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.     

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.     

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.     

Study on rail corrugation of a metro tangential track with Cologne-egg type fasteners

In Chinese metro lines, rail corrugation on both tangential and tight curved tracks with Cologne-egg type fasteners is very severe. Based on the viewpoint of friction-induced vibration causing rail corrugation, the rail corrugation on a tangential track with Cologne-egg type fasteners is studied in this paper. A vibration model of an elastic multiple-wheelset-track system with Cologne-egg type fasteners is established. Both the complex eigenvalue analysis and the transient dynamic analysis are performed to study the stability and the dynamic performance of the wheelset-track system. The simulation results show that a low rail support stiffness value is responsible for rail corrugation on the tangential track. When the Cologne-egg fasteners characterised by a lower stiffness value are replaced with the DTVI2 fasteners characterised by a higher stiffness value, rail corrugation disappears. However, rail corrugation on tight curved tracks cannot be suppressed using the same replacement. The above conclusions are consistent with the corrugation occurrences in actual metro tracks.     

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.     

An investigation into the mechanism of the polygonal wear of metro train wheels and its effect on the dynamic behaviour of a wheel/rail system

This paper presents a detailed investigation conducted into the mechanism of the polygonal wear of metro train wheels through extensive experiments conducted at the sites. The purpose of the experimental investigation is to determine from where the resonant frequency that causes the polygonal wear of the metro train wheels originates. The experiments include the model tests of a vehicle and its parts and the tracks, the dynamic behaviour test of the vehicle in operation and the observation test of the polygonal wear development of the wheels. The tracks tested include the viaducts and the tunnel tracks. The structure model tests show that the average passing frequency of a polygonal wheel is approximately close to the first bending resonant frequency of the wheelset that is found by the wheelset model test and verified by the finite element analysis of the wheelset. Also, the dynamic behaviour test of the vehicle in operation indicates the main frequencies of the vertical acceleration vibration of the axle boxes, which are dominant in the vertical acceleration vibration of the axle boxes and close to the passing frequency of a polygonal wheel, which shows that the first bending resonant frequency of the wheelset is very exciting in the wheelset operation. The observation test of the polygonal wear development of the wheels indicates an increase in the rate of the polygonal wear of the wheels after their re-profiling. This paper also describes the dynamic models used for the metro vehicle coupled with the ballasted track and the slab track to analyse the effect of the polygonal wear of the wheels on the wheel/rail normal forces.     

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.     

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.     

Experimental and numerical investigation of the effect of rail corrugation on the behaviour of rail fastenings

This paper presents the results of a detailed investigation of the effects of rail corrugation on the dynamic behaviour of metro rail fastenings, obtained from extensive experiments conducted on site and from simulations of train–track dynamics. The results of tests conducted with a metro train operating on corrugated tracks are presented and discussed first. A three-dimensional (3D) model of the metro train and a slab track was developed using multi-body dynamics modelling and the finite element method to simulate the effect of rail corrugation on the dynamic behaviour of rail fastenings. In the model, the metro train is modelled as a multi-rigid body system, and the slab track is modelled as a discrete elastic support system consisting of two Timoshenko beams for the rails, a 3D solid finite element (FE) model for the slabs, periodic discrete viscoelastic elements for the rail fastenings that connect the rails to the slabs, and uniformly viscoelastic elements for the subgrade beneath the slabs. The proposed train–track model was used to investigate the effects of rail corrugation on the dynamic behaviour of the metro track system and fastenings. An FE model for the rail fastenings was also developed and was used to calculate the stresses in the clips, some of which rupture under the excitation of rail corrugation. The results of the field experiments and dynamics simulations provide an insight into the root causes of the fracture of the clips, and several remedies are suggested for mitigating strong vibrations and failure of metro rail fastening systems.     

Field measurements of the evolution of wheel wear and vehicle dynamics for high-speed trains

This investigation demonstrates the wheel wear evolution and related vehicle dynamics of high-speed trains with an operating distance (OD) of around two million kilometres. A long-term experimental test lasting two years was conducted to record the wheel profiles and structural vibrations of various trainsets. The wheel wear, namely the profile shape, worn distribution and wheelset conicity, is investigated for several continuous reprofiling cycles. Typical results are illustrated for the stability analysis, and the ride quality is examined with increasing OD. In addition, the vibration transition characteristics between suspensions are investigated in both the time and frequency domains. The experiments show that the dominant wear concentrates on the nominal rolling radius, and the wear rate increases with OD because of the surface softening resulting from the loss of wheel material. The vibration of structural components is aggravated by the increase of the equivalent conicity of the wheelset, which rises approximately linearly with the wheel wear and OD. High-frequency vibrations arise in the bogie and car body related to the track arrangement and wheel out-of-roundness, causing the ride comfort to worsen significantly. Additionally, the system vibration characteristics are strongly dependent on the atmospheric temperature. Summaries and conclusions are obtained regarding the wheel wear and related vehicle dynamics of high-speed trains over long operating times and distances.     

基于小波变换的四轮车辆非平稳振动时频研究

基于8自由度的车辆动力学模型，以四轮相关滤波白噪声路面为系统输入，对四轮车辆的非平稳随机振动过程进行了计算机时域模拟，进而采用谱分析和小波分析技术分析了系统响应，在时频平面内建立了各振级之间的振动联系，考察了振动能量的流动情况，深入揭示了车辆非平稳振动过程的本质。     

Experimental investigation into the mechanism of the polygonal wear of electric locomotive wheels

Experiments were conducted at field sites to investigate the mechanism of the polygonal wear of electric locomotive wheels. The polygonal wear rule of electric locomotive wheels was obtained. Moreover, two on-track tests have been carried out to investigate the vibration characteristics of the electric locomotive's key components. The measurement results of wheels out-of-round show that most electric locomotive wheels exhibit polygonal wear. The main centre wavelength in the 1/3 octave bands is 200?mm and/or 160?mm. The test results of vibration characteristics indicate that the dominating frequency of the vertical acceleration measured on the axle box is approximately equal to the passing frequency of a polygonal wheel, and does not vary with the locomotive speed during the acceleration course. The wheelset modal analysis using the finite element method (FEM) indicates that the first bending resonant frequency of the wheelset is quite close to the main vibration frequency of the axle box. The FEM results are verified by the experimental modal analysis of the wheelset. Moreover, different plans were designed to verify whether the braking system and the locomotive's adhesion control have significant influence on the wheel polygon or not. The test results indicate that they are not responsible for the initiation of the wheel polygon. The first bending resonance of the wheelset is easy to be excited in the locomotive operation and it is the root cause of wheel polygon with centre wavelength of 200?mm in the 1/3 octave bands.     

Modelling the effects of friction modifiers on rail corrugation in cornering

A proposed solution to the problem of rail corrugation on curves of urban lines is the use of friction modifiers. Recent experimental research indicates this approach can be effective. This paper makes use of two theoretical models to study the effects of friction modifiers on corrugation in cornering. The first one is a nonlinear time-domain model that predicts corrugation growth from a series of simulated passes of a bogie. The second one is a frequency domain model of wheel–rail interaction, linearised about a steady cornering state, estimated from the nonlinear model. Both models predict reduction of growth of corrugation due to the use of friction modifiers. Friction modifiers can alter the steady cornering state to one with somewhat lower creeps and much lower tractions. Major reductions in corrugation growth rate have been shown to occur if a wheel can be prevented from reaching a state of full sliding when subject to oscillating creeps caused by existing rail corrugation.     

Short wavelength rail corrugation and non-steady-state contact mechanics

J. J. Kalker has been the first to consider non-steady-state or transient contact mechanics. Based on Kalker the second author developed a linear contact model for the non-steady-state rolling contact of a wheel running over slightly corrugated rails. The theoretical investigations are concentrated on linear, non-steady-state contact mechanics superimposed to a nonlinear reference state. The reference state is given by the running behaviour of a wheelset due to traction, curving or hunting. For the linear, non-steady-state analysis Kalker's theory has to be modified to predict wear rates in dependency of the corrugation wavelengths. As a result corrugations are only amplified in the range between 2 and 10 cm. Therefore, non-steady-state contact mechanics and wear are responsible for a wavelength fixing mechanism. Structural mechanics of the rail indicate that wavelength in this range is predominantly amplified.     

基于Simulink的轮边驱动电动车振动分析与仿真

为解决轮边驱动电动车安全性和平顺性低的问题,文章以基于吸振原理的轮边驱动电动车垂向3自由度系统为例,运用机械振动学原理建立动力学微分方程,采用状态空间法将此系统的微分方程转化为便于Matlab/Simulink软件仿真的模型。通过分析和仿真可以直接获得轮边驱动电动车沿垂直地面方向的运动曲线图,在正弦激励作用下,动力吸振器、车轮及车身均作周期性运动。将机械振动学和Simulink软件相结合能够准确方便地对轮边驱动电动车的振动进行分析与仿真,为处理类似的汽车振动系统仿真提供了参考。     

基于矢量控制的混合动力汽车电机控制器设计

为满足HEV扭矩响应快的要求,本文研究基于转子磁定向的矢量控制算法并建立仿真模型,仿真结果表明,该方法能够获得良好的动态跟随性;然后对控制器的软、硬件进行模块化设计,为实现异步感应电机矢量控制构建平台;同时,采取多种抗干扰及隔振措施使控制器能够适应HEV的工作环境;最后通过电机台架试验验证,所设计的驱动系统具有扭矩响应快、调速范围宽、综合效率高等特性。     

Long-term wear and rolling contact fatigue behaviour of a conformal wheel profile designed for large radius curves

There are many reasons to optimise the wheel–rail interface through redesign or maintenance. Minimising wear and rolling contact fatigue (RCF) initiation on wheels and/or rails is often at the forefront of such considerations. This paper covers the design of a conformal wheel profile and its long-term wear and RCF performance to optimise the wheel–rail interface and subsequently reduce the occurrence of surface-initiated RCF on South Africa’s iron ore export line. A comparative study is performed using multibody dynamics simulation together with numerical wheel wear and RCF predictions. The advantages of a conformal wheel profile design are illustrated by evaluating the worn shape and resulting contact conditions of the conformal design. The conformal design has a steadier equivalent conicity progression and a smaller conicity range compared with the current wheel profile design over the wheel’s wear life. The combination of a conformal wheel profile design with 2?mm hollow wear and inadequate adherence to grinding tolerances often result in two-point contact, thereby increasing the probability of RCF initiation. The conformal wheel profile design proved to have wear and potential RCF benefits compared with the current wheel profile design. However, implementation of such a conformal wheel profile must be accompanied by improved rail grinding practices to ensure rail profile compliance.     

Model for dynamic behavior of the crankshaft of an air cooled diesel engine subjected to severe functioning

The dynamic behavior of the engine organs in severe conditions is complicated to identify. In this paper, the dynamic behavior of the crankshaft of the diesel engine Deutz F8L413 direct injection-type air cooled in the severe operating conditions is investigated in a 3D global model. The maximum operating characteristics of the engine are experimentally measured on a bench test equipped with a hydraulic brake. The most stressed areas of the crankshaft are determined by numerical simulations. In addition, an analysis of the fatigue behavior of the crankshaft is carried out by using two fatigues criteria. The efficiency of the model is demonstrated by comparing between the numerical results and the experimental data obtained with the natural modes of vibration test.     

Investigation of the effects of sleeper-passing impacts on the high-speed train

The sleeper-passing impact has always been considered negligible in normal conditions, while the experimental data obtained from a High-speed train in a cold weather expressed significant sleeper-passing impacts on the axle box, bogie frame and car body. Therefore, in this study, a vertical coupled vehicle/track dynamic model was developed to investigate the sleeper-passing impacts and its effects on the dynamic performance of the high-speed train. In the model, the dynamic model of vehicle is established with 10 degrees of freedom. The track model is formulated with two rails supported on the discrete supports through the finite element method. The contact forces between the wheel and rail are estimated using the non-linear Hertz contact theory. The parametric studies are conducted to analyse effects of both the vehicle speeds and the discrete support stiffness on the sleeper-passing impacts. The results show that the sleeper-passing impacts become extremely significant with the increased support stiffness of track, especially when the frequencies of sleeper-passing impacts approach to the resonance frequencies of wheel/track system. The damping of primary suspension can effectively lower the magnitude of impacts in the resonance speed ranges, but has little effect on other speed ranges. Finally, a more comprehensively coupled vehicle/track dynamic model integrating with a flexible wheel set is developed to discuss the sleeper-passing-induced flexible vibration of wheel set.