Prediction of Wheel/Rail Profile Wear

The alteration in wheel and rail profiles due to wear involves considerable vehicle and track-maintenance costs, and influences the loading capacity of the rails, as well as the operation safety and riding comfort of the vehicles. In the past twenty years a vehicle dynamics, contact mechanics and tribology based research work has emerged which is also recently continuous in an international scale, and this research is more and more intensive. Parallel to the growing possibilities of computer based analyses, several algorithms and numerical procedures have been elaborated, as well as measurement based experiments have been carried out to establish the reliable prediction of wear-caused wheel and rail profile alterations and to maximise the mileage performance by selecting the optimum vehicle system parameters for running gears operating on a selected railway line or a whole network under specified -in general inherently stochastic - traffic conditions. This paper takes an attempt to introduce the extended sphere of problems of wheel and rail wear prediction, as well as the latest results reflecting the present state of the art.     

Development and validation of a wear model for the analysis of the wheel profile evolution in railway vehicles

The numerical wheel wear prediction in railway applications is of great importance for different aspects, such as the safety against vehicle instability and derailment, the planning of wheelset maintenance interventions and the design of an optimal wheel profile from the wear point of view. For these reasons, this paper presents a complete model aimed at the evaluation of the wheel wear and the wheel profile evolution by means of dynamic simulations, organised in two parts which interact with each other mutually: a vehicle's dynamic model and a model for the wear estimation. The first is a 3D multibody model of a railway vehicle implemented in SIMPACK?, a commercial software for the analysis of mechanical systems, where the wheel–rail interaction is entrusted to a C/C++user routine external to SIMPACK, in which the global contact model is implemented. In this regard, the research on the contact points between the wheel and the rail is based on an innovative algorithm developed by the authors in previous works, while normal and tangential forces in the contact patches are calculated according to Hertz's theory and Kalker's global theory, respectively. Due to the numerical efficiency of the global contact model, the multibody vehicle and the contact model interact directly online during the dynamic simulations.

The second is the wear model, written in the MATLAB® environment, mainly based on an experimental relationship between the frictional power developed at the wheel–rail interface and the amount of material removed by wear. Starting from a few outputs of the multibody simulations (position of contact points, contact forces and rigid creepages), it evaluates the local variables, such as the contact pressures and local creepages, using a local contact model (Kalker's FASTSIM algorithm). These data are then passed to another subsystem which evaluates, by means of the considered experimental relationship, both the material to be removed and its distribution along the wheel profile, obtaining the correspondent worn wheel geometry.

The wheel wear evolution is reproduced by dividing the overall chosen mileage to be simulated in discrete spatial steps: at each step, the dynamic simulations are performed by means of the 3D multibody model keeping the wheel profile constant, while the wheel geometry is updated through the wear model only at the end of the discrete step. Thus, the two parts of the whole model work alternately until the completion of the whole established mileage. Clearly, the choice of an appropriate step length is one of the most important aspects of the procedure and it directly affects the result accuracy and the required computational time to complete the analysis.

The whole model has been validated using experimental data relative to tests performed with the ALn 501 ‘Minuetto’ vehicle in service on the Aosta–Pre Saint Didier track; this work has been carried out thanks to a collaboration with Trenitalia S.p.A and Rete Ferroviaria Italiana, which have provided the necessary technical data and experimental results.     

Tangential force variation due to the bogie direction reversal procedure

A range of tangential forces is generated within the contact patch when a wheelset moves on the rail. These forces are intensified when incorporating curved tracks and motored axle rail vehicles [Arrus, P., de Pater, A.D. and Meyers, P., 2002, The stationary motion of a one-axle vehicle along a circular curve with real rail and wheel profiles. Vehicle System Dynamics, 37(1), 29–58]. The wheelset is subject to flange contact if an unbalanced force remains in a curve towards the high rail gauge face. The resultant force in the transverse direction includes the lateral force, the radial force, and the creep forces in addition to the effect of the frequent wheelset displacement due to the kinematic oscillation [Iwnicki, S., 2003, Simulation of wheel–rail contact forces. Fatigue Fracture Engineering Material Structure, 26, 887–900]. This article has focused on a potential variation in some of the forces cited when the wheelset is subject to backward and forward movements. A severe wear rate observed within the wheel flange region in Iranian Railways was investigated by operating a test bogie on a curvaceous track. An obvious improvement in the wear rate and wear pattern of the wheels was attained when the second test bogie encountered a bogie direction reversal procedure. This enhancement is considered in this article from the force analysis standpoint.     

A survey of wheel–rail contact models for rail vehicles

Accurate and efficient contact models for wheel–rail interaction are essential for the study of the dynamic behaviour of a railway vehicle. Assessment of the contact forces and moments, as well as contact geometry provide a fundamental foundation for such tasks as design of braking and traction control systems, prediction of wheel and rail wear, and evaluation of ride safety and comfort. This paper discusses the evolution and the current state of the theories for solving the wheel–rail contact problem for rolling stock. The well-known theories for modelling both normal contact (Hertzian and non-Hertzian) and tangential contact (Kalker's linear theory, FASTSIM, CONTACT, Polach's theory, etc.) are reviewed. The paper discusses the simplifying assumptions for developing these models and compares their functionality. The experimental studies for evaluation of contact models are also reviewed. This paper concludes with discussing open areas in contact mechanics that require further research for developing better models to represent the wheel–rail interaction.     

A linear complementarity method for the solution of vertical vehicle–track interaction

A new method is proposed for the solution of the vertical vehicle–track interaction including a separation between wheel and rail. The vehicle is modelled as a multi-body system using rigid bodies, and the track is treated as a three-layer beam model in which the rail is considered as an Euler-Bernoulli beam and both the sleepers and the ballast are represented by lumped masses. A linear complementarity formulation is directly established using a combination of the wheel–rail normal contact condition and the generalised-α method. This linear complementarity problem is solved using the Lemke algorithm, and the wheel–rail contact force can be obtained. Then the dynamic responses of the vehicle and the track are solved without iteration based on the generalised-α method. The same equations of motion for the vehicle and track are adopted at the different wheel–rail contact situations. This method can remove some restrictions, that is, time-dependent mass, damping and stiffness matrices of the coupled system, multiple equations of motion for the different contact situations and the effect of the contact stiffness. Numerical results demonstrate that the proposed method is effective for simulating the vehicle–track interaction including a separation between wheel and rail.     

An investigation into the mechanism of the out-of-round wheels of metro train and its mitigation measures

This paper presents an investigation into the mechanism of polygonal wear of metro train wheels through experiments conducted at field sites. The experiments comprise dynamic behaviour test of vehicle and track system, the wheel transverse wear and polygonal wear measurements, rail corrugation and rail weld joint irregularities’ measurements. Moreover, the numerical modal analysis of the wheelset is also performed. The wheel measurement results show that most wheels exhibit obvious eccentricity and polygonal wear with 5–8 harmonics. The investigation results indicate that the wavelength-fixing mechanism of the wheel out-of-roundness with 5–8 harmonics is the P2 resonance. Four measures have been proposed to mitigate the formation of wheel polygonal wear based on the field measurement results.     

Carbody elastic vibrations of high-speed vehicles caused by bogie hunting instability

In particular locations of the high-speed track, the worn wheel profile matched up with the worn rail profile will lead to an extremely high-conicity wheel–rail contact. Consequently, the bogie hunting instability arises, which further results in the so-called carbody shaking phenomenon. In this paper, the carbody elastic vibrations of a high-speed vehicle in service are firstly introduced. Modal tests are conducted to identity the elastic modes of the carbody. The ride comfort and running safety indices for the tested vehicle are evaluated. The rigid–flexible coupling dynamic model for the high-speed passenger car is then developed by using the FE and MBS coupling approach. The rail profiles in those particular locations are measured and further integrated into the simulation model to reproduce the bogie hunting and carbody elastic vibrations. The effects of wheel and rail wear on the vehicle system response, e.g. wheelset bifurcation graph and carbody vibrations, are studied. Two improvement measures, including the wheel profile modification and rail grinding, are proposed to provide possible solutions. It is found that the wheel–rail contact conicity can be lowered by decreasing wheel flange thickness or grinding rail corner, which is expected to improve the bogie hunting stability under worn rail and worn wheel conditions. The carbody elastic vibrations caused by bogie hunting instability can be further restrained.     

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.     

New methodology for fast prediction of wheel wear evolution

In railway applications wear prediction in the wheel–rail interface is a fundamental matter in order to study problems such as wheel lifespan and the evolution of vehicle dynamic characteristic with time. However, one of the principal drawbacks of the existing methodologies for calculating the wear evolution is the computational cost. This paper proposes a new wear prediction methodology with a reduced computational cost. This methodology is based on two main steps: the first one is the substitution of the calculations over the whole network by the calculation of the contact conditions in certain characteristic point from whose result the wheel wear evolution can be inferred. The second one is the substitution of the dynamic calculation (time integration calculations) by the quasi-static calculation (the solution of the quasi-static situation of a vehicle at a certain point which is the same that neglecting the acceleration terms in the dynamic equations). These simplifications allow a significant reduction of computational cost to be obtained while maintaining an acceptable level of accuracy (error order of 5–10%). Several case studies are analysed along the paper with the objective of assessing the proposed methodology. The results obtained in the case studies allow concluding that the proposed methodology is valid for an arbitrary vehicle running through an arbitrary track layout.     

Influence of polygonal wear of railway wheels on the wheel set axle stress

The coupled vehicle/track dynamic model with the flexible wheel set was developed to investigate the effects of polygonal wear on the dynamic stresses of the wheel set axle. In the model, the railway vehicle was modelled by the rigid multibody dynamics. The wheel set was established by the finite element method to analyse the high-frequency oscillation and dynamic stress of wheel set axle induced by the polygonal wear based on the modal stress recovery method. The slab track model was taken into account in which the rail was described by the Timoshenko beam and the three-dimensional solid finite element was employed to establish the concrete slab. Furthermore, the modal superposition method was adopted to calculate the dynamic response of the track. The wheel/rail normal forces and the tangent forces were, respectively, determined by the Hertz nonlinear contact theory and the Shen–Hedrick–Elkins model. Using the coupled vehicle/track dynamic model, the dynamic stresses of wheel set axle with consideration of the ideal polygonal wear and measured polygonal wear were investigated. The results show that the amplitude of wheel/rail normal forces and the dynamic stress of wheel set axle increase as the vehicle speeds rise. Moreover, the impact loads induced by the polygonal wear could excite the resonance of wheel set axle. In the resonance region, the amplitude of the dynamic stress for the wheel set axle would increase considerably comparing with the normal conditions.     

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.     

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.     

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.     

Dynamic responses of a high-speed railway car due to wheel polygonalisation

The polygonal wear around the wheel circumference could pose highly adverse influences on the wheel/rail interactions and thereby the performance of the vehicle system. In this study, the effects of wheel polygonalisation on the dynamic responses of a high-speed rail vehicle are investigated through development and simulations of a comprehensive coupled vehicle/track dynamic model. The model integrates flexible slab track, wheelsets and axle boxes subsystem models so as to account for elastic deformations caused by impact loads induced by the wheel polygonalisation. A field-test programme was undertaken to acquire the polygonal wear profile and axle box acceleration response of a high-speed train, and the data are used to demonstrate the validity of the coupled vehicle/track system model. Subsequently, the effects of wheel polygonalisation are evaluated in terms of wheel/rail impact forces, axle box vertical acceleration and dynamic stress developed in the axle considering different amplitudes and harmonic orders of the polygonal wear. The results suggest that the high-order wheel polygonalisation can give rise to high-frequency impact loads at the wheel/rail interface, and excite some of the vibration modes of the wheelset and the axle box leading to high-magnitude axle box acceleration and dynamic stress in the wheelset axle.     

Modification of the semi-Hertz wheel–rail contact method based on recalculating the virtual penetration value

ABSTRACT

Wheel–rail contact calculation is of vital importance in vehicle system dynamics. In the existing methods of wheel–rail contact calculation, the finite element method and Kalker’s CONTACT program, which are based on the complementary energy principle, are the two methods with accuracy recognised. However, because of its very slow calculation speed, it cannot meet the requirement of online calculation, so a variety of fast non-elliptic algorithms have been proposed. The semi-Hertz method, which is recognised for its great contributions to the fast wheel–rail contact calculation, is based on the concept of virtual penetration. The calculation of virtual penetration is crucial to evaluate the shape and normal pressure distribution of the contact patch. In practice, the virtual penetration is related to the curvature of the whole contact patch; however, the range of the contact patch is determined by the value of penetration. Such an interaction leads the calculation into a dead loop. In the semi-Hertz method, the penetration is calculated by the Hertz parameters of the initial contact point. Thus, the practical range of the method is limited. In this paper, a fast-iterative method for solving virtual penetration is proposed, and a reliable value of virtual penetration can be obtained under any lateral wheel–rail relative curvature variation with good stability and speed. The normal and tangential solutions are analysed with different methods in this paper.     

General Purpose Vehicle System Dynamics Software Based on Multibody Formalisms

SUMMARY

This paper pursues two objectives: Firstly, to review the state-of-the-art of general purpose vehicle system dynamics software and secondly, to describe two representatives, the program MEDYNA and the program NEWEUL. The general modeling requirements for vehicle dynamics software, the multibody system approach and a comparative discussion of multibody software are given. The two programs NEWEUL and MEDYNA are described with respect to modeling options, computational methods, software engineering as well as their interfaces to other software. The applicability of these programs is demonstrated on two selected examples, one from road vehicle problems and the other from wheel/rail dynamics. It is concluded that general purpose software based on multibody formalisms will play the same role for mechanical systems, especially vehicle systems, as finite element methods play for elastic structures.     

Computer-Aided Analysis of Urban Railway Vehicles

SUMMARY

Computer-aided dynamic simulations are usually employed when designing modern urban railway vehicles. Even if the modeling procedure is similar to the one used for trains, specific features have to be taken into account for tramways: they are designed for low speeds (less than 80 km/h) and narrow curves (less than 20 m of radius). Moreover, in order to improve accessibility, low floor designs have been developed (the floor lying at about 300 mm above the rails level). The simulation procedure has therefore to take account of the occurence of multiple wheel/rail contacts or the modelization of independent wheels. A specific software well adapted to the computer-aided design of urban railway vehicles has been developed by the Faculte Polytechnique de Mons. It performs the following classical analyses:

lateral linearization, modal analysis and root locii plots;

vertical linearization and comfort prediction;

non-linear time simulation in straight track (limit cycles) and in curve (derailment study)

parametric analyses

The vehicle model is formed by combination of bodies ( or flexible bodies, rotating bodies like wheelsets or independent wheels) and interconnection elements ( spring and damper elements). Contact between rails and wheels is treated as a part of the rotating bodies. A residual formulation has been preferred. When combined with the use of a complete iteration matrix, this formulation is well adapted to the treatment of stiff differential equations. It is based on a fast determination of the residues of the dynamic equations combined with the calculation of the iteration matrix through a numerical derivation procedure. The advantages of the approach are discussed. The model of a partial low floor vehicle with wheelsets and independent wheels is described.