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.

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.

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.

Equilibrium of crack growth and wear rates during unlubricated rolling-sliding contact of pearlitic rail steel

2000 ◽  
Vol 214 (2) ◽  
pp. 93-105 ◽  
Author(s):  
D. I. Fletcher ◽  
J. H. Beynon
Keyword(s):  
Steady State ◽  
Crack Growth ◽  
Rail Steel ◽  
Fatigue Cracks ◽  
Rolling Contact Fatigue ◽  
Crack Depth ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Sliding Contact ◽  
Test Machine

It is generally accepted that large rolling contact fatigue cracks in rails do not develop during unlubricated rolling-sliding contact, and damage under these conditions is restricted to wear of the rail steel. However, close examination of a worn rail steel surface reveals the presence of a multitude of wear flakes, the roots of which closely resemble shallow rolling contact fatigue cracks. Experiments have been conducted under unlubricated rolling-sliding conditions to examine the early development of flakes, or cracks, using a laboratory-based, twin-disc test machine to simulate the contact pressure and slip characteristic of the contact between a rail and a locomotive driving wheel. Small defects were found after as few as 125 unlubricated contact cycles. It was found that an equilibrium between crack growth rate and surface wear rate was established after approximately 10 000 cycles, leading to a shallow steady state crack depth. Initial crack growth by ratchetting (accumulation of unidirectional plastic strain until the critical failure strain of the material is reached), followed by shear stress-driven crack growth described by fracture mechanics, was found to be a sequence of mechanisms in qualitative agreement with the observed crack growth and steady state crack depth.

Rail RCF and the Effects of Different Wheel Profiles

2008 ◽  
Author(s):  
Mehdi Mehrgou ◽  
Asghar Nasr
Keyword(s):  
Dynamic Simulation ◽  
Rolling Contact Fatigue ◽  
Tangential Force ◽  
Contact Fatigue ◽  
Simulation Software ◽  
Contact Forces ◽  
Rolling Contact ◽  
Dynamic Interactions ◽  
Railway Passenger ◽  
Vehicle Dynamic Simulation

Wheel lateral profile has considerable effects on the wheel/rail dynamic interactions such as the shape and size of the contact area, instantaneous rolling radius and contact forces. Theses themselves have indirectly important roles on the rolling contact fatigue (RCF) which is known to be the main reason for large portion of rail maintenance costs. In this study the wheel/rail dynamic interaction of an Iranian railway passenger wagon under three different wheel profiles are investigated using ADAMS\Rail commercial simulation software. The dynamic simulation results regarding contact load and contact features of the wheel and rail are used for fatigue analysis to calculate RCF damage to the rail using reliable damage criteria reported in the literature. The two major parameters having serious roles on the RCF are believed to be the contact stress and the tangential force at the contact patch. These parameters are obtained from vehicle dynamic simulation studies. This paper describes and compares the effects of three different wheel profiles known as S1002, P8 and IR1002 on the rail RCF in both the curved and tangent sections of a track. The primary results clearly identify the effects of wheel profile on the RCF.

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.

Tribological Prototype for Wear Tests on Pavement Surfaces

2014 ◽  
Vol 902 ◽  
pp. 121-128
Author(s):  
E.E. Vera Cardenas ◽  
F. González Hernández ◽  
M.A. Flores Rentería
Keyword(s):  
Computer Aided Design ◽  
Quality Function Deployment ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Test Machine ◽  
Element Analysis ◽  
Computer Aided ◽  
Static Conditions ◽  
Aided Design

In this work the design and manufacturing of a new test machine to simulate the Rolling Contact Fatigue (RCF) wear on pavement surfaces is carried out. The method of Quality Function Deployment (QFD) was used to determine the conceptual design of the machine; from this a detailed design of the machine was developed, through additional computer aided design software. The machine basically consists of a frame and two mechanisms; one is for transmitting the force and the other one the motion. The static conditions were calculated and a finite element analysis was performed by computer aided engineer software to determine the failure due to mechanical stresses. Finally it is showed the machine assembly and some preliminary tests in order to verify the performance of the tribological prototype.

scholarly journals Modelling of Frictional Conditions in the Wheel–Rail Interface Due to Application of Top-of-Rail Products

Lubricants ◽  
2021 ◽  
Vol 9 (10) ◽  
pp. 100
Author(s):  
Gerald Trummer ◽  
Zing Siang Lee ◽  
Roger Lewis ◽  
Klaus Six
Keyword(s):  
Simulation Model ◽  
Coefficient Of Friction ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Operating Conditions ◽  
Contact Forces ◽  
Rolling Contact ◽  
Application Site ◽  
Small Scale ◽  
The Coefficient Of Friction

The coefficient of friction between a wheel tread and the top of the rail should be maintained at intermediate levels to limit frictional tangential contact forces. This can be achieved by applying top-of-rail products. Reducing the coefficient of friction to intermediate levels reduces energy consumption and fuel costs, as well as damage to the wheel and rail surfaces, such as, e.g., wear, rolling contact fatigue, and corrugation. This work describes a simulation model that predicts the evolution of the coefficient of friction as a function of the number of wheel passes and the distance from the application site for wayside application of top-of-rail products. The model considers the interplay of three mechanisms, namely the pick-up of product by the wheel at the application site, the repeated transfer of the product between the wheel and rail surfaces, and the product consumption. The model has been parameterized with data from small-scale twin disc rig experiments and full-scale wheel–rail rig experiments. Systematic investigations of the model behaviour for a railway operating scenario show that all three mechanisms may limit the achievable carry-on distance of the product. The developed simulation model assists in understanding the interplay of the mechanisms that govern the evolution of the coefficient of friction in the field. It may aid in finding optimal product application strategies with respect to application position, application amount, and application pattern depending on specific railway operating conditions.

scholarly journals Investigation on Wheel-Rail Contact and Damage Behavior in a Flange Bearing Frog with Explicit Finite Element Method

2019 ◽  
Vol 2019 ◽  
pp. 1-17
Author(s):  
Yuan Gao ◽  
Ping Wang ◽  
Yibin Liu ◽  
Jingmang Xu ◽  
Zhiguo Dong ◽  
...  
Keyword(s):  
Finite Element ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Numerical Procedure ◽  
Contact Forces ◽  
Rolling Contact ◽  
Fe Model ◽  
Wheel Load ◽  
Explicit Finite Element ◽  
Contact Behavior

Flange bearing frogs are designed to provide continuous rolling surfaces for trains traveling on the through line, but the interaction between wheel and rail in a diverging line is more complex than that for a common crossing, especially including flange bearing mode and multipoint contact during the transition. The wheel load will be transited from tread to flange and back to tread, which will intensify the wheel-rail interaction. In this paper, a numerical procedure is presented for the analysis of wheel-rail rolling contact behavior and damage prediction for the flange bearing frog. The three-dimensional explicit finite element (FE) model of a wheel passing the flange bearing frog is established to obtain the dynamic wheel-rail interaction in both the facing and the trailing move. The evolution of contact forces, the distribution of adhesion-slip regions, and shear surface stress and microslip at the contact patch are revealed. Then, the competition relationship between RCF (rolling contact fatigue) and wear of a flange bearing frog is analyzed. The results of numerical simulations can contribute to an understanding of the mechanism of the transient rolling contact behavior and provide guidance in design optimization for flange bearing frogs.

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