scholarly journals Optimizing wheel profiles and suspensions for railway vehicles operating on specific lines to reduce wheel wear: a case study

2020 ◽  
Vol 51 (1) ◽  
pp. 91-122 ◽  
Author(s):  
Yunguang Ye ◽  
Yu Sun ◽  
Shiping Dongfang ◽  
Dachuan Shi ◽  
Markus Hecht
Keyword(s):  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Optimal Choice ◽  
Contact Forces ◽  
Rolling Contact ◽  
Wheel Wear ◽  
Material Loss ◽  
Railway Vehicles ◽  
Wheel Profile ◽  
Designing Method

AbstractThe selection of a wheel profile is a topic of great interest as it can affect running performances and wheel wear, which needs to be determined based on the actual operational line. Most existing studies, however, aim to improve running performances or reduce contact forces/wear/rolling contact fatigue (RCF) on curves with ideal radii, with little attention to the track layout parameters, including curves, superelevation, gauge, and cant, etc. In contrast, with the expansion of urbanization, as well as some unique geographic or economic reasons, more and more railway vehicles shuttle on fixed lines. For these vehicles, the traditional wheel profile designing method may not be the optimal choice. In this sense, this paper presents a novel wheel profile designing method, which combines FaSrtip, wheel material loss function developed by University of Sheffield (USFD function), and Kriging surrogate model (KSM), to reduce wheel wear for these vehicles that primarily operate on fixed lines, for which an Sgnss wagon running on the German Blankenburg–Rübeland railway line is introduced as a case. Besides, regarding the influence of vehicle suspension characteristics on wheel wear, most of the studies have studied the lateral stiffness, longitudinal stiffness, and yaw damper characteristics of suspension systems, since these parameters have an obvious influence on wheel wear. However, there is currently little research on the relationship between the vertical suspension characteristics and wheel wear. Therefore, it is also investigated in this paper, and a suggestion for the arrangement of the vertical primary spring stiffness of the Y25 bogie is given.

Predicted Wheel Wear and RCF Performance Using VAMPIRE Automation Routines

2009 ◽  
Author(s):  
Philip J. Rogers ◽  
Matthew G. Dick
Keyword(s):  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
National Research Council ◽  
Research Process ◽  
Rolling Contact ◽  
Wheel Wear ◽  
The United Kingdom ◽  
Rail Wear ◽  
Invaluable Tool ◽  
Wheel Profile

Predicted wheel performance is an invaluable tool in developing new components such as wheel profiles and truck components and also in understanding and controlling wheel and rail wear and rolling contact fatigue (RCF). This paper outlines a vehicle dynamics trial using VAMPIRE Pro to compare the predicted wear and RCF performance of the WRISA2 wheel profile developed by the National Research Council of Canada (NRC) and the United Kingdom P8 wheel profile using measured wheel profiles from an in-service trial. WRISA2 and P8 profiles were fitted to two passenger trains running in normal service. Wheel profiles were measured every 10,000 miles. These measured profiles were used to predict wear and RCF damage for each wheel of the investigated rail vehicle, using a combination of VAMPIRE transient analysis and another program called the “Whole Life Rail Model” (WLRM). This process was repeated up to 190,000 miles run in service, allowing a clear comparison of the changing rail wear and RCF performance of the two profiles up to this mileage. This process was automated using new features within VAMPIRE that allow communication to 3rd party computer programs including the WLRM, Microsoft Excel, and Microsoft Visual Basic. This research process presents itself to be a very useful tool in predicting wheel wear performance for any number of new wheel and truck components.

Assessment of running gear performance in relation to rolling contact fatigue of wheels and rails based on stochastic simulations

2019 ◽  
Vol 234 (4) ◽  
pp. 405-416
Author(s):  
Klaus Six ◽  
Tomislav Mihalj ◽  
Gerald Trummer ◽  
Christof Marte ◽  
Visakh V Krishna ◽  
...  
Keyword(s):  
Early Stage ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Stochastic Simulations ◽  
Wheel Wear ◽  
Contact Data ◽  
Wheel Profile ◽  
Wheel Profile Wear ◽  
Vehicle Development Process

In this work, the authors present a methodology for assessing running gear with respect to rolling contact fatigue of wheels and rails. This assessment is based on the wheel/rail contact data of different wheel profile wear states obtained from a wheel profile prediction methodology. The approach allows a cumulative assessment of the rolling contact fatigue of rails in different curve radii (e.g. the sum of damage over the lifetime of wheel profiles). Furthermore, the assessment of the rolling contact fatigue can be undertaken at different wear states of the wheel profiles to provide an insight on how the rolling contact fatigue of wheels and rails varies depending on the evolution of wheel wear. The presented methodology is exemplarily applied to two bogie types, the UIC-Y25 standard bogie and the so-called FR8RAIL bogie with a mechanical wheelset steering device. The presented methodology has been shown to be a useful tool for the optimisation of vehicles already in an early stage of the vehicle development process.

scholarly journals Use of railway wheel wear and damage prediction tools to improve maintenance efficiency through the use of economic tyre turning

2018 ◽  
Vol 233 (1) ◽  
pp. 103-117 ◽  
Author(s):  
Yousif Muhamedsalih ◽  
Julian Stow ◽  
Adam Bevan
Keyword(s):  
Rolling Contact Fatigue ◽  
Damage Model ◽  
Contact Fatigue ◽  
Operating Conditions ◽  
Rolling Contact ◽  
Wheel Wear ◽  
Wear Model ◽  
Dynamic Simulations ◽  
Damage Prediction ◽  
Wheel Profile

This paper investigates the wear rate and pattern for wheels turned with thin flanges using economic tyre turning. Economic tyre turning refers to the process of turning wheels to a profile that has the same tread shape but a thinner flange than the design case profile, allowing less material to be removed from the wheel diameter during re-profiling. Modern wheel lathes are typically capable of turning such profiles but the GB railway group standards do not currently permit their use. The paper demonstrates how the wheel profile damage model (WPDM) can be used, with a good degree of accuracy, to predict both the magnitude of wheel wear and the worn profile shape of the design and economic tyre turning re-profiled wheels for service mileages exceeding 100,000 miles. The WPDM simulations were run for two typical electric multiple units (one suburban and one intercity train fleet) and a two-axle freight wagon. Additionally, it discusses the calibration methodology used to adjust the wear coefficients contained within the Archard wear model to improve the accuracy of the WPDM simulation results for specific routes and vehicle types. Furthermore, this paper presents the findings of a trial of economic tyre turning on a fleet of intercity trains. The analysis is extended to predict the effect of using economic tyre turning on rail rolling contact fatigue for typical routes and operating conditions using a series of vehicle dynamic simulations. The analysis considers new 56E1 and 60E2 rails together with a selection of worn wheel. The research provides valuable evidence to support a future change to the standards which will allow train operators/maintainers to implement economic tyre turning policies.

scholarly journals The effect of rolling contact fatigue mitigation measures on wheel wear and rail fatigue

Wear ◽  
2018 ◽  
Vol 398-399 ◽  
pp. 56-68 ◽  
Author(s):  
Ulrich Spangenberg ◽  
Robert Desmond Fröhling ◽  
Pieter Schalk Els
Keyword(s):  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Mitigation Measures ◽  
Wheel Wear ◽  
Fatigue Mitigation

The Effects of Wheelset Position and Operating Environment on Rolling Contact Fatigue

2008 ◽  
Author(s):  
Scott M. Cummings ◽  
Paul Krupowicz
Keyword(s):  
Environmental Factors ◽  
Impact Load ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Contact Forces ◽  
Rolling Contact ◽  
Minor Role ◽  
Operating Environment ◽  
Lead Position ◽  
Defect Prevention

The Wheel Defect Prevention Research Consortium (WDPRC) conducted analyses of wheel impact load detector (WILD) data to explore how wheelset position and operating environment affect rolling contact fatigue (RCF). The typical three-piece freight car truck used in North America produces higher tangential wheel/rail contact forces on the wheelset in the lead position than on the wheelset in the trail position of a truck as a car negotiates a curve. An analysis of WILD data shows that these higher forces are contributing to more shelling damage on wheelsets that are consistently in the lead position of a truck. Datasets in which the cars are frequently oriented with the A-end leading show the largest percentage of elevated WILD readings in the lead position of the lead truck (axle 4) followed by the lead position of the trail truck (axle 2). Likewise, datasets in which the cars are frequently oriented with the B-end leading show the largest percentage of elevated WILD readings in the lead position of the lead truck (axle 1) followed by the lead position of the trail truck (axle 3). Additionally, datasets in which there is an equal mix of car orientations show a much more evenly distributed location of elevated WILD readings. Another analysis of WILD data from five trainsets of nearly identical cars shows that any differences in wheel tread damage due to component differences are insignificant in comparison to the differences in wheel tread damage associated with environmental factors. While this analysis does not address component specification differences that could potentially have a large influence on shelling (such as M-976 trucks in comparison to standard trucks), it does show that environmental factors can play a large role in wheel tread damage. Car routing and loading characteristics were investigated as possible wheel damage factors. It appears that cars running on routes through terrain with longer, steeper grades may be prone to increased wheel shelling, probably due to thermal mechanical shelling (TMS). Side-to-side imbalanced loading appears to play a minor role in wheel shelling for two of the five trainsets.

scholarly journals Effect of Gas Nitriding on Interface Adhesion and Surface Damage of CL60 Railway Wheels under Rolling Contact Conditions

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 911
Author(s):  
Qiang Wu ◽  
Tao Qin ◽  
Mingxue Shen ◽  
Kangjie Rong ◽  
Guangyao Xiong ◽  
...  
Keyword(s):  
Wear Behavior ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Wheel Surface ◽  
Fatigue Wear ◽  
Material Loss ◽  
Surface Protection ◽  
Gas Nitriding ◽  
Railway Wheels

The influence of surface gas nitriding on wheel/rail rolling contact fatigue and wear behavior of CL60 wheel was studied on a new rolling contact fatigue/wear tester (JD-DRCF/M). The failure mechanisms of the wheel/rail surface after the gas nitriding and without gas nitriding on the wheel surface were compared and analyzed. The results show that the wheel with gas nitriding could form a dense and hard white bright layer which was approximately 25 μm thick and a diffusion layer which was approximately 70 μm thick on the wheel surface. Thus, the gas nitriding on the railway wheel not only significantly improved the wear resistance on the surface of the wheel, but also effectively reduced the wear of the rail; the results show that the material loss reduced by 58.05% and 10.77%, respectively. After the wheel surface was subjected to gas nitriding, the adhesive coefficient between the wheel/rail was reduced by 11.7% in dry conditions, and was reduced by 18.4% in water media, but even so, the wheel with gas nitriding still could keep a satisfactory adhesive coefficient between the wheel/rail systems, which can prevent the occurrence of phenomena such as wheel-slip. In short, the gas nitriding on the wheel surface can effectively reduce the wear, and improve the rolling contact fatigue resistance of the wheel/rail system. This study enlarges the application field of gas nitriding and provides a new method for the surface protection of railway wheels in heavy-duty transportation.

Impact of wheel profile evolution on wheel-rail dynamic interaction and surface initiated rolling contact fatigue in turnouts

Wear ◽  
2019 ◽  
Vol 438-439 ◽  
pp. 203109 ◽  
Author(s):  
Rong Chen ◽  
Jiayin Chen ◽  
Ping Wang ◽  
Jiasheng Fang ◽  
Jingmang Xu
Keyword(s):  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Dynamic Interaction ◽  
Rolling Contact ◽  
Wheel Profile

Thermal Effects on Wheel Performance Based on Twin Disc Testing

2020 ◽  
Author(s):  
Dingqing Li ◽  
Monique Stewart
Keyword(s):  
Thermal Effects ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Contact Forces ◽  
Rolling Contact ◽  
Test Machine ◽  
Testing Program ◽  
Different Types ◽  
Different Temperatures ◽  
Surface Performance

Abstract This paper presents the results and findings from a testing program conducted to investigate how temperature at the wheel-rail interface may affect wheel surface performance; i.e., development of rolling contact fatigue (RCF) and wear. Under this testing program, a twin disc test machine was used to test two different types of wheel specimens (cast and forged) under a range of temperatures (ambient to 800° F) and slip ratios from 0 to 0.75 percent. This testing program included a total of 32 tests, covering two wheel materials, four different temperatures, four slip ratios, and various traction coefficients as a ratio of longitudinal and vertical wheel/rail contact forces.

Influence of Track Properties on Railway Vehicles Wheel Rolling Contact Fatigue

2008 ◽  
Author(s):  
Mahdi Mehrgou ◽  
Asghar Nasr
Keyword(s):  
Rolling Contact Fatigue ◽  
Tangential Force ◽  
Contact Fatigue ◽  
Contact Forces ◽  
Rolling Contact ◽  
Vehicle Dynamic ◽  
Wheel Load ◽  
Wheel Rolling ◽  
Railway Passenger ◽  
Vehicle Dynamic Simulation

Track properties such as rail inclination, cant and gage width have significant effects on the shape and size of the contact area, actual rolling radius and also on the contact forces. These effects have an important role on rolling contact fatigue (RCF) which is known to be the main reason for large portion of wheel set failures and expenses. In this study the wheel/rail dynamic interaction of an Iranian railway passenger wagon under different track features are investigated through simulations using ADAMS\Rail commercial software. The calculated results regarding contact load data and contact properties of the wheel and rail are used for fatigue analysis to calculate RCF damage to the wheels using damage criteria based on previous studies. Two major parameters believed to have serious roles on RCF are the contact stress and the tangential force in the contact patch. These parameters are obtained from vehicle dynamic simulation studies. This paper describes and compares effects of different track geometries in curved and tangent tracks on RCF of three different wheel profiles S1002, P8 and IR1002. It is to identify which combinations of wheel load, wheel and rail profiles and vehicle dynamic characteristics cause RCF more severely.

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