Out-of-round railway wheels—a study of wheel polygonalization through simulation of three-dimensional wheel–rail interaction and wear

The objective of this study is to develop a tool for investigation of wheel tread polygonalization with radial irregularities including 1 to 20 wavelengths around the circumference of the wheel. Therefore, an existing multibody system model for simulation of general three-dimensional train–track interaction (accounting for frequencies up to several kHz) is extended with rolling contact mechanics according to FASTSIM. Furthermore, the model is also modified to allow for general wheel–rail profiles. The numerical model uses the concept of an iteration scheme including simulation of dynamic train–track interaction in the time domain coupled with a long-term wear model. A demonstration example including a bogie of a subway train travelling on a straight track is presented. In the example, an initial wheel out-of-roundness (OOR) is applied to the wheels. This irregularity is based on an amplitude spectrum derived from measurements on new wheels. Simulation results show that the most important wavelength-fixing mechanisms of the wheel OOR are (i) the vertical resonance of the coupled train–track system at approximately 40 Hz (the P2 resonance) and (ii) the frequency region including the lowest vertical track antiresonance at 165 Hz, where the dynamic track stiffness is high. Only a straight track is studied, but the model allows for asymmetric train motion on such a track.     

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.     

Mathematical modelling of train–turnout interaction

The paper proposes a mathematical model of train–turnout interaction in the mid-frequency range (0–500 Hz). The model accounts for the effects of rail profile variation along the track and of local variation of track flexibility. The proposed approach is able to represent the condition of one wheel being simultaneously in contact with more than one rail, allowing the accurate prediction of the effect of wheels being transferred from one rail to another when passing over the switch toe and the crossing nose. Comprehensive results of train–turnout interaction during the negotiation of the main and the branch lines are presented, including the effect of wear of wheel/rail profiles and presence of track misalignment. In the final part of the paper, comparisons are performed between the results of numerical simulations and line measurements performed on two different turnouts for urban railway lines, showing a good agreement between experimental and numerical results.     

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.     

High-speed wheel/rail contact determining method with rotating flexible wheelset and validation under wheel polygon excitation

A rotating flexible wheelset model is developed and integrated into a vehicle/track dynamic model. Flexible wheelset modes with natural frequencies less than 1000?Hz are considered in the wheelset modelling. An innovation of the paper is that wheel/rail rolling contact calculation considers the effect of the wheelset flexibility and the rotating effect. By introducing two half dummy rigid wheelsets the rolling contact between the flexible wheelset and the two rails can be transformed to that between a rigid wheelset and the rails. As an extension application, the wheel OOR (Out-Of-Round) wears with the 11th, 15th, and 17th orders are used to the vehicle system dynamic model with rigid, flexible and rotating-flexible wheelset model. The results of the three models are compared to study the influence of wheelset flexibility and rotation. The ‘online searching contact method’ developed in this paper is compared with the traditional contact method with considering the rotating flexible wheelset. And then a measured OOR is used to excite the rotating flexible wheelset, the response of which is analysed and verified.     

Simulation of dynamic interaction between train and railway turnout

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

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.     

Establishment and verification of three-dimensional dynamic model for heavy-haul train–track coupled system

For the long heavy-haul train, the basic principles of the inter-vehicle interaction and train–track dynamic interaction are analysed firstly. Based on the theories of train longitudinal dynamics and vehicle–track coupled dynamics, a three-dimensional (3-D) dynamic model of the heavy-haul train–track coupled system is established through a modularised method. Specifically, this model includes the subsystems such as the train control, the vehicle, the wheel–rail relation and the line geometries. And for the calculation of the wheel–rail interaction force under the driving or braking conditions, the large creep phenomenon that may occur within the wheel–rail contact patch is considered. For the coupler and draft gear system, the coupler forces in three directions and the coupler lateral tilt angles in curves are calculated. Then, according to the characteristics of the long heavy-haul train, an efficient solving method is developed to improve the computational efficiency for such a large system. Some basic principles which should be followed in order to meet the requirement of calculation accuracy are determined. Finally, the 3-D train–track coupled model is verified by comparing the calculated results with the running test results. It is indicated that the proposed dynamic model could simulate the dynamic performance of the heavy-haul train well.     

Dynamic Train-Track Interaction: Variability Attributable to Scatter in the Track Properties

A numerical method to simulate vertical dynamic interaction between a rolling train and a railway track has been used to investigate the influence of stochastic properties of the track structure. A perturbation technique has been used to investigate the influence of the scatter in selected track properties. The train-track interaction problem has been numerically solved by use of an extended state-space vector approach in conjunction with a complex modal superposition for the whole track structure. All numerical simulations have been carried out in the time-domain with a moving mass model. Properties such as rail pad stiffness, ballast stiffness, dynamic ballast-subgrade mass and sleeper spacing have been studied. To obtain sufficient statistical information from track structures, full-scale measurements in the field and laboratory measurements have been carried out. The influence of scatter in the track properties on the maximum contact force between the rail and the wheel, the maximum magnitude of the vertical wheelset acceleration, and the maximum sleeper displacement have been studied. Mean values and standard deviations of these quantities have been calculated. The effects of the variation of the investigated track properties are discussed.     

Dynamic Train-Track Interaction: Variability Attributable to Scatter in the Track Properties

A numerical method to simulate vertical dynamic interaction between a rolling train and a railway track has been used to investigate the influence of stochastic properties of the track structure. A perturbation technique has been used to investigate the influence of the scatter in selected track properties. The train-track interaction problem has been numerically solved by use of an extended state-space vector approach in conjunction with a complex modal superposition for the whole track structure. All numerical simulations have been carried out in the time-domain with a moving mass model. Properties such as rail pad stiffness, ballast stiffness, dynamic ballast-subgrade mass and sleeper spacing have been studied. To obtain sufficient statistical information from track structures, full-scale measurements in the field and laboratory measurements have been carried out. The influence of scatter in the track properties on the maximum contact force between the rail and the wheel, the maximum magnitude of the vertical wheelset acceleration, and the maximum sleeper displacement have been studied. Mean values and standard deviations of these quantities have been calculated. The effects of the variation of the investigated track properties are discussed.     

High-speed trains subject to abrupt braking

The dynamic response of high-speed train subject to braking is investigated using the moving element method. Possible sliding of wheels over the rails is accounted for. The train is modelled as a 15-DOF system comprising of a car body, two bogies and four wheels interconnected by spring-damping units. The rail is modelled as a Euler–Bernoulli beam resting on a two-parameter elastic damped foundation. The interaction between the moving train and track-foundation is accounted for through the normal and tangential wheel–rail contact forces. The effects of braking torque, wheel–rail contact condition, initial train speed and severity of railhead roughness on the dynamic response of the high-speed train are investigated. For a given initial train speed and track irregularity, the study revealed that there is an optimal braking torque that would result in the smallest braking distance with no occurrence of wheel sliding, representing a good compromise between train instability and safety.     

Effect of curved track support failure on vehicle derailment

In order to investigate the effect of curved track support failure on railway vehicle derailment, a coupled vehicle–track dynamic model is put forward. In the model, the vehicle and the structure under rails are, respectively, modelled as a multi-body system, and the rail is modelled with a Timoshenko beam rested on the discrete sleepers. The lateral, vertical, and torsional deformations of the beam are taken into account. The model also considers the effect of the discrete support by sleepers on the coupling dynamics of the vehicle and track. The sleepers are assumed to move backward at a constant speed to simulate the vehicle running along the track at the same speed. In the calculation of the coupled vehicle and track dynamics, the normal forces of the wheels/rails are calculated using the Hertzian contact theory and their creep forces are determined with the nonlinear creep theory by Shen et al [Z.Y. Shen, J.K. Hedrick, and J.A. Elkins, A comparison of alternative creep-force models for rail vehicle dynamic analysis, Proceedings of the 8th IAVSD Symposium, Cambridge, MA, 1984, pp. 591–605]. The motion equations of the vehicle/track are solved by means of an explicit integration method. The failure of the components of the curved track is simulated by changing the track stiffness and damping along the track. The cases where zero to six supports of the curved rails fail are considered. The transient derailment coefficients are calculated. They are, respectively, the ratio of the wheel/rail lateral force to the vertical force and the wheel load reduction. The contact points of the wheels/rails are in detail analysed and used to evaluate the risk of the vehicle derailment. Also, the present work investigates the effect of friction coefficient, axle load and vehicle speed on the derailments under the condition of track failure. The numerical results obtained indicate that the failure of track supports has a great influence on the whole vehicle running safety.     

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.     

Dynamic Interaction between Wheel and Track - A Parametric Search towards an Optimal Design of Rail Structures

The dynamic vertical interaction between a moving rigid wheel and a flexible railway track is investigated. A round and smooth wheel tread and an initially straight and noncorrugated rail surface are assumed in the present optimization study. A symmetric linear three-dimensional beam structure model of a finite portion of the track is suggested including rail, pads, sleepers and ballast with spatially nonproportional damping. The full interaction problem is numerically solved by use of an extended state-space vector approach in conjunction with a complex modal superposition for the track. Transient bending stresses in sleepers and rail are calculated. The influence of seven selected track parameters on the dynamic behaviour of the track is investigated. A two-level fractional factorial design method is used in the search for a combination of numerical levels of these parameters making the maximum bending stresses a minimum.     

Behaviour of the Normal Contact Force Under Multiple Wheel/Rail Interaction

The wheel/rail contact forces are calculated in the frequency domain using a track model with multiple wheels on the rail. The effects of the wave reflections between the wheels on the contact force are studied. Different pad stiffnesses are used in the calculations to investigate the influence on the contact force. It is shown that the contact force can have up to four main peaks in the frequency region 550-1200?Hz due to the wave reflections between the wheels, so that the wavelengths of short pitch corrugation can be expected to be associated with multiple frequencies. As a conclusion, it is recommended that in a model for predicting short pitch corrugation the effects of multiple wheel/rail interactions need to be included.     

Dynamic Interaction between Wheel and Track - A Parametric Search towards an Optimal Design of Rail Structures

SUMMARY

The dynamic vertical interaction between a moving rigid wheel and a flexible railway track is investigated. A round and smooth wheel tread and an initially straight and noncorrugated rail surface are assumed in the present optimization study. A symmetric linear three-dimensional beam structure model of a finite portion of the track is suggested including rail, pads, sleepers and ballast with spatially nonproportional damping. The full interaction problem is numerically solved by use of an extended state-space vector approach in conjunction with a complex modal superposition for the track. Transient bending stresses in sleepers and rail are calculated. The influence of seven selected track parameters on the dynamic behaviour of the track is investigated. A two-level fractional factorial design method is used in the search for a combination of numerical levels of these parameters making the maximum bending stresses a minimum.     

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.     

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

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