Wear of railroad rolling stock and rails costs millions of dollars annually in all rail systems throughout the world. The rail industry has attempted to address flange wear using rail curve lubricants and presently use a variety of lubricants and lubricant applicators. The choice of lubricant and applicator is currently based on considerations that do not address the wear problem directly. This research quantified rail curve lubricant performance through laboratory simulation. The effects of lubricants in the wheel/rail contact were investigated. Rail curve lubricant performance was measured with a laboratory rail/wheel simulator for the purpose of optimising the choice of lubricant. New methods for measurement of rail curve lubricant performance have been presented. These performance measurements are total absorbed energy, the energy absorbed in the lubricant film instead of being utilised for wear processes; total distance slid, the sliding distance or accumulated strain achieved prior to development of a set tractive force limit; half life of lubricant, the time taken for a lubricant to lose half of its sliding performance; and apparent viscosity, a measure of the lubricity presented with respect to accumulated strain. The rail/wheel simulator used in this research consists of two dissimilar wheels (disks) rotating in contact with one another simulating a conformal gauge corner contact. The first wheel, a simulated rail, is driven by an electric motor which then drives the second wheel, a simulated railroad wheel, through the contact. Hydraulic braking on the railroad wheel is used to simulate the rolling/sliding conditions. The variables of the simulated contact that are controlled with this equipment are normal force, input wheel speed, slip ratio between samples, sample geometries and material properties, and lubricant types. Rail curve lubricants were laboratory tested to define their properties using the ASTM and other appropriate standards. The performance differences measured using ASTM standards based tests were susceptible to repeatability problems and did not represent the contact as accurately as the rail/wheel simulator. This laboratory simulator was used to gather data in lubricated and unlubricated conditions for the purpose of providing lubricant performance measurements. These measurements were presented and the tested lubricants were ranked conclusively using three industrially relevant performance criteria. Total sliding distance and total absorbed energy measurements of the rail curve lubricants displayed clear differences in lubricant performance for both of these criteria. Total sliding distance is equivalent to the number of axles in the field situation, while total absorbed energy is the energy unavailable for wear processes of rails and wheels. Lubricants designed using these measurements will increase lubricant performance with respect to these performance criteria which in turn will reduce wear to both rails and wheels. Measurement of the apparent viscosity of rail curve lubricants, using the rail/wheel simulator, displayed changes in rheological characteristics with respect to accumulated strain. Apparent viscosity is a measure of the shear stress transmitted from the wheels to the rails. Designing a rail curve lubricant after analysing measurements taken from the rail/wheel simulator will assist in identifying lubricant properties to reduce the wear producing shear stresses generated in a rail wheel contact. Decay of lubricant performance was measured for three different rail curve lubricants under simulated conditions. The research found appreciable and quantifiable differences between lubricants. Industrial application of the findings will improve positioning of lubrication systems, improve choice of lubricants and predict effective lubrication distance from the lubricant application point. Using the new methods of lubricant performance measurement developed in this thesis, the objective of this research, to quantify rail curve lubricant performance through laboratory simulation, has been achieved.

In this thesis the sheet metal forming effects such as plastic strain and thickness changes in the crash have been investigated by numerical analysis. The sheet metal forming histories of the components of the load path that absorbs the highest energy during a frontal crash have been considered. To find out the particular load path, the frontal crash analysis of Ford F250 Pickup has been performed at 56 kph into a rigid wall with finite element analysis without considering the forming history. The sheet metal forming simulations have been realized for each structural component building up the particular load path. After forming histories have been acquired, plastic strain and thickness distributions have been transferred to the frontal crash analysis. The frontal crash analysis of Ford F250 Pickup has been repeated by including these to introduce the effect of forming on crash response of the vehicle. The results of the simulations with and without forming effect have been compared with the physical crash test results to evaluate the sheet metal forming effect on the overall crash response. The results showed that with forming history the crash response of the vehicle and deformations of the particular components have been changed and the maximum deceleration pulse transferred to the passenger compartment has decreased. It has seen that a good agreement with physical test results has been achieved.