Since the investigation of wear particles from rail transport started in the late 1910s, the high mass concentrations of these particles have prompted concern among researchers interested in air quality. However, effective action has yet to be taken because relevant knowledge is still missing. This thesis provides knowledge of airborne wear particles originating from rail transport. Some aspects of their characteristic parameters, such as size, mass concentration, number concentration, and morphology, were investigated in the field and in laboratory tests. We also discuss means to mitigate non-exhaust emissions, as well as the advantages and disadvantages of various test set-ups in the seven appended journal papers:Paper A reviews recent studies of exhaust and non-exhaust emissions from rail vehicles. The results, measurements, adverse health effects, and proposed or applied solutions presented in this literature are summarized in this paper.Paper B summarizes the results of field tests we conducted. The effects of curve negotiation and braking under different real conditions were investigated in a field test in which on-board measurements were made. The elemental composition and morphology of the particles emitted and their potential sources were also investigated.Paper C describes how a pin-on-disc machine can be used to reproduce real operating conditions during mechanical train braking in a controlled laboratory setting. The results were validated by comparing the field test results with the results of laboratory studies.Paper D presents comprehensive results of laboratory studies of airborne particles from different braking materials. A new index is introduced in this paper, which can be used as a quantitative metric for assessing airborne wear particle emission rates.Paper E describes the effects of using various friction modifiers and lubricants on the characteristics of airborne particles from wheel–rail contact under lubricated and unlubricated conditions.Paper F reports work to simulate thermoelastic instability in the cast-iron braking material. We simulated the fluctuation of the flash temperature by considering the temperature dependency of the material properties and the transformation of the contact state due to thermomechanical phenomena and wear.Paper G reviews new full- and sub-scale measurements of non-exhaust emissions from ground transport. The advantages and disadvantages of on-board measurements, pin-on-disc tests, dynamometer tests, and test rig studies are discussed in this paper. / <p>QC 20131025</p>

Numerical procedures for reliable wheel and rail wear prediction are rare. Recent development of simulation techniques and computer power together with tribological knowledge do however suggest computer aided wear prediction as possible. The present objective is to devise a numerical procedure able to simulate profile evolution due to uniform wear sufficiently accurate for application to vehicle dynamics simulation. Such a tool should be useful for maintenance planning, optimisation of the railway system and its components as well as trouble-shooting. More specifically, the field of application may include estimation of reprofiling frequency, optimisation of wheel – rail profile match, optimisation of running gear suspension parameters, and recognition of unfavourable profile evolution influencing the dynamic response of the vehicle. The research contribution accounted for in this thesis includes, besides a literature review, modelling of the wheel – rail interface, benchmarking against traditional methods, and validation with respect to full-scale measurements. The first part addresses wheel – rail contact conditions in the context of wear simulation as well as tribological environment and tractive forces. The current approach includes Archard’s wear model with associated wear maps, vehicle dynamics simulation, and railway network definition. One objective is to be able to include variations in operation conditions in the set of simulations instead of using scaling factors. In particular the influence of disc braking and varying lubrication conditions have been investigated. Both environmental factors like moist and contamination and deliberate lubrication need to be considered. As part of the associated contact analysis the influence of tangential elastic deformation of the contacting surfaces has been investigated and found to be essential in case of partial slip contact conditions. The influence on the calculated wear of replacing the Hertzian contact by a non-elliptic semi-Hertzian method has been investigated, showing relocation of material loss towards increased profile curvature. In the second part comparisons have been carried out with traditional methods, where the material loss is assumed to be directly related to the energy dissipated in the contact. Attention has been paid to the understanding of the principle differences between the investigated methods, comparing the distribution of friction energy, sliding velocity, and wear depth. As a prerequisite, contact conditions with dependence on wheelset guidance and curving performance as well as influence of tractive forces have been investigated. In the final part validation of the developments related to wheel wear simulation is addressed. Disc braking has been included and a wear map for moist contact conditions based on recent tests has been drafted. Good agreement with measurements from the reference operation, is achieved. Further a procedure for simulation of rail wear and corresponding profile evolution has been formulated. A simulation set is selected defining the vehicles running on the track to be investigated, their operating conditions, and contact parameters. Trial calculations of a few curves show qualitatively good results in terms of profile shape development and difference in wear mechanisms between gauge corner and rail head. The wear rates related to traffic tonnage are however overestimated. The impact of the model improvements accounted for in the first part of the thesis has been investigated, indicating directions for further development. / QC 20110124

Friction modification within the wheel-rail interface is an important way of achieving ecologically friendly transportation of both persons and goods. This thesis aims to develop a new TOR lubricant, which will be able to maintain suitable frictional conditions while securing minimal adhesion required for traction. All measurements were carried out on tribometer MTM in the ball-on-disc configuration. In the first step, individual components were examined. More complex compositions were measured after that and the three best of them were compared with commercial TOR lubricants. The results show a good ability of developed compositions to maintain required adhesion, reduce wear, and all of them had resistivity against over-lubrication. Lastly, the process of lubricant verification before its application in real traffic was discussed.

Wheel-rail contact is an important aspect of railway, the forces transferred between the wheel and rail are the one that guide, brake, or accelerate the train, and that is why the understanding of the contact between wheel and rail is an interesting research topic. In this master thesis wheel-rail contact model named ANALYN is used to see the effect of the different geometrical input, like undeformed distance, relative longitudinal curvature, and relative lateral curvature calculation affect the contact patch estimation formed at the wheel-rail contact.  In the process, a geometrical contact search code is made to find the contact point between wheel and rail for certain lateral displacement, yaw angle, and roll angle of the wheelset. The codes used to calculate the three geometrical inputs are also prepared, with two methods are prepared for each input. The results that generated from combination of the geometrical contact search and geometrical input preparation are used as the input to ANALYN. The results showed that different geometrical input calculations do affect the shape of the contact patch, with the calculation of lateral curvature being the most important since it affects the shape of the contact patch greater than other geometrical inputs. It is also shown that taking yaw angle into account in the contact search will affect the shape of the contact patch.

In order to ensure safe travel, railway vehicles must be stable under every condition along the track. Thus, a vehicle can be certified for operation only when it can fulfil certain criteria related to the ride stability. The stability of the vehicle is highly dependent on the wheel-rail friction coefficient: higher friction results in worse ride. So, to ensure a good evaluation of the stability, the friction should be high enough during tests. The same applies to the risk of wheel flange climbing. At the present time, the wheel-rail friction can not be measured directly but there are different procedures utilized to ensure that the conditions are suitable for testing the stability of the vehicle. In this study an algorithm is proposed to estimate the wheel-rail friction coefficient by using quantities which can be measured in reality. The algorithm is tried out in computer simulations. The algorithm has two parts: in Part 1 the friction coefficient is proposed to be equal to the ratio of the total creep force divided by the normal force; in Part 2 the total creep and spin creep are estimated to observe their correlation to the estimated friction. The contact angle in Part 1 is estimated by a contact point function. In the simulations, different conditions are tried. There are four horizontal radii: tangent track, R1300m, R1000m, and R400m. Three friction coefficients are used: 0.5, 0.4 and 0.3. In addition to this, track irregularities are included. A single vehicle is simulated in two modes: capable and incapable of passive radial steering. The track irregularities caused high values of the proposed estimated friction coefficient. The values in some instances were close or equal to the input friction coefficient of the simulation. Thus, if the highest values of the estimated friction were taken over a certain distance or time, the friction of the simulation could be approximated. In most cases, the total creep was following the trend of the estimated friction. The total creep and spin creep were used as a quality factor to determine how close the estimated friction was to the simulation’s friction. In this study when the total creep was greater than 0.006 and the spin creep was less than 1.0 m-1, the estimated friction was close to the input friction. The closeness was dependent on the simulation’s friction. Higher input friction resulted in larger deviation compared to lower friction. A sensitivity analysis has been performed by deliberately introducing errors in the position of the contact point and the angle of attack. The analysis shows that the errors are not critical when the contact point is close to the tread circle. When the contact point is close to the flange, a good measurement of the wheel profile and the contact point position required to obtain accurate results. On the other hand, the errors affect the friction estimate for high spin and low total creepage. These results are discarded by the algorithm, the influence of the errors is minimized.

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.

Early detection of rail defects is necessary for preventing derailments and costly damage to the train and railway infrastructure. A rail surface flaw can quickly propagate from a small fracture to a broken rail after only a few train cars have passed over it. Rail defect detection is typically performed by using an instrumented car or a separate railway monitoring vehicle. Rail surface irregularities can be measured using accelerometers mounted to the bogie side frames or wheel axles. Typical signal processing algorithms for detecting defects within a vertical acceleration signal use a simple thresholding routine that considers only the amplitude of the signal. As a result, rail surface defects that produce low amplitude acceleration signatures may not be detected, and special track components that produce high amplitude acceleration signatures may be flagged as defects. The focus of this research is to develop an intelligent signal processing algorithm capable of detecting and classifying various rail surface irregularities, including defects and special track components. Three algorithms are proposed and validated using data collected from an instrumented freight car. For the first two algorithms, one uses a windowed Fourier Transform while the other uses the Wavelet Transform for feature extraction. Both of these algorithms use an artificial neural network for feature classification. The third algorithm uses the Wavelet Transform to perform a regularity analysis on the signal. The algorithms are validated with the collected data and shown to out-perform the threshold-based algorithm for the same data set. Proper training of the defect detection algorithm requires a large data set consisting of operating conditions and physical parameters. To generate this training data, a dynamic wheel-rail interaction model was developed that relates defect geometry to the side frame vertical acceleration signature. The model was generated by using combined systems dynamic modeling, and the system was solved with a developed combined lumped and distributed parameter system numerical approximation. The broken rail model was validated with real data collected from an instrumented freight car. The model was then used to train and validate the defect detection methodologies for various train and rail physical parameters and operating conditions. / Ph. D.

The primary purpose of this research is to investigate the effectiveness of a scaled roller rig for accurately assessing the contact mechanics and dynamics between a profiled steel wheel and rail, as is commonly used in rail vehicles. The established creep models of Kalker and Johnson and Vermeulen are used to establish correction factors, scaling factors, and transformation factors that allow us to relate the results from a scaled rig to those of a tangent track. �Correction factors, which are defined as the ratios of a given quantity (such as creep coefficient) between a roller rig and a track, are derived and used to relate the results between a full-size rig and a full-size track. Scaling factors are derived to relate the same quantities between roller rigs of different scales. Finally, transformation factors are derived by combining scaling factors with correction factors in order to relate the results from a scaled roller rig to a full-size tangent track. Close-end formulae for creep force correction, scaling, and transformation factors are provided in the thesis, along with their full derivation and an explanation of their limitations; these formulae can be used to calculate the correction factors for any wheel-rail geometry and scaling. For Kalker's theory, it is shown that the correction factor for creep coefficients is strictly a function of wheel and rail geometry, primarily the wheel and roller diameter ratio. For Johnson and Vermeulen's theory, the effects of creepage, scale, and load on the creep force correction factor are demonstrated. �It is shown that INRETS' scaling strategy causes the normalized creep curve to be identical for both a full-size and a scaled roller rig. �It is also shown that the creep force correction factors for Johnson and Vermeulen's model increase linearly with creepage, starting with the values predicted by Kalker's theory. �Therefore, Kalker's theory provides a conservative estimate for creep force correction factors. �A case study is presented to demonstrate the creep curves, as well as the correction and transformation factors, for a typical wheel-rail configuration. �Additionally, two studies by other authors that calculate the correction factor for Kalker's creep coefficients for specific wheel-rail geometries are reviewed and show full agreement with the results that are predicted by the formulae derived in this study. �Based on a review of existing and past roller rigs, as well as the findings of this thesis, a number of recommendations are given for the design of a roller rig for the purpose of assessing the wheel-rail contact mechanics. �A scaling strategy (INRETS') is suggested, and equations for power consumption of a roller rig are derived. Recommendations for sensors and actuators necessary for such a rig are also given. Special attention is given to the resolution and accuracy of velocity sensors, which are required to properly measure and plot the creep curves. / Master of Science

The focus of this study is on the development of a state-of-the-art single-wheel roller rig for studying contact mechanics and dynamics in railroad applications. The use of indoor-based simulation tools has become a mainstay in vehicle testing for the automotive and railroad industries. In contrast to field-testing, roller rigs offer a controlled laboratory environment that can provide a successful path for obtaining data on the mechanics and dynamics of railway systems for a variety of operating conditions. The idea to develop a laboratory test rig started from the observation that there is a need for better-developed testing fixtures capable of accurately explaining the complex physics of wheel-rail contact toward designing faster, safer, and more efficient railway systems. A review of current roller rigs indicated that many desired functional requirements for studying contact mechanics currently are not available. Thus, the Virginia Tech Railway Technologies Laboratory (RTL) has embarked on a mission to develop a state-of-the-art testing facility that will allow experimental testing of contact mechanics in a dynamic, controlled, and consistent manner. VT roller rig will allow for closely replicating the boundary conditions of railroad wheel-rail contact via actively controlling all the wheel-rail interface degrees of freedom: cant angle, angle of attack, and lateral displacement. Two sophisticated independent drivelines are configured to precisely control the rotational speed of the wheels, and therefore their relative slip or creepage. A novel force measurement system, suitable for steel on steel contact, is configured to precisely measure the contact forces and moments at the contact patch. The control architecture is developed based on the SynqNet data acquisition system offered by Kollmorgen, the motors supplier. SynqNet provides a unified communication protocol between actuators, drives, and data acquisition system, hence eliminating data conversion among them. Various design analysis indicates that the rig successfully meets the set requirements: additional accuracy in measurements, and better control on the design of experiments. The test results show that the rig is capable of conducting various contact mechanics studies aimed for advancing the existing art. Beyond developing the experimental testing fixture for studying contact mechanics, this study provides a comprehensive review of the contact models. It discusses the simplifying assumptions for developing the models, compares the models functionality, and highlights the open areas that require further experimental and theoretical research. In addition, a multi-body dynamic model of the entire rig, using software package SIMPACK, is developed for conducting modal analysis of the rig and evaluating the performance of the rig's components. A MATLAB routine is also developed that provides a benchmark for developing creep curves from measurements of the rig and comparing them with existing creep curves. / Ph. D.

The diploma thesis deals with construction design and practical realisation of experimental apparatus for investigation of wheel flange track vehicle lubrication. Experimental apparatus in full-scale uses optical interferometry for investigation of lubrication behaviour in wheel flange contact. It is an innovative approach which has not been used for such experiments so far. The aim of the following measurement with this apparatus is to determine the minimal amount of ecological lubrication in wheel flange contact under certain conditions when there is no lubrication film interruption. The apparatus enables to measure real rail wear. This work contains the apparatus description for the study of wheel flange lubrication, wheel flange contact specifications, the description of its influence on wear and acoustic emission, and a detailed description of the experimental apparatus.