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Current design process can be simplified and accelerated, if computer simulation based on finite element method (FEM) is used. FEM numerical calculations of different wheels of railway wheelsets are investigated in the Department of Railway Engineering. The justification for undertaking this issue is that there is no methodology in the design of railway wheelsets both in Poland and abroad. In order to assess the calculation model, experimental tests of static loads (due to carriage weight) and thermal loads (due to braking) have been run. The results of these tests have been compared with the results of numerical analysis. The proposed calculation model has been compared with the results of test stand investigation. Comparison of the results has confirmed the correctness of the proposed discrete model and calculation algorithm. In the framework of the common scientific-didactic projects of Railway Engineering Department and Central Rail Research Institute in Moscow and producer of railway wheelsets-BONATRANS a.s. in Bohumin (Czech Republic), the method was worked out, and the experimental researches were conducted on specialists certified stands for railway wheelset researches (Sitarz, M., Bizoń, K., and Chruzik, K. Numerical calculations reckonings of railway wheel sets. W: Scientific Proceedings of Riga Technical University, 2002, str 84-89, Sladkowski, A., Bizoń, K., and Chruzik, K. Porównanie wyników analizy MES z wynikami pomiarów tensometrycznych deformacji kól kolejowych zestawów kolowych, Zeszyty Naukowe Katedry Mechaniki Stosowanej nr 18/2002, Gliwice, 2002, str 397-402, Zima, R., Bizoń, K., Chruzik, K. Badania teoretyczne i eksperymentalne kól kolejowych zestawów kolowych, W: XLII Sympozjon ‘Modelowanie w mechanice’, Wisla, 2003).

This study investigates how current design processes for railway wheels can be simplified and accelerated if computer simulation based on finite element method (FEM) is used. The justification for undertaking this study is that there is no methodology in the design of railway wheelsets either in Poland or abroad; and that there is no way of optimizing wheelsets' construction characteristics depending on manufacturing process and service parameters. FEM numerical calculations of different wheels of railway wheelsets are investigated using 3 FEM software packages. The results of reduced stress obtained are compared with respect to mesh type and pattern, value-dependent stress distribution, wheel construction, degree of wear, and software used. The analysis of this problem has made possible: (a) the comparison of software used in strain calculation of railway wheelsets; (b) an elaboration of design methodology for railway wheelsets; (c) an increase in durability of railway wheelsets; (d) an increase in the safety of rail transport; and (e) a decrease in manufacturing and service costs of railway wheelsets. The findings show that mesh type and pattern have a great impact on temperature, displacement and stress fields values. Geometry of the wheel mesh and hub influence the distribution and values of the stresses. The analysis of the impact of the degree of wear on the distribution and values of the stresses shows that its influence is only significant in the case of loads due to braking. Results also demonstrate the importance of using the correct FEM model, with different software showing significant differences in the computation of temperature field caused by braking.