A new method for determining wheel–rail multi-point contact

A new method for wheel–rail multi-point contact is presented in this paper. In this method, the first- and the second-order derivatives of the wheel–rail interpolation distance function and the elastic wheel–rail virtual penetration are used to determine multiple contact points. The method takes account of the yaw angle of the wheelset and allows the identification of all possible points of contact between wheel and rail surfaces with an arbitrary geometry. Static contact geometry calculations are first carried out using the developed method for both new and worn wheel profiles and with a new rail profile. The validity of the method is then verified by simulations of a coupled vehicle and track system dynamics over a small radius curve. The simulation results show that the developed method for multi-point contact is efficient and reliable enough to be implemented online for simulations of vehicle–track system dynamics.     

Method for obtaining the wheel–rail contact location and its application to the normal problem calculation through ‘CONTACT’

This work presents a robust methodology for calculating inter-penetration areas between railway wheel and rail surfaces, the profiles of which are defined by a series of points. The method allows general three-dimensional displacements of the wheelset to be considered, and its characteristics make it especially suitable for dynamic simulations where the wheel–rail contact is assumed to be flexible. The technique is based on the discretisation of the geometries of the surfaces in contact, considering the wheel as a set of truncated cones and the rail as points. By means of this approach, it is possible to reduce the problem to the calculation of the intersections between cones and lines, the solution for which has a closed-form expression. The method has been used in conjunction with the CONTACT algorithm in order to solve the static normal contact problem when the lateral displacement of the wheelset, its yaw angle and the vertical force applied in the wheelset centroid are prescribed. The results consist of smooth functions when the dependent coordinates are represented as a function of the independent ones, lacking the jump discontinuities that are present when a rigid contact model is adopted. Example results are shown and assessed for the normal contact problem for different lateral and yaw positions of the wheelset on the track.     

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.     

A third-order approximation method for three-dimensional wheel–rail contact

Multibody train analysis is used increasingly by railway operators whenever a reliable and time-efficient method to evaluate the contact between wheel and rail is needed; particularly, the wheel–rail contact is one of the most important aspects that affects a reliable and time-efficient vehicle dynamics computation. The focus of the approach proposed here is to carry out such tasks by means of online wheel–rail elastic contact detection. In order to improve efficiency and save time, a main analytical approach is used for the definition of wheel and rail surfaces as well as for contact detection, then a final numerical evaluation is used to locate contact. The final numerical procedure consists in finding the zeros of a nonlinear function in a single variable. The overall method is based on the approximation of the wheel surface, which does not influence the contact location significantly, as shown in the paper.     

Numerical investigation on effect of the relative motion of stock/switch rails on the load transfer distribution along the switch panel in high-speed railway turnout

In railway turnout, the stock rail and switch rail are separated to enable the vehicle changing among the tracks, and they are provided with different rail resilience level on the baseplate. Therefore, there will be vertical relative motion between stock/switch rails under the wheel loads, and the relative motion will affect consequentially the wheel–rail contact conditions. A method is developed to investigate the effect of the relative motion of stock/switch rails on the load transfer distribution along the switch panel in high-speed railway turnout. First, the rigid wheel–rail contact points of stock/switch rails are calculated based on the trace line method, and then the contact status is determined by the presented equations, finally, the distribution of wheel–rail contact forces of stock/switch rails is obtained based on the continuity of interface displacements and forces which using an approximate surface deformation method. Some parametric studies have been performed, such as the lateral displacement of wheel set, the vertical contact forces, the wheel profiles and the vertical stiffness of rail pad. The results of the parametric study are presented and discussed.     

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.     

Research into the problem of wheel tread spalling caused by wheelset longitudinal vibration

This study mainly focuses on the mechanism of wheel tread spalling through wheelset longitudinal vibration that has been often neglected. Analysis of two actual cases of the wheel tread spalling problem leads to the conclusion that the wheel tread spalling is closely related to the wheelset longitudinal vibration in some locomotives, and many of these problems can be reasonably explained if the wheelset longitudinal vibration is considered. For better understanding of some abnormal wheel spalling problems, the formations of the wheelset longitudinal vibration and the wheel/rail contact parameters were analysed in the initial wheel tread spalling. With the preliminary analytical results, the wheelset longitudinal dynamic behaviour, the characteristics of wheel/rail contact and the mechanics in the condition of the wheelset longitudinal vibration were further studied quantitatively. The results showed that the wheelset longitudinal vibration changed not only the limit of these parameters and the position of principal stress, but also the direction of the principal stress on the surface of wheel/rail contact patch. It is likely that the significant stress changes provoke too much stress on the surface of wheel/rail contact patch, cause fatigue in wheel/rail contact patch and eventually lead to wheel tread spalling. The results of these studies suggest that the suppression of the wheelset longitudinal vibration extends wheel/rail life and the addition of a vertical damper with an ahead angle provides a possible solution to the wheel spalling problem.     

Wheel/Rail Non-linear Interactions With Coupling Between Vertical and Lateral Directions

Summary A theoretical model is developed to explore the high frequency wheel/rail interaction with coupling between the vertical and lateral directions. This coupling is introduced through the track dynamics due to the offset of the wheel/rail contact point from the rail centre line. Equivalent models of the railway track in the time domain are developed according to the rail vibration receptances in the frequency domain. The wheel is represented by a mass in each direction with no vertical-lateral coupling. The vertical wheel/rail interaction is generated through a non-linear Hertzian contact stiffness, allowing for the possibility of loss of contact between the wheel and rail. The lateral interaction is represented by a contact spring and a creep force damper in series and their values depend on the vertical contact force. The vibration source is the roughness on the wheel and rail contact surfaces which forms a relative displacement excitation in the vertical direction. Using the combined interaction model with this relative displacement excitation, the wheel/rail interactions with coupling between the vertical and lateral vibrations are simulated. It is found that the lateral interaction force caused by the offset is usually less than thirty percent of the vertical dynamic force. The lateral vibration of the rail is significantly reduced due to the presence of the lateral coupling, whereas the vertical interaction is almost unaffected by the lateral force.     

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.     

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.     

An inverse design method for rail grinding profiles

Inspired by the optimisation design method for restoration of worn wheel profiles, an inverse design method based on optimal rail grinding profiles is presented in this paper. To improve grinding quality, vehicle dynamic performance is chosen as the main criteria and rolling radii difference function is selected as the key factor (also main target function) determining dynamic performance. Grinding material to be removed is chosen as the auxiliary target aimed at extending rail service life. Besides that, wheel–rail contact distribution is also taken into consideration as an auxiliary target preventing stress concentration and fatigue growth. By introducing certain presuppositions, all the design targets will form an inverse design problem. This problem can be solved using hybrid discrete numerical methods. Considering different grinding requirements, two examples of grinding profile design for straight and curved track will be discussed. Results show that the presented method is efficient and effective. Practical implementation has been carried out at several grinding sites in China.     

Prediction of the interaction between a simple moving vehicle and an infinite periodically supported rail – Green's functions approach

This paper herein describes the interaction between a simple moving vehicle and an infinite periodically supported rail, in order to signalise the basic features of the vehicle/track vibration behaviour in general, and wheel/rail vibration, in particular. The rail is modelled as an infinite Timoshenko beam resting on semi-sleepers via three-directional rail pads and ballast. The time-domain analysis was performed applying Green's matrix of the track method. This method allows taking into account the nonlinearities of the wheel/rail contact and the Doppler effect. The numerical analysis is dedicated to the wheel/rail response due to two types of excitation: the steady-state interaction and rail irregularities. The study points out to certain aspects regarding the parametric resonance, the amplitude-modulated vibration due to corrugation and the Doppler effect.     

A new method for wheel–rail contact force continuous measurement using instrumented wheelset

With the aim of improving the continuous measurement of wheel–rail contact force by instrumented wheelset, instead of solving the non-linear equations, we proposed a new method based on state space theory. With this new method, the wheel–rail contact force can be calculated by the recurrence relation and the signals from strain gauge bridges on wheel web. The implementation of continuous instrumented wheelset is quite general and simplified, due to the specific bridging scheme is not necessary. It means that continuous measurement of the contact force could be realised with a simple bridging scheme, even as simple as discrete instrumented scheme. In this work, we first demonstrated and discussed the effectiveness and accuracy of this new method by estimation results with the numerical simulations, and we also applied this new method to two field tests, including one was conducted in a loop test line using a high-speed train and the other one was conducted in an urban line with a light rail vehicle. In a word, this new method is proved to be an effective way to monitor the wheel–rail contact force of rail vehicle track system.     

A new method for the solution of the normal contact problem in the dynamic simulation of railway vehicles

Due to requirements related to computational efficiency, in the majority of railway dynamic simulators the Hertz theory is used for solving the normal problem in wheel/rail contact. This theory is based on a large number of assumptions. Particularly noteworthy is the assumed simplification that the undeformed distance between the bodies in contact can be assimilated by a quadratic function. There are many situations in which the undeformed distance cannot be represented by this kind of function. As such, the results obtained with Hertz theory in these cases are not accurate.

In this paper, a new method for solving the normal problem that overcomes the above-mentioned limitation is presented. First, the exactness of the new method is tested with Hertzian cases. The results obtained are almost exact. Second, the results calculated with the new method in more general cases are compared with the ones obtained with the variational method of Kalker (more exact but computationally less efficient).     

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.     

Computation of wheel–rail contact force for non-mapping wheel–rail profile of Translohr tram

Translohr tram has steel wheels, in V-like arrangements, as guide wheels. These operate over the guide rails in inverted-V arrangements. However, the horizontal and vertical coordinates of the guide wheels and guide rails are not always mapped one-to-one. In this study, a simplified elastic method is proposed in order to calculate the contact points between the wheels and the rails. By transforming the coordinates, the non-mapping geometric relationship between wheel and rail is converted into a mapping relationship. Considering the Translohr tram’s multi-point contact between the guide wheel and the guide rail, the elastic-contact hypothesis take into account the existence of contact patches between the bodies, and the location of the contact points is calculated using a simplified elastic method. In order to speed up the calculation, a multi-dimensional contact table is generated, enabling the use of simulation for Translohr tram running on curvatures with different radii.     

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.