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 problem solution for non-elliptical contact areas with the FastSim algorithm

This article deals with the application of the FastSim algorithm to the solution of the tangential contact problem for non-elliptical contact areas. At first, the causes creating problems for the solution of non-hertzian contact areas with this algorithm shall be analyzed. Then, different currently existing methods shall be studied, analyzing their accuracy characteristics and computational cost to determine whether or not they are appropriate to use in dynamic simulations. Finally, a new strategy shall be proposed that, in the opinion of the authors, offers good characteristics of precision and computational cost.     

Design of an optimised wheel profile for rail vehicles operating on two-track gauges

This article sets out an optimum synthesis methodology for wheel profiles of railway vehicles in order to secure good dynamic behaviour with different track configurations. Specifically, the optimisation process has been applied to the case of rail wheelsets mounted on double-gauge bogies that move over two different gauges, which also have different types of rail: the Iberian gauge (1668 mm) and the International Union of Railways (UIC) gauge (1435 mm). Optimisation is performed using Genetic Algorithms and traditional optimisation methods in a complementary way. The objective function used is based on an ideal equivalent conicity curve which ensures good stability on straight sections and also proper negotiation of curves. To this end, the curve is constructed in such a way that it is constant with a low value for small lateral wheelset displacements (with regard to stability), and increases as the displacements increase (to facilitate negotiation of curved sections). Using this kind of ideal conicity curve also enables a wheel profile to be secured where the contact points have a larger distribution over the active contact areas, making wear more homogeneous and reducing stresses. The result is a wheel profile with a conicity that is closer to the target conicity for both gauges studied, producing better curve negotiation while maintaining good stability on straight sections of track. The article shows the resultant wheel profile, the contact curves it produces, and a number of dynamic analyses demonstrating better dynamic behaviour of the synthesised wheel on curved sections with respect to the original wheel.     

Dynamic assessment of existing soft catenary systems using modal analysis to explore higher train velocities: a case study of a Norwegian contact line system

Significant advances made on the rolling stock have considerably increased the possibility of higher speeds in existing railways. Thus, it is important to explore higher speeds and potential limiting factors of existing soft catenary systems. The present paper investigates procedures to assess the dynamic behaviour of these systems using response sampling and modal analysis. The assessment evaluates and quantifies dynamic response along the section. To verify the approach, a case study is conducted and the following assessment methods are used: lengthwise track correlation estimating dynamic predictability, power spectral density estimations before and after passage and short-time Fourier transforms and spectrograms. The combination provides detailed information on the dynamic behaviour. The first part introduces necessary considerations for suggested modal analysis. The second part describes an existing Norwegian section. The case study is conducted using a finite element model including a straight and a given section between Oslo-Trondheim, providing detailed evaluations and system limitation detections.     

Estimation of wheel–rail friction for vehicle certification

In certification of new rail vehicles with respect to running characteristics, a wide variety of operating conditions needs to be considered. However, in associated test runs the wheel–rail friction condition is difficult to handle because the friction coefficient needs to be fairly high and the friction is also generally hard to assess. This is an issue that has been studied in the European project DynoTRAIN and part of the results is presented in this paper. More specifically, an algorithm for estimating the wheel–rail friction coefficient at vehicle certification tests is proposed. Owing to lack of some measurement results, the algorithm here is evaluated in a simulation environment which is also an important step towards practical implementation. A quality measure of the friction estimate is suggested in terms of estimated wheel–rail spin and total creep. It is concluded that, tentatively, the total creep should exceed 0.006 and the spin should be less than 1.0 m^?1 for the algorithm to give a good friction estimate. Sensitivity analysis is carried out to imitate measurement errors, but should be expanded in further work.     

A comparison of various algorithms to extract Magic Formula tyre model coefficients for vehicle dynamics simulations

Tyre models are a prerequisite for any vehicle dynamics simulation. Tyre models range from the simplest mathematical models that consider only the cornering stiffness to a complex set of formulae. Among all the steady-state tyre models that are in use today, the Magic Formula tyre model is unique and most popular. Though the Magic Formula tyre model is widely used, obtaining the model coefficients from either the experimental or the simulation data is not straightforward due to its nonlinear nature and the presence of a large number of coefficients. A common procedure used for this extraction is the least-squares minimisation that requires considerable experience for initial guesses. Various researchers have tried different algorithms, namely, gradient and Newton-based methods, differential evolution, artificial neural networks, etc. The issues involved in all these algorithms are setting bounds or constraints, sensitivity of the parameters, the features of the input data such as the number of points, noisy data, experimental procedure used such as slip angle sweep or tyre measurement (TIME) procedure, etc. The extracted Magic Formula coefficients are affected by these variants. This paper highlights the issues that are commonly encountered in obtaining these coefficients with different algorithms, namely, least-squares minimisation using trust region algorithms, Nelder–Mead simplex, pattern search, differential evolution, particle swarm optimisation, cuckoo search, etc. A key observation is that not all the algorithms give the same Magic Formula coefficients for a given data. The nature of the input data and the type of the algorithm decide the set of the Magic Formula tyre model coefficients.     

Prohibited–permitted right-turn phasing strategy based on capacity analysis of right-turn movements

In traffic-crowded metropolitan areas, such as Shanghai and Beijing in China, right-turn vehicles that operate with a permitted phase at signalized intersections are normally permitted to filter through large numbers of pedestrians and bicycles. To alleviate such conflicts and improve safety, traffic engineers in Shanghai introduced a prohibited–permitted right-turn operation, adding a subphase to the permitted phase in which right-turns are prohibited. Unfortunately, the prohibited subphase would reduce the capacity of right-turn movements when it prohibits right turns even if there are few pedestrians and bicycles crossing the street. This paper aims at quantifying the impact of both non-vehicular flows and the prohibited subphase on the right-turn capacity, and then proposes a strategy to determine appropriate prohibited–permitted right-turn operation that minimizes the capacity reduction caused by the prohibited subphase. To achieve this goal, we improved the pedestrian and bicycle adjustment factor described in the Highway Capacity Manual by taking into account: (1) the variety in space competition between pedestrians and bicycles, and (2) the effect of two conflict zones in each phase on right-turn operation. In addition, we revised the capacity estimation model in the Highway Capacity Manual, and developed a model based on bicycle/pedestrian volume fluctuation to describe the capacity reduction due to both non-vehicular flows and the prohibited subphase. Furthermore, we proposed a timing strategy for the onset and duration of appropriate prohibited subphase. When bicycle and pedestrian volumes are low, the actuated strategy turns to the permitted phase. When these volumes are moderate, the strategy turns to the prohibited–permitted operation. With the volumes increasing, the prohibited subphase onset advances and duration increases. In these two scenarios, the new strategy has higher right-turn capacity than the current pretimed prohibited–permitted operation. Unfortunately, when bicycle and pedestrian volumes are high, the strategy yields similar right-turn capacity. However, the new prohibited subphase has less potential vehicle–bicycle and vehicle–pedestrian conflicts.     

Specification of the cross-nested logit model with sampling of alternatives for route choice models

We present an operational estimation procedure for the estimation of route choice multivariate extreme value (MEV) models based on sampling of alternatives. The procedure builds on the state-of-the-art literature, and in particular on recent methodological developments proposed by Flötteröd and Bierlaire (2013) and Guevara and Ben-Akiva (2013b). Case studies on both synthetic data and a real network demonstrate that the new method is valid and practical.