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This paper studies the evolvement of the wear irregularity of contact wire using wire thickness data measured yearly from a section of railway catenary. The power spectral density and time-frequency representation based on the wavelet transform are employed for data analysis, with an emphasis on local wear irregularities that are crucial for contact wire condition assessment. To investigate the cause of wear irregularity evolvement and the mutual influence with the pantograph-catenary dynamic interaction, simulations considering the influence of wear irregularity are carried out based on the finite element method. Analyses of the actual wear irregularities and the dynamic contact force under singular and complex wear irregularities are performed. Although the wear irregularity has limited impact on the pantograph-catenary interaction, it can induce the vibration of pantograph and contact wire that will lead to a notable increase of contact force standard deviation. The evolvement of wear irregularity is closely associated with the span length and dropper distribution of catenary structure and the running direction of pantograph. In addition, it is found feasible to detect the wear irregularity based on contact force, on condition that the sampling frequency is high enough to reflect the indicative frequencies. [ABSTRACT FROM AUTHOR]

A three-dimensional (3D) finite element (FE) dynamic frictional rolling contact model is presented for the study of short pitch corrugation that considers direct and instantaneous coupling between the contact mechanics and the structural dynamics in a vehicle-track system. In this study, we examine the system responses in terms of vibration modes, contact forces and the resulting wear with smooth rail and corrugated rail with progressively increasing amplitude to infer the conditions for consistent corrugation initiation and growth. Wear is assumed to be the damage mechanism, and short pitch corrugation is modeled using wavelengths from field observations of a Dutch railway. The contribution of this paper is a global perspective of the consistency conditions that govern the evolution of short pitch corrugation. The main insights are as follows: (1) the longitudinal vibration modes are probably dominant for short pitch corrugation initiation; (2) during short pitch corrugation evolution, the interaction and consistency between longitudinal and vertical modes should determine the development of short pitch corrugation, and once a certain severity is reached, vertical modes become dominant; and (3) in the case simulated in this paper, corrugation does not grow probably due to not only the different resulting main frequencies of the vertical and longitudinal contact forces, but also the inconsistency between the frequencies of the vertical and longitudinal vibration modes and the resulting wear. It is inferred that in the continuous process of initiation and growth of the corrugation, there should be a consistency between them, and this could be done by the control of certain track parameters. [ABSTRACT FROM AUTHOR]

Spin in frictional rolling contact can cause significant stress, which is the key to understanding and predicting the wear and fatigue behavior of contact components, such as wheels, rails, and rolling bearings. The lateral creep force arising from spin influences the kinematics of a wheelset and thus of vehicles. The solution that is currently employed in the field of elasticity and continuum statics was developed by Kalker and uses a boundary element method (BEM). In this paper, a new approach based on Lagrangian explicit finite element (FE) analysis is employed. This approach is able to consider arbitrary geometric profiles of rails and wheels, complex material behavior and dynamic effects, and some other factors. The new approach is demonstrated using a three-dimensional (3D) model of a wheel with a coned profile rolling along a quarter cylinder and can be easily adapted to apply to wheels and rails of arbitrary profiles. The 3D FE model is configured with elastic material properties and is used to obtain both normal and tangential solutions. The results are compared with those of the Hertz theory and the Kalker's model. The 3D FE model is then configured with elastoplastic material properties to study the spin-rolling contact with plasticity. The continuum dynamics phenomenon is captured by the FE model, which enhances the ability of the model to mimic reality. This improvement considerably extends the applicability of the FE model. The model can be applied to fatigue and wear analyses at gauge corners or rails as well as to deep groove bearings, where a large geometrical spin is present and plastic deformation may be of importance. [ABSTRACT FROM AUTHOR]

The squat, a kind of rolling contact fatigue occurring on the rail top, can excite the high-frequency vehicle–track interaction effectively due to its geometric deviations with a typical wavelength of 20–40 mm, leading to the accelerated deterioration of a track. In this work, a validated 3D transient finite element model is employed to calculate in the time domain the vertical and the longitudinal dynamic contact forces between the wheel and the rail caused by squats. The vehicle–track structure and the wheel–rail continua are both considered in order to include all the important eigencharacteristics of the system related to squats. By introducing the rotational and translational movements of the wheel, the transient wheel–rail rolling contact is solved in detail by a 3D frictional contact model integrated. The contact filter effect is considered automatically in the simulations by the finite size of the contact patch. The present work focuses on the influences of the length, width and depth of a light squat on the resulted dynamic contact forces, for which idealised defect models are used. The growth of a squat is also modelled to a certain extent by a series of defects with different dimensions. The results show that the system is mainly excited at two frequencies separately in the vertical and the longitudinal dynamics. Their superposition explains the typical appearance of mature squats. As a squat grows up, the magnitude of the excited vibration at the lower frequency increases faster than the one at the higher frequency. [ABSTRACT FROM AUTHOR]

Squats have become a major problem in the track of many railways. In the quest for the root causes of squats, it is observed that they are occasionally found at locations of track stiffness changes such as at fish-plated insulated joints and at switches and crossings. Obviously, there should be other factors in the track, which, together with the stiffness change, have played important roles otherwise there will be squats at all such locations. A validated hybrid multibody-finite element model of vehicle-track vertical interaction is extended to simulate the frictional dynamic rolling contact at a fish-plated insulated joint in order to identify such factors. Elastic-plastic rail material property is taken into account. It is found that it is track short defect in the preload condition of the bolts and the contact between the fishplates and the rail head, which together with the stiffness change, causes large normal and longitudinal contact force variation at the fishplate end so that differential wear and differential plastic deformation may accumulate at a fixed location. With proper wavelength, the accumulated rail top geometry deviation may grow into a squat. The significance of the present work lies in that other track short defects such as damaged and improper railpads and fastening, and ballast voids may also have such effects, which may be responsible for a large portion of the many squats in the tracks. This gives the direction for further work. [ABSTRACT FROM AUTHOR]

This paper presents an analysis of the transient contact solutions of wheel-rail frictional rolling impacts calculated by an explicit finite element model of the wheel-insulated rail joint (IRJ) dynamic interaction. The ability of the model to simulate the dynamic behavior of an IRJ has been validated against a comprehensive field measurement in a recent paper (Yang et al., 2018). In addition to the measured railhead geometry and bi-linear elastoplastic material model used in Yang et al. (2018), this study adopts a nominal railhead geometry and an elastic material model for the simulations to provide an overall understanding of the transient contact behavior of wheel-IRJ impacts. Each simulation calculates the evolution of the contact patch area, stress magnitude and direction, micro-slip distribution, and railhead nodal vibration velocity in the vicinity of the joint during the wheel-IRJ impacts. The simulations apply small computational and output time steps to capture the high-frequency dynamic effects at the wheel-IRJ impact contact. Regular wave patterns that indicate wave generation, propagation and reflection are produced by the simulations; this has rarely been reported in previous research. The simulated waves reflect continuum vibrations excited by wheel-rail frictional rolling and indicate that the simulated impact contact solutions are reliable. [ABSTRACT FROM AUTHOR]

By considering real wheel and track geometry and structures, as well as their coupled interaction, an explicit finite element method is applied to simulate the transition of wheel–rail rolling from single-point tread contact to two-point tread-flange contact. The evolutions of the contact position, stress magnitude and direction, adhesion–slip distribution, and wheel–rail relative velocities in the two contact patches are considered to investigate the transient dynamic effects during the contact transition. Important findings include that the transition to two-point contact can result in friction saturation and excite waves in the contact, causing local intensification and relaxation of compression, as well as turbulence of the micro-slip; the local relative velocity in the contact patch is a good measure of the dynamic effects. [ABSTRACT FROM AUTHOR]

Polygonal wear is a type of damage commonly observed on the railway wheel tread. It induces wheel-rail impacts and consequent train/track components failure. This study presents a finite element (FE) thermomechanical wheel-rail contact model, which is able to cope with the three possible generation and development mechanisms of polygonal wear: initial defects, thermal effect, and structural dynamics. The polygonal wear-induced impact contact and further development of wear are simulated. The simulated elastic contact solutions are verified against the program CONTACT. Different material properties (elastic, elasto-plastic and elasto-plastic-thermo, i.e. with thermal softening) and initial polygonal profiles are then applied to the FE model to investigate the influence of wheel/rail material and wear amplitude on wheel-rail contact stress and wear development. The simulations indicate that the wheel-rail impact-induced temperature may reach up to 362 ℃ at the contact interface, and the high temperature at the contact area influences wheel-rail contact stress and wear depth. • An innovative thermomechanical FE model is presented to study polygonal wear growth. • The simulated contact solutions are verified against the program CONTACT. • Using elastic material models causes overestimation of contact stress and wear depth. • Incorporating thermal effects is crucial for wear predication with high slip ratio. • The simulated contact temperature reaches up to 362 ℃ at the wheel-rail interface. [ABSTRACT FROM AUTHOR]

Abstract: Short track defects cause large dynamic contact forces at the wheel–rail interface, leading to fast deterioration of the track. Early detection of such defects is very important for timely maintenance. The track technical state can be assessed with the aid of axle box acceleration measurements, which can indicate short track defects like squats, welds with poor finishing quality, insulated joints, corrugation, etc. As a first attempt to determine a quantitative relationship between the characteristics of the accelerations and the track defects, axle box acceleration at a squat and a thermite weld were simulated through finite-element modeling. The magnitude and frequency contents of axle box acceleration at squats agreed with measurements. The results for welds had some discrepancies, which were mainly attributed to the fact that the modeled geometry of the weld deviated from the real one. [Copyright &y& Elsevier]

In this paper, we present a method for evaluating the performance of railway crossing rails after long-term service. The method includes 1) 3D profile and hardness measurements; 2) finite element simulation of wheel/rail interaction; and 3) numerical prediction of rail degradation. We conducted a case study on a crossing that had been in service for several years. The results indicate that the crossing experienced a run-in process in the major traffic direction, manifested as a widening of the running band, an enlargement of the contact patch size, a decrease in contact stress and eventually a reduction in plastic deformation and wear. However, the wheel/rail interaction was exacerbated in the minor traffic direction which induced more severe plastic deformation and wear. [ABSTRACT FROM AUTHOR]

As essential track components for rail connections and signal transmission and control, insulated rail joints (IRJs) have been widely used in traditional and high-speed railways. However, the IRJ is considered as one of the weakest parts of railway track structures due to the significant discontinuities in stiffness and geometry. When a train runs over an IRJ, a wheel-rail impact occurs and it increases with train speed. The impact consequently leads to vibration and noise and accelerates track deterioration in the vicinity of the IRJ. This paper establishes an explicit finite element wheel-IRJ dynamic interaction model to simulate high-frequency impact vibration and noise generated at a typical IRJ in the Dutch railway network, and validates the model against a comprehensive hammer test and a pass-by measurement. Good agreements between the simulation and measurements indicate that the proposed model can effectively reproduce high-frequency impact vibration and noise up to 10 kHz. This paper also connects the dominant frequencies of wheel-IRJ impact vibration and noise with the dynamic behaviour of the target IRJ, which may contribute to the mitigation of impact vibration and noise at IRJs as well as to train-borne detection of deterioration types of IRJs. [ABSTRACT FROM AUTHOR]

This research presents a coupled thermomechanical modelling procedure for the wheel-rail contact problem and computes the flash-temperature and stress-strain responses when thermal effects are present. A three-dimensional elasto-plastic finite element model was built considering the wheel-track interaction. When the wheel is running on rail, frictional energy is generated and converted into heat. To evaluate the contribution of thermal effects and plasticity, five different material models were studied among them TEPS was nonlinear and temperature-dependent including thermal softening. Discussions were made on the effect of solution type and material type. The rail temperature, calculated for a critical creepage case, confirmed the potential of martensitic phase transformation. Thermal effects were also important at lower creepages, where a synchronization effect causes earlier damage. [ABSTRACT FROM AUTHOR]

The half-space assumption has been employed in many solution methods for non-conforming contact problems in elasticity such as the Hertz theory and the Kalker's variational theory. It is generally believed that to guarantee acceptable accuracy in these half-space-based methods, the characteristic size (twice length of one semi-axis) of the contact patch should be much smaller than the significant dimensions (i.e. the height, width, length and the principal radii of curvature) of each body in contact. In engineering practice, the 3x rule is often employed, which requires that the significant dimensions be at least three times as large as the characteristic size. However, this requirement has not been justified. In this paper, the applicability of half-space-based methods is investigated by comparing the solutions obtained using the Hertz theory and the Kalker's theory with those of the Finite Element (FE) method which is not limited to the half-space assumption. Different combinations of significant dimensions in terms of height, width and length are studied. Various contact patch eccentricities and contact body shapes are considered. It is found that the half-space-based methods yield high-accuracy calculation for non-conforming contact problems. Even when the significant dimensions are as small as 1.1x the characteristic size, the differences between the solutions of the half-space-based methods and the FE method are within 9%. The findings of this paper indicate that the typically assumed 3x restriction can be greatly relaxed. Since a clear estimation of the deviation of the results of half-space-based methods from those of the FE method is provided, the applicability of half-space-based methods in mechanical engineering can be much better understood. [ABSTRACT FROM AUTHOR]

Squats are associated with high frequency vibrations of the wheel-rail system and can be registered using axle box acceleration (ABA) measurements. In this paper a three-dimensional finite-element (FE) model is proposed to capture the dynamic features of the ABA related to squats in the high frequency range. The FE model is validated relying on a set of real-life ABA measurements at two characteristic rail surface defects (light and severe squats), located in a section of the railway network in Assen. The Netherlands. The FE model managed to properly capture the dynamic features in the range of frequencies up to 2000 Hz. [ABSTRACT FROM AUTHOR]

Abstract: Nowadays squats are a severe rolling contact problem on some railways. The root causes of it are not yet clear. From railway operation and maintenance points of view, root causes have to be known so that effective maintenance policies and plans can be made based on measurements and prediction. In the present work first a correlation analysis is performed based on measured data and field observations, and then a relation between squat occurrence and some parameters of the vehicle–track system is identified. Subsequently a transient finite element model of vehicle–track interaction is built up to analyze the contact forces and the resulting stresses and strains. The numerical results show good correspondence with observed phenomena at squats, and suggest certain relation between squat development and some eigen frequencies of the coupled vehicle–track system. A squat growth process is accordingly postulated. [Copyright &y& Elsevier]

This study evaluates the degradation of wheels and rails at railway crossings. The evaluation method is composed of 1) finite element simulation of dynamic wheel/crossing interaction and 2) multi-criteria analysis of wheel/rail degradation in terms of yield behavior, rolling contact fatigue (RCF) and wear. With the aid of this method, we conducted a case study identifying the proper yield strength of rail steel material for a 54E1-1:9 crossing under a specified traffic condition. The case study indicates that the wear of contact bodies is more sensitive to train speed compared with yield and RCF; the increase of rail yield strength suppresses rail degradation while exacerbating wheel degradation; and rail yield strength in the range of 500–600 MPa is preferred to achieve a good trade-off between the wheel and rail degradations. • A method is proposed to evaluate the degradation of wheels and rails at railway crossings. • The method uses finite element simulation and multi-criteria analysis. • Wheel/rail degradation is evaluated in terms of yield behavior, rolling contact fatigue (RCF) and wear. • A case study is conducted to identify the proper yield strength of rail steel material for a 54E1-1:9 crossing. [ABSTRACT FROM AUTHOR]