are modelled, using experimental data, as a stochastic field which is representative of the considered railway network. The tracks thus generated are introduced as the input of a railway dynamics software to characterise the stochastic contact patch and the parameters on which it depends: contact forces and wheelset–rail relative position. A variance-based global sensitivity analysis is performed on quantities of interest representative of the dynamic behaviour of the system, with respect to the stochastic geometry irregularities and for different curve radius classes and operating conditions. The estimation of the internal stresses and the fatigue index being more time-consuming than the dynamical simulations, the sensitivity analysis is performed through a metamodel, whose input parameters are the wheel–rail relative position and velocity. The coefficient of variation of the number of fatigue cycles, when the simulations are performed with random geometry irregularities, varies between 0.13 and 0.28. In a large radius curve, the most influent irregularity is the horizontal curvature, while, in a tight curve, the gauge becomes more important.     

An analytical mathematical method for calculation of the dynamic wheel–rail impact force caused by wheel flat

The simplified method to determine a vertical impact force of wheel with flat and rail interaction is presented in this article. The presented simplified method can be used to identify maximum contact force and its distribution in the contact length between the damaged wheel and the rail. The vertical impact force depends on geometrical parameters of the rail and wheel with flat, speed of vehicle and the angle of deviation of rail. This article demonstrates the influence of wheel with flat geometrical parameters, speed of vehicle to maximum contact force and its distribution in the contact zone. The obtained values of the simplified method for determination of a vertical contact force are compared with the results obtained from field measurements.     

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.     

Effect of temperature- and frequency-dependent dynamic properties of rail pads on high-speed vehicle–track coupled vibrations

The soft under baseplate pad of WJ-8 rail fastener frequently used in China’s high-speed railways was taken as the study subject, and a laboratory test was performed to measure its temperature and frequency-dependent dynamic performance at 0.3?Hz and at ?60°C to 20°C with intervals of 2.5°C. Its higher frequency-dependent results at different temperatures were then further predicted based on the time–temperature superposition (TTS) and Williams–Landel–Ferry (WLF) formula. The fractional derivative Kelvin–Voigt (FDKV) model was used to represent the temperature- and frequency-dependent dynamic properties of the tested rail pad. By means of the FDKV model for rail pads and vehicle–track coupled dynamic theory, high-speed vehicle–track coupled vibrations due to temperature- and frequency-dependent dynamic properties of rail pads was investigated. Finally, further combining with the measured frequency-dependent dynamic performance of vehicle’s rubber primary suspension, the high-speed vehicle–track coupled vibration responses were discussed. It is found that the storage stiffness and loss factor of the tested rail pad are sensitive to low temperatures or high frequencies. The proposed FDKV model for the frequency-dependent storage stiffness and loss factors of the tested rail pad can basically meet the fitting precision, especially at ordinary temperatures. The numerical simulation results indicate that the vertical vibration levels of high-speed vehicle–track coupled systems calculated with the FDKV model for rail pads in time domain are higher than those calculated with the ordinary Kelvin–Voigt (KV) model for rail pads. Additionally, the temperature- and frequency-dependent dynamic properties of the tested rail pads would alter the vertical vibration acceleration levels (VALs) of the car body and bogie in 1/3 octave frequencies above 31.5?Hz, especially enlarge the vertical VALs of the wheel set and rail in 1/3 octave frequencies of 31.5–100?Hz and above 315?Hz, which are the dominant frequencies of ground vibration acceleration and rolling noise (or bridge noise) caused by high-speed railways respectively. Since the fractional derivative value of the adopted rubber primary suspension, unlike the tested rail pad, is very close to 1, its frequency-dependent dynamic performance has little effect on high-speed vehicle–track coupled vibration responses.     

High-frequency random vibration analysis of a high-speed vehicle–track system with the frequency-dependent dynamic properties of rail pads using a hybrid SEM–SM method

A hybrid Spectral Element Method (SEM)–Symplectic Method(SM) method for high-efficiency computation of the high-frequency random vibrations of a high-speed vehicle–track system with the frequency-dependent dynamic properties of rail pads is presented. First, the Williams-Landel-Ferry (WLF) formula and Fractional Derivative Zener (FDZ) model were, respectively, applied for prediction and representation of the frequency-dependent dynamic properties of Vossloh 300 rail pads frequently used in China's high-speed railway. Then, the proposed hybrid SEM–SM method was used to investigate the influence of the frequency-dependent dynamic performance of Vossloh 300 rail pads on the high-frequency random vibrations of high-speed vehicle–track systems at various train speeds or different levels of rail surface roughness. The experimental results indicate that the storage stiffness and loss factors of Vossloh 300 rail pad increase with the decrease in dynamic loads or the increase in preloads within 0.1–10,000?Hz at 20°C, and basically linearly increase with frequency in a logarithmic coordinate system. The results computed by the hybrid SEM–SM method demonstrate that the frequency-dependent viscous damping of Vossloh 300 rail pads, compared with its constant viscous damping and frequency-dependent stiffness, has a much more conspicuous influence on the medium-frequency (i.e. 20–63?Hz) random vibrations of car bodies and rail fasteners, and on the mid- (i.e. 20–63?Hz) and high-frequency (i.e. 630–1250?Hz) random vibrations of bogies, wheels and rails, especially with the increase in train speeds or the deterioration of rail surface roughness. The two sensitive frequency bands can also be validated by frequency response function (FRF) analysis of the proposed infinite rail–fastener model. The mid and high frequencies influenced by the frequency-dependent viscous damping of rail pads are exactly the dominant frequencies of ground vibration acceleration and wheel rolling noise caused by high-speed railways, respectively. Even though the existing time-domain (or frequency-domain) finite track models associated with the time-domain (or frequency-domain) fractional derivative viscoelastic (FDV) models of rail pads can also be used to reach the same conclusions, the hybrid SEM–SM method in which only one element is required to compute the high-order vibration modes of infinite rail is more appropriate for high-efficiency analysis of the high-frequency random vibrations of high-speed vehicle–track systems.     

A method to determine the two-point contact zone and transfer of wheel–rail forces in a turnout

A practical method to determine the zone of two contact points and the transfer of wheel–rail forces between two rails in a turnout is presented in this paper. The method is based on a wheel–rail elastic penetration assumption and used to study a turnout system for a 200 km/h high-speed railway in China. Rail profiles in a number of key sections in the turnout are identified first, and profiles in other sections are then obtained by interpolation between key sections. The track is modelled as flexible with rails and sleepers represented by beams and the interaction between the vehicle and turnout is simulated for cases of the vehicle passing the turnout. Results are mainly presented for two-point contact positions and the characteristics of the wheel–rail forces transference. It is found that the heights of the switch and crossing rail top have significant effects on the wheel–rail contact forces. Finally, the optimised top height for the crossing rails is proposed to reduce the system dynamic force in the turnout system.