The Gautrain Rapid Rail Link (GRRL) is a rail transit system in South Africa that links Johannesburg and Pretoria, as well as Johannesburg and the O.R. Tambo International Airport. Travelling at speeds of up to 160 km/h, the Gautrain system is the first of its kind on the African continent. This dissertation covers an investigation into the relationship between the vertical and lateral forces, speed and superelevation in a GRRL curve. The research described in this dissertation is based on an experiment which involved running a test train through a curve at various speeds, changing the cant of the curve by tamping and repeating the train runs. The cant was changed due to high wheel wear rates. The curve already had a cant deficiency, and this cant deficiency was subsequently increased by reducing the curve’s cant. Assessing the before and after tamping test data validated the existence of the expected relationships between the vertical and lateral rail forces, the speed and the cant. The change in cant had a minimal effect on the magnitude of the vertical forces, although a transfer of loading between the high and low legs did occur. The theory indicates that the 14 % reduction in cant in this curve given all of the other curve characteristics should have resulted in an increase in the lateral forces. There was however a roughly 50 % reduction in the maximum lateral forces after the cant was reduced that can be explained from a train dynamics point of view. In addition, there was an increase in safety due to a reduced derailment ratio at this curve’s normal operating speed of 85 km/h. It is not unreasonable to presume that a 50 % reduction in the maximum lateral forces could lead to a halving of the wear rate of the rail and wheels in this curve with similar results to be expected in other curves on the rail network. / Dissertation (MEng)--University of Pretoria, 2016. / The Chair in Railway Engineering at the University of Pretoria / Civil Engineering / MEng / Unrestricted

Heavy haul railway operations permit the transport of huge volumes at lower cost than other modes of transport. The low cost can only be sustained if the maintenance costs associated with such railway operations are minimised. The maintenance costs are mainly driven by wheel and rail damage in the form of wear and rolling contact fatigue (RCF). Low wear rates in the wheel-rail interface have resulted in an increase in the prevalence of rail RCF, thereby increasing rail maintenance costs. The aim of this study is to develop an approach to reduce rail RCF on South Africa’s iron ore export line by managing the worn wheel shape. This approach is developed by evaluating wheel and rail profile shapes that contribute the most to RCF initiation, studying the influence of suspension stiffness and rail profile changes as well as a redesign of the wheel profile. The influence of wheel and rail profile shape features on the initiation of rolling contact fatigue (RCF) cracks was evaluated based on the results of multibody vehicle dynamics simulations. The damage index and surface fatigue index were used as two damage parameters to assess the influence of the different features. The damage parameters showed good agreement to one another and to in-field observations. The wheel and rail profile shape features showed a correlation to the predicted RCF damage. The RCF damage proved to be most sensitive to the position of hollow wear and thus bogie tracking. RCF initiation and crack growth can be reduced by eliminating unwanted shape features through maintenance and design and by improving bogie tracking. Two potential mitigation measures had been adapted from those published in literature to reduce RCF. The mitigation measures involved changes in suspension stiffness to spread wheel wear across the tread and the use of gauge corner relief rail profiles. These mitigation measures were evaluated by means of multibody dynamics and wear maintenance costs. These mitigation measures, however, did not prove to be successful in reducing RCF initiation while maintaining a low wheel wear rate. The current operating conditions on South Africa’s iron ore line, although still not optimal overall, were found to be better in terms of their wear and RCF performance than the two proposed RCF mitigation measures. Based on the finding of the study on two RCF mitigation measures it was recommended that a conformal wheel profile be developed to spread the wheel wear across the tread to reduce the occurrence and propagation of RCF cracks, while still maintaining low wheel wear rates. A comparative study of this new wheel profile design and the current wheel profile design was therefore performed using multibody dynamics simulation together with numerical wheel wear and RCF predictions. The advantages of the conformal wheel profile design were illustrated by evaluating the worn shape and resulting kinematic behaviour of the conformal design. The conformal design had a steadier equivalent conicity progression and a smaller conicity range compared with the current wheel profile design over the wheel’s wear life. The combination of a conformal wheel profile design with 2 mm hollow wear and inadequate adherence to grinding tolerances often result in two-point contact, thereby increasing the probability of RCF initiation. The conformal wheel profile design was shown to have many wear and RCF benefits compared with the current wheel profile design. However, implementation of such a conformal wheel profile must be accompanied by improved rail grinding practices to ensure rail profile compliance. Based on these findings an approach is proposed where the conformal wheel profile design together with improved compliance of the in-service rail profiles to the target rail profile are implemented. This has the potential to reduce RCF initiation on South Africa’s iron ore export line. / Thesis (PhD)--University of Pretoria, 2017. / Mechanical and Aeronautical Engineering / PhD / Unrestricted

This study provides a detailed experimental evaluation of wheel-rail interaction for railroad vehicles, using the Virginia Tech Federal Railroad Administration (VT-FRA) Roller Rig. Various contact dynamics that emulate field application of railroad wheels on tracks are set up on the rig under precise, highly-controlled and repeatable conditions. For each setup, the longitudinal and lateral traction (creep) forces are measured for different percent creepages, wheel loads, and angles of attack. The tests are performed using quarter-scaled wheels with different profiles, one cylindrical and the other AAR-1B with a 1:20 taper. Beyond the contact forces, the wheel wear and the deposition of worn materials are measured and estimated as a function of time using a micron-precision laser optics measurement device. The change in traction versus amount of worn material at the contact surface is analyzed and related to wheel-rail friction. It is determined that the accumulation of the worn material at the contact surface, which appears as a fine gray powder, acts as a friction modifier that increases friction. The friction (traction) increase occurs asymptotically. Initially, it increases rapidly with time (and worn material accumulation) and eventually reaches a plateau that defines the maximum friction (traction) at a stable rate. It is estimated that the maximum is reached when the running surface is saturated with the worn material. Prior to the saturation, the friction increases directly with an increasing amount of deposited material. The material that accumulates naturally at the surface—hence, referred to as "natural third-body layer"—is estimated to be a ferrous oxide. It has an opposite effect from the Top of Rail (ToR) friction modifiers that are deposited onto the rail surface to reduce friction in a controlled manner. Additionally, the results of the study indicate that longitudinal traction decreases nonlinearly with increasing angle of attack (AoA), while lateral traction increases, also nonlinearly. The AoA is varied from -2.0 to 2.0 degrees, representing a right- and left-hand curve. Lateral traction increases at a high rate with increasing AoA between 0.0 – 0.5 degrees, and increases at a slow rate beyond 0.5 degree. Similarly, longitudinal traction reduces at a high rate for smaller AoA and at a slower rate for larger AoA. For the tapered wheel, an offset in lateral forces is observed for a right-hand curve versus a left-hand curve. The wheel taper generates a lateral traction that is present at all times. In one direction, it adds to the lateral traction due to the AoA, while in the opposite direction, it subtracts from it, resulting in unequal lateral traction for the same AoA in a right-hand versus a left-hand curve. The change in traction with changing wheel load is nearly linear under steady state conditions. Increasing the wheel load increases both longitudinal and lateral tractions linearly. This is attributed to the friction-like behavior of longitudinal and lateral tractions. An attempt is made to measure the contact shape with wheel load using pressure-sensitive films with various degrees of sensitivity. Additionally, the mathematical modeling of the wheel-roller contact in both pure steel-to-steel contact and in the presence of pressure-sensitive films is presented. The modeling results are in good agreement with the measurements, indicating that the pressure-sensitive films have a measurable effect on the shape and contact patch pressure distribution, as compared with steel-to-steel. / Doctor of Philosophy / This study provides a detailed experimental evaluation of wheel-rail interaction for railroad vehicles, using the Virginia Tech Federal Railroad Administration (VT-FRA) Roller Rig. Better understanding the dynamics and mechanics of wheel-rail interaction would significantly contribute to the development of technologies, materials, and operational methods that can further improve fuel efficiency, and reduce wheel and rail wear. Considering that the railroads are the backbone of cargo and passenger transportation and are critical to economic well-being, the results of this study are expected to contribute to the betterment of society. An attempt is made to emulate the field application of railroad wheels on tracks on the rig under precise, highly-controlled and repeatable conditions. For each set up, the contact forces are measured for different parameters, such as wheel loads. Beyond the contact forces, the wheel profile degradation and the deposition of worn materials are measured and estimated as a function of time using a micron-precision laser optics measurement device. It is determined that the accumulation of the worn material at the contact surface, which appears as a fine gray powder, increases contact forces. The effect of wheel load on contact forces is almost linear. Additionally, the results of the study indicate that the yaw angle between the wheel and the roller (AoA) changes the contact forces direction, which has a higher rate of change for a small AoA such as 0.0 – 0.5 degrees, compared to a larger AoA. An attempt is made to measure the contact shape with wheel load and AoA using pressure-sensitive films with various degrees of sensitivity. Additionally, the mathematical modeling of the wheel-roller contact in both pure steel-steel contact and in the presence of pressure-sensitive films is presented. As expected, both the model and test result indicate that the presence of a film at the contact surface changes both the dimensions and pressure distribution at the contact patch. Quantifying the distortion that occurs as a result of the pressure-sensitive film allows for a better assessment of the pressure distribution measurements that are made with the films in order to potentially discount the resulting distortions.

Road vehicle tyres, railway wheels and ball bearings all generate rolling contact forces which are transferred within a finite area of contact between the rolling element and the substrate. Either it is visible or not for the human eye, a certain degree of roughness is always present on the contacting surfaces and it influences the generation of both vertical and lateral contactforces. The purpose of this investigation is to enhance the understanding and modelling of the influence from small-scale surface roughness on the generation of rolling contact forces. To this end, a computationally efficient method to include roughness-induced contact nonlinearities in the dynamic modelling of rolling contacts is proposed. The method is implemented in a time domain model for vertical wheel–track interaction to model rolling-induced rail vibrations, showing good agreement with measurements. Furthermore, a test rig is developed and used for the investigation of tyre–road rolling contact forces. Detailed studies are performed on the influence of substrate roughness on the resulting contact forces for a tyre tread block which is rolling at different operating conditions. The choice of substrate as well as the rolling velocity and the slip ratio is observed to have significant influence on the resulting friction coefficient. For high slip ratios, stick–slip oscillations appear, exhibiting frequency content which is largely dependent on the choice of substrate. The outcomes of this study can potentially be used to improve future tyre–road contacts with respect to wear, traction and noise generation. / <p>QC 20161013</p> / Centre for Eco2 Vehicle Design

Tesis por compendio / [ES] El ruido de rodadura de vehículos ferroviarios presenta importantes desafíos en entornos urbanos y suburbanos, siendo precisa una comprensión integral de sus mecanismos subyacentes para una mitigación efectiva. Esta Tesis ofrece una investigación exhaustiva sobre la generación de ruido de rodadura, tanto en vías rectas como curvas, a través del desarrollo de modelos avanzados de alta frecuencia y herramientas de cálculo para una rigurosa predicción de niveles de ruido. El ruido de rodadura surge de la interacción entre las ruedas y los carriles en presencia de imperfecciones en sus superficies de contacto. Los principales componentes ferroviarios que contribuyen a la emisión acústica son las traviesas, los carriles y las ruedas. Las traviesas y los carriles están conectados por medio de las placas de asiento, mientras que las ruedas y los carriles están dinámicamente acoplados a través de su contacto. En consecuencia, cambios en cualquier componente pueden afectar al comportamiento dinámico y acústico del resto, subrayando la necesidad de un modelo integral para abordar eficazmente la radiación por ruido de rodadura. En esta Tesis se exploran y desarrollan diferentes modelos dinámicos de la vía y del eje montado. La vía, que se asume infinita, se describe utilizando la teoría de estructuras periódicas y se caracteriza por sus números y formas de onda. El eje montado se modeliza mediante el Método de Elementos Finitos y se caracteriza por sus frecuencias naturales y modos de vibración. La interacción rueda/carril se describe como una relación linealizada entre el movimiento relativo de ambos componentes y las fuerzas de contacto. Cabe indicar que los modelos explorados en este trabajo están formulados en el dominio de la frecuencia. Asimismo, se realiza un estudio de influencia del diseño de la vía en la radiación por ruido de rodadura, cuantificando los parámetros contribuyentes a la emisión acústica mediante técnicas estadísticas. Los resultados apuntan a que la geometría del carril tiene un impacto limitado en la radiación, mientras que las propiedades viscoelásticas de la vía, en particular la rigidez de la placa de asiento, desempeñan un papel fundamental en la generación de ruido. Es remarcable que, entre los distintos diseños, se han encontrado variaciones de hasta 7,4 dB(A) en la radiación acústica. Durante el desarrollo de esta investigación, se ha prestado atención al modelizado del eje montado. Su rotación se incluye usando coordenadas Eulerianas, lo que resulta un enfoque conveniente ya que el punto de contacto de la rueda con el carril permanece en una posición espacial constante. Dada la simetría axial de su geometría, la respuesta dinámica del eje montado se expande a lo largo de la dirección circunferencial mediante series de Fourier, lo que permite formular el comportamiento dinámico y acústico de este cuerpo tridimensional (3D) en un marco bidimensional (2D), resolviendo analíticamente la coordenada circunferencial. Esta metodología ofrece sin pérdida de generalidad una reducción del tiempo de cálculo computacional, lo que hace que el modelo sea idóneo para su integración en algoritmos de optimización. Por último, se realiza una investigación pionera sobre el ruido de rodadura cuando el vehículo negocia una curva. Si bien la curva está generalmente asociada con el ruido por chirridos, esta Tesis explora y confirma la importancia que también tiene el ruido de rodadura en estas condiciones. Para ello, se modelizan los efectos inerciales y giroscópicos que sufre un eje montado al describir una trayectoria curva. Además, diferentes fenómenos complejos que ocurren en el contacto rueda/carril, como por ejemplo el movimiento relativo entre estos elementos, se incorporan en el modelo de interacción. Los resultados indican que la posición del contacto rueda/carril sirve como un buen indicador del impacto que la negociación de una curva tiene en el ruido de rodadura. / [CA] El soroll de rodament de vehicles ferroviaris presenta importants reptes en entorns urbans i suburbans, requerint una comprensió integral dels seus mecanismes subjacents per a una mitigació efectiva. Aquesta Tesi ofereix una investigació exhaustiva sobre la generació de soroll de rodament, tant en vies rectes com corbes, mitjançant el desenvolupament de models avançats d'alta freqüència i eines de càlcul per a la rigorosa predicció dels nivells de soroll radiat. El soroll de rodament sorgeix de la interacció entre les rodes i els carrils en presència d'imperfeccions en les seues superfícies de contacte. Els principals components ferroviaris que contribueixen a l'emissió acústica són les travesses, els carrils i les rodes. Les travesses i els carrils estan connectats a través de les plaques d'assentament, mentre que les rodes i els carrils estan acoblats mitjançant la seua interacció. En conseqüència, canvis en qualsevol component poden afectar al comportament dinàmic i acústic de la resta, subratllant la necessitat d'un model integral. En aquesta Tesi s'exploren i desenvolupen diversos models dinàmics de la via i de l'eix muntat. La via, que es considera infinita, es descriu utilitzant la teoria d'estructures periòdiques i es caracteritza pels seus números i formes d'ona. L'eix muntat es modelitza mitjançant el Mètode d'Elements Finits i es caracteritza per les seues freqüències naturals i modes de vibració. La interacció entre l'eix muntat i la via es descriu com una relació linealitzada entre el moviment relatiu d'ambdós components i les forces de contacte. Cal assenyalar que els models explorats en aquest treball estan formulats en el domini de la freqüència. Així mateix, es realitza un estudi d'influència del disseny de la via en la radiació, quantificant els paràmetres contribuents a l'emissió acústica mitjançant tècniques estadístiques. Els resultats apunten que la geometria del carril té un impacte limitat en la radiació sonora, mentre que les propietats viscoelàstiques de la via, en particular la rigidesa de la placa d'assentament, tenen un paper fonamental en la generació de soroll. És destacable que, entre els diferents dissenys, s'han trobat variacions de fins a 7,4 dB(A) en la radiació per soroll de rodament. Durant el desenvolupament d'aquesta investigació, s'ha prestat atenció al modelatge de l'eix muntat. La seua rotació s'inclou en la formulació utilitzant coordenades Eulerianes, la qual cosa resulta un enfocament convenient ja que el punt de contacte de la roda amb el carril roman en una posició constant. Donada la simetria axial de la seua geometria, la resposta dinàmica de l'eix muntat s'amplia al llarg de la direcció circumferencial mitjançant sèries de Fourier, permetent formular el comportament dinàmic i acústic d'aquest cos tridimensional (3D) en un marc bidimensional (2D), i resolent la coordenada circumferencial analíticament. Aquesta metodologia ofereix sense pèrdua de generalitat una reducció del temps de càlcul computacional, la qual cosa fa que el model siga idoni per a la seua integració en algoritmes d'optimització. Finalment, es realitza una investigació pionera sobre el soroll de rodament quan el vehicle negocia una corba. Si bé la corba està generalment associada amb el soroll per grinyols, aquesta Tesi explora i confirma la importància que també té el soroll de rodament en aquestes condicions. Per a això, es modelitzen els efectes inercials i giroscòpics que pateix un eix muntat al descriure una trajectòria corba. A més, diferents fenòmens complexes que ocorren en el contacte roda/carril, com el moviment relatiu entre aquests elements, s'incorporen en el model d'interacció. Els resultats indiquen que la posició del contacte roda/carril serveix com un bon indicador de l'impacte que la negociació d'una corba té en el soroll de rodament. / [EN] Rolling noise emission in railway systems presents significant challenges in urban and suburban environments, requiring a comprehensive understanding of its underlying mechanisms for effective mitigation. This Thesis offers a thorough investigation into rolling noise generation, considering both tangent and curved tracks, through the development of advanced high-frequency models and calculation tools to predict noise levels accurately. Rolling noise arises from the interaction between railway wheels and tracks in the presence of roughness on their contact surfaces. The principal components contributing to the acoustic emission are the sleepers, rails, and wheels. Sleepers and rails are interconnected through rail pads, while wheels and rails are dynamically coupled due to their contact. Consequently, changes in any component might impact the dynamic and acoustic behaviour of all of them, outlining the necessity of a comprehensive model to address rolling noise radiation effectively. Various models for the track and wheelset are explored and developed in this Thesis. The track, assumed to be infinite, is described using periodic structure theory and it is characterised by its wavenumbers and waveshapes. The wheelset is modelled through the Finite Element Method (FEM) and it is characterised by its natural frequencies and vibration modes. The wheelset and track interaction is described as a linearised relationship between the relative motion of both components and the contact forces. The models examined in this work are formulated in the frequency domain. Identified track properties influencing rolling noise radiation are quantified using statistical techniques. While the rail geometry is found to have a limited impact on the total radiation, the viscoelastic properties of the track, particularly the rail pad stiffness, play a crucial role in noise generation. Variations up to 7.4 dB(A) were observed for different track designs. Special attention is devoted to the wheelset modelling in this Thesis. Its rotation is considered using Eulerian coordinates, a convenient approach as the wheel contact point with the rail remains at a constant spatial position. Given the axial symmetry of its geometry, the wheelset dynamic response is expanded around the circumferential direction using Fourier series, which yields a two-dimensional (2D) formulation of the dynamic and acoustic behaviour of this three-dimensional (3D) system, with the circumferential coordinate being solved analytically. This methodology, denoted as axisymmetric approach, offers a significant reduction in the associated computational calculation time while preserving accuracy, making the model well suited for its integration into optimisation algorithms. Lastly, a novel investigation into rolling noise when the vehicle negotiates a curve is conducted. While curved tracks are generally associated with squeal noise, this Thesis offers valuable insights into the importance of rolling noise as well. To achieve this, the inertial and gyroscopic effects associated with a wheelset running on a curve are modelled. Complex phenomena occurring at the wheel/rail contact, such as the relative motion between these two elements, are incorporated into the interaction model. The results indicate that the wheel/rail contact position serves as a reliable indicator of the impact of a curve on the rolling noise. / This Thesis has been supported by Ministerio de Ciencia, Innovación y Universidades in the framework of the FPU grant program. Grants FPU18/03999, EST21/00213, and EST22/00353 as well as projects TRA2017-84701-R, PID2020-112886RA-I00, and PID2023-148483OB-I00 funded by MCIN/AEI/10.13039/501100011033, “ESF Investing in your future”, and “ERDF A way of making Europe” are acknowledged. The author also expresses his gratitude for the support provided by Programa PROMETEO/2021/046 of Generalitat Valenciana. / Andrés Ruiz, VT. (2024). Comprehensive dynamic models of railway wheelsets and tracks for the prediction of rolling noise [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/206074 / Compendio