Presented master's thesis is focused on the experimental research of the sanding parameters in order to improve adhesion in the contact between wheel and rail. Sanding is the application of the sanding material directly in the wheel/rail contact. It is still common, most effective and traditional way how to deal with low adhesion problem, which is mainly caused by environmental contaminants. Research is important for the better understanding of the sanding process and also provides data, which are necessary for it's optimization and efficiency improvement. Newly developed twin-disc machine was used to carry out the presented experimental research. The influence of common contaminants on the adhesion is investigated, considering various operating parameters. Different amount of the applied sand is used to increase adhesion in the contaminated contact at various slip and rolling speed. Results show, that there is the amount of the sand, from which no significant adhesion increase occur. Obtained findings and the results presented in this thesis will be used to optimize sanding system, which will contribute to reduce cost associated with sanding and low adhesion.

Turnouts (Switches & Crossings) are important components in railway networks, as they provide the necessary flexibility for train operations by allowing trains to change among the tracks. But the turnout’s geometry with discontinuity in rail profiles and lack of transition curve causes additional wear both on track and on vehicle. The main goal of this MSc thesis is to investigate the influence of turnouts on wheel wear of a freight vehicle. This will be obtained by simulations in the commercial MBS software GENSYS. The wheel-rail contact is modelled according to Hertz’s theory and Kalker’s simplified theory, with the FASTSIM algorithm, and the wear calculations are performed according to Archard’s law. Wheel wear is estimated by considering variations in parameters which have effect on wheel-rail contact. All these variations are common in daily rail operation, and they are caused by it, i.e. worn wheel profiles, worn crossing nose and different stiffness of the stock and the switch rails at the beginning of the turnout. Moreover, the wheel wear is calculated for both possible directions which a vehicle can run, the diverging and the straight direction of the turnout. Especially for the straight direction, various running speeds have been tested as the speed limit when the vehicle follows the straight direction is higher than for the diverging part. Running with worn wheel profiles has the greatest impact in terms of increasing the wheel wear, especially on the outer part of wheel tread. In addition, the worn crossing nose results in increased wheel wear in this area. The results of the simulations concerning the different stiffness showed that the wheel wear caused by the contact of wheel and stock rail increases whereas the wear caused by the contact with the switch rail is kept at about the same level or decreases. It is concluded that turnouts have a significant impact on wheel wear, mainly because of the discontinuity in rail geometry and all the investigated parameters increase this impact. Moreover, great differences in wear values for areas close to each other are observed, mainly because of the wear coefficient values chosen in Archard’s wear map.

Railway vehicles require a certain level of adhesion between wheel and rail to operate efficiently, reliably, and economically. Different levels of adhesion are needed depending on the vehicle running conditions. In the wheel tread–railhead contact, the dominant problem is low adhesion, as low adhesion on the railhead negatively affects railway operation: on one hand, the vehicle will lose traction resulting in delay when driving on low-adhesion tracks; on the other hand, low adhesion during deceleration will extend the braking distance, which is a safety issue. This thesis examines the influence of several contaminants, i.e., water, oil, and leaves, on the adhesion in the wheel tread–railhead contact. This study will improve our knowledge of the low-adhesion mechanism and of how various contaminants influence adhesion. The thesis consists of a summary overview of the topic and three appended papers (A–C). Papers A and B focus mainly on water and oil contamination examined using two methods, numerical simulation and lab testing. In paper A, real measured wheel and rail surfaces, low- and high-roughness surfaces, along with generated smooth surfaces are used as input to the numerical model for predicting the adhesion coefficient. Water-lubricated, oil-lubricated, and dry contacts are simulated in the model. In the research reported in paper B, scaled testing using a mini traction machine (MTM) was carried out to simulate the wheel–rail contact under lubricated conditions. Two types of disc surfaces of different roughnesses were run at different contact pressures and temperatures. A stylus machine and atomic force microscopy (AFM) were used to measure the surface topography. A study of leaf contamination on the railhead surface, based on field testing, is presented in paper C. Railhead surface samples were cut and the friction coefficient was measured on five occasions over the course of a year. Electron spectroscopy for chemical analysis (ESCA) and glow discharge optical emission spectrometry (GD-OES) were used to detect the chemical composition of the leaf-contamination layer on the railhead surface. The main conclusion of the thesis is that different contaminants reduce the adhesion coefficient in different ways. Oil reduces the adhesion coefficient by carrying the normal force due to its high viscosity. Water can reduce the adhesion coefficient to different degrees depending on the surface topography and water temperature. The mixture of an oxide layer and water contamination may have an essential impact. A leaf-formed blackish layer causes low adhesion by means of a chemical reaction between the leaves and bulk material. The thickness of the friction-reducing oxide layer predicts the friction coefficient and the extent of leaf contamination. / QC 20111123

For efficient transportation in either trains, busses or passenger cars, rolling elements such as wheels, tyres, bearings and transmission elements are fundamental. The energy efficiency and the generation of noise and vibrations in rolling contacts depend on the surface roughness of contacting bodies. In order to optimize the surfaces of rolling elements, prediction of its impact on the dynamic response from rolling excitation is required. A computationally efficient method to include surface roughness in the modelling of rolling contacts is presented. More specifically, nonlinear effects on the contact force due to the threedimensional shape and roughness of the contacting surfaces are introduced in a moving point force formulation. As a consequence of the point force approximation follows the assumption that any dynamic wave motion within the contact area is negligible.The rolling contact force is nonlinear due to a varying relative displacement between contacting bodies and is therefore referred to as state-dependent. A study case for the state-dependent method consisting of a steel ball rolling on a steel beam showed good agreement between numerical predictions and measured beam vibrations. Furthermore, an application to the wheel-rail interaction show that roughness-induced contact nonlinearities have a significant impact on the dynamic response caused by rolling excitation. / <p>QC 20141103</p> / ECO2 Vehicle Design

The application of Model Reference Adaptive Control (MRAC) for train dynamic braking is investigated in order to control dynamic braking forces while remaining within the allowable adhesion and coupler forces.  This control method can accurately determine the train braking distance.  One of the critical factors in Positive Train Control (PTC) is accurately estimating train braking distance under different operating conditions.  Accurate estimation of the braking distance will allow trains to be spaced closer together, with reasonable confidence that they will stop without causing a collision.  This study develops a dynamic model of a train consist based on a multibody formulation of railcars, trucks (bogies), and suspensions.   The study includes the derivation of the mathematical model and the results of a numerical study in Matlab.  A three-railcar model is used for performing a parametric study to evaluate how various elements will affect the train stopping distance from an initial speed.  Parameters that can be varied in the model include initial train speed, railcar weight, wheel-rail interface condition, and dynamic braking force.  Other parameters included in the model are aerodynamic drag forces and air brake forces. An MRAC system is developed to control the amount of current through traction motors under various wheel/rail adhesion conditions while braking.  Minimizing the braking distance of a train requires the dynamic braking forces to be maximized within the available wheel/rail adhesion.  Excessively large dynamic braking can cause wheel lockup that can damage the wheels and rail.  Excessive braking forces can also cause large buff loads at the couplers.  For DC traction motors, an MRAC system is used to control the current supplied to the traction motors.  This motor current is directly proportional to the dynamic braking force.  In addition, the MRAC system is also used to control the train speed by controlling the synchronous speed of the AC traction motors.  The goal of both control systems for DC and AC traction motors is to apply maximum available dynamic braking while avoiding wheel lockup and high coupler forces.  The results of the study indicate that the MRAC system significantly improves braking distance while maintaining better wheel/rail adhesion and coupler dynamics during braking.  Furthermore, according to this study, the braking distance can be accurately estimated when MRAC is used.  The robustness of the MRAC system with respect to different parameters is investigated, and the results show an acceptable robust response behavior. / Ph. D.

During life of railway vehicles, shape irregularities develop on wheels and rails because of wear. The shape irregularities then affect forces in wheel-rail contact and cause further damage of contact surfaces, vibrations and noise and increase risk of derailment. A numerical simulation of railway vehicle motion with more details on contact surfaces geometry was created to investigate dynamic contact loads in wheel-rail contact. A variety of methods can be used to evaluate forces in rolling contact, the method chosen for this study was algorithm CONTACT based on boundary element method. Four studies are presented in this papers: contact loads from a wheel with a flat and with a wavy tread pattern, loads on wavy rail and load in a curve. The first three studies investigated effects of existing wear patterns, the last one looked for cause of common wear pattern developing on rails. Results of the studies with worn components used showed that the worst kind of shape irregularities is a flat present on wheel. This type of shape cause loss of contact and following impacts. The study of ride in curve showed that cause of high wear in curves, especially those with small radii, is caused by vibration of wheelset. This vibration is then caused by different length of inner and outer rail and wheels travelling along a different path.

The primary purpose of this study is to perform accurate dynamic measurements on a scaled roller rig designed and constructed by Virginia Tech and the Federal Railroad Administration (VT-FRA Roller Rig). The study also aims at determining the effect of naturally generated third-body layer deposits (because of the wear of the wheel and/or roller) on creep or traction forces. The wheel-rail contact forces, also referred to as traction forces, are critical for all aspects of rail dynamics. These forces are quite complex and they have been the subject of several decades of research, both in experiments and modeling. The primary intent of the VT-FRA Roller Rig is to provide an experimental environment for more accurate testing and evaluation of some of the models currently in existence, as well as evaluate new hypothesis and theories that cannot be verified on other roller rigs available worldwide. The Rig consists of a wheel and roller in a vertical configuration that allows for closely replicating the boundary conditions of railroad wheel-rail contact via actively controlling all the wheel-rail interface degrees of freedom: angle of attack, cant angle, normal load and lateral displacement, including flanging. The Rig has two sophisticated independent drivelines to precisely control the rotational speed of the wheels, and therefore their relative slip or creepage. The Rig benefits from a novel force measurement system, suitable for steel on steel contact, to precisely measure the contact forces and moments at the wheel-rail contact. Experimental studies are conducted on the VT ��" FRA Roller Rig that involved varying the angle of attack, wheel and rail surface lubricity condition (i.e., wet vs. dry rail), and wheel wear, to study their effect on wheel-rail contact mechanics and dynamics. The wheel-rail contact is in between a one-fourth scale AAR-1B locomotive wheel and a roller machined to US-136 rail profile. A quantitative assessment of the creep-creepage measurements, which is an important metric to evaluate the wheel-rail contact mechanics and dynamics, is presented. A MATLAB routine is developed to generate the creep-creepage curves from measurements conducted as part of a broad experimental study. The shape of the contact patch and its pressure distribution have been discussed. An attempt is made to apply the results to full-scale wheels and flat rails. The research results will help in the development of better simulation models for non-Hertzian contact and non-linear creep theories for wheel-rail contact problems that require further research to more accurately represent the wheel-rail interaction. / MS / Rail vehicles are supported, steered, accelerated, and decelerated by contact forces acting in extremely small wheel-rail contact areas. The behavior of these forces is quite complex and a broad interdisciplinary research is needed to understand and optimize the contact mechanics and dynamics problem. Key industry issues, such as control of Rolling Contact Fatigue (RCF), maximizing wheelset mileages, and minimizing the impact of rolling stock on the infrastructure, are directly related to the interaction at the wheel-rail contact. The Rig consists of a wheel and roller in a vertical configuration that allows for closely replicating the boundary conditions of railroad wheel-rail contact via actively controlling all the wheel-rail interface degrees of freedom: angle of attack, cant angle, normal load and lateral displacement, including flanging. The Rig has two sophisticated independent drivelines to precisely control the rotational speed of the wheels, and therefore their relative slip or creepage. The Rig benefits from a novel force measurement system, suitable for steel on steel contact, to precisely measure the contact forces and moments at the wheel-rail contact. The primary purpose of this study is to perform accurate dynamic measurements on a scaled roller rig designed and constructed by Virginia Tech and the Federal Railroad Administration (VT-FRA Roller Rig). Experimental studies are conducted on the VT – FRA Roller Rig that involved varying the angle of attack, the wheel and rail surface lubricity condition (i.e., wet vs. dry rail), and the wheel wear to study their effects on wheel-rail contact mechanics and dynamics. The wheel-rail contact is in between a one-fourth scale AAR-1B locomotive wheel and a roller machined to US-136 rail profile. A quantitative assessment of the creep-creepage measurements, which is an important metric to evaluate the wheel-rail contact mechanics and dynamics, is presented. A MATLAB routine is developed to generate the creep-creepage curves from measurements conducted as part of a broad experimental study. The shape of the contact patch and its pressure distribution have been discussed. An attempt is made to apply the results to full-scale wheels and flat rails. The research results will help in the development of better simulation models for non-Hertzian contact and non-linear creep theories for wheel-rail contact problems that require further research to more accurately represent the wheel-rail interaction.

Orientador: Auteliano Antunes dos Santos Junior / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-10T23:11:33Z (GMT). No. of bitstreams: 1 Santos_FranciscodeCarvalho_M.pdf: 2597661 bytes, checksum: 7a02462088e7914e422081012b449048 (MD5) Previous issue date: 2008 / Resumo: Este trabalho propõe um modelo numérico de contato roda-trilho, baseado no método dos elementos finitos, para estimar a vida em fadiga até o surgimento da trinca, e quanto à falha por escamação, de uma roda ferroviária classe C de um vagão de carga de uma ferrovia nacional, de Serra dos Carajás. O modelo tem como principal contribuição à abordagem elastoplástica juntamente com a inclusão das tensões residuais provenientes do tratamento térmico do processo de fabricação da roda. O modelo de elementos finitos utilizou técnicas de submodelagem, tanto na determinação no campo de tensões residuais de fabricação, quanto no de contato roda-trilho. Para efeito de comparação, determinaram-se as tensões e deformações também com um modelo semi-analítico elástico, baseado na teoria de Hertz, além de um modelo numérico elastoplástico sem tensões residuais de fabricação. A vida foi determinada através de dois critérios de fadiga, que incorporam a influencia das tensões hidrostáticas e planos críticos. O critério de alto ciclo de Dang Van foi modificado para adaptar-se ao problema de dois corpos em contato. O outro critério utilizado foi o de Fatemi¿Socie, baseado em deformações cisalhantes. O número de ciclos encontrado para o início da trinca foi então corrigido de acordo com uma distribuição normal estatística da posição lateral do ponto de contato. O trabalho mostrou que as tensões residuais, benéficas para a propagação de trincas, reduzem a vida até o surgimento destas / Abstract: This work proposes a wheel-rail contact model based on finite element method to estimate the fatigue life to shelling, until the beginning of the crack of a railroad wheel class C of a heavyhull Brazilian railroad from Serra dos Carajás. The main contribution of this work is the elastoplastic approach with the inclusion of the residual stress generated by the heat treatment of the wheel manufacture process. Submodeling techniques were used to determinate the residual stresses from manufacture process and the contact stresses. Aiming the comparison, the wheelrail contact stresses was calculated using an analytic model, based on Hertz theory, and a numeric model (FEM) without residual stress from the manufactured process. The fatigue life was calculated using two criterions based on critical planes and hydrostatic stresses. The high cycle fatigue criterion from Dang Van was adapted to be used in contact problems. The other one was the Fatemi¿Socie criterion, based on shear strains. The number of cycles until the arising of the fatigue crack was correct using a statistical normal distribution of the lateral position of the contact point. This work shows that the residual stress generated by the manufacture process, which prevents the crack propagation, reduces the fatigue life until the arising of the crack / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

Le squat est un défaut de fatigue de contact apparaissant à la surface du rail et dont le mécanisme d’amorçage est mal compris. Afin de pallier ce manque, une analyse tribologique locale de la bande de roulement du rail est mise en oeuvre à proximité d’un squat naissant. Cette caractérisation révèle une anisotropie importante des couches superficielles du rail associée aux développements de Transformations Tribologiques Superficielles. Ces résultats témoignent de conditions de contact roue/rail particulières dans la zone d’étude, notamment d’un niveau d’efforts de cisaillement inhabituel pour une voie en alignement. Dans le but de valider ces observations, plusieurs essais sont effectués. D’une part les conditions de contact roue/rail dans une zone de squats sont mesurées à partir d’un train instrumenté. D’autre part, la réponse tribologique de l’acier à rail à ces conditions de contact est étudiée à travers le suivi régulier d’une zone d’essais soumise à la circulation ferroviaire. Ces essais permettent d’identifier un déséquilibre important des efforts de traction sur les bogies moteurs et des glissements locaux élevés de la roue sur le rail. Différents mécanismes d’amorçage thermo-mécaniques sont alors proposés au sein d’un schéma global de la réponse tribologique de l’acier à rail. / Squats have recently become recognised as one of the major rolling contact fatigue defects in modern railway networks for which there is currently no solution other than preventive grinding operations or costly rail renewal. To better understand the entire damage mechanism of squat, A tribological and metallurgical analysis of the rolling band and the near surface layer was performed close to an incipient squat. This characterization show a significant anisotropy of the rail surface layer associated with developments of Tribological Transformation of Surface. These results reflect some specific wheel/rail contact conditions in this squat area, including an unusual level of shear forces in a straight track. In order to validate this observations, two tests were performed. On the one hand, the contact conditions in a squat area were measured from an instrumented train. On the other hand, the tribological response of the rail steel was studied through regular monitoring of a test site subjected to railway traffic. These tests allow to identify a high imbalance of the traction forces and the presence of local slips at the wheel/rail interface. Several thermomechanical initiation mechanism of squats are then given in a overall diagram of the tribological response of rail steels.

Le calcul des efforts normaux et tangents est important pour la modélisation dynamique du système véhicule-voie en ferroviaire. Pour déterminer les forces tangentielles au contact roue-rail, les coefficients de Kalker sont utilisés dans la plupart des codes de dynamique ferroviaire, pour les différents modèles de contact. Ces coefficients ont été mesurés sur banc à plusieurs reprises dans les années 80. Une synthèse de ces travaux, réalisée par Hobbs, montre que certaines de ces mesures présentent une baisse pouvant atteindre 50% par rapport à la théorie de Kalker. L’objet de cette thèse est d’identifier d’abord les véritables causes de la dispersion constatée entre les différentes mesures, généralement attribuée à la contamination de la surface, puis de développer un modèle numérique capable d’en tenir compte.La démarche numérique proposée est sur deux volets. Dans le premier volet, une méthode itérative directe par éléments de frontière basée sur les intégrales de surface de Boussinesq-Cerruti est réécrite pour l’étude du contact normal et glissant entre deux corps élastiques, puis étendue pour la résolution du problème de contact roulant. Appliquée avec succès au contact roue-rail non-Hertzien, cette méthode est un outil prometteur pour l’étude des paramètres influençant les coefficients de Kalker qui allie à la fois la précision et la rapidité.Dans le deuxième volet, le problème du contact roue-rail élastique est résolu à l’aide de la méthode des éléments finis en utilisant les schémas d’intégration temporelle explicite et implicite. La solution élastique est comparée avec le logiciel de référence CONTACT. Le modèle par éléments finis 3D développé a permis de prendre en compte d’une part le comportement élasto-plastique des corps en contact et d’autre part l’existence d’une couche de troisième corps sur l’interface du contact roue-rail. Ainsi, en fin de cette étude, une correction aux coefficients de Kalker est estimée à partir d’un modèle qui prend mieux en compte la réalité physique du contact roue-rail.Afin d’évaluer l’influence de cette correction sur la vitesse critique du véhicule ferroviaire, une étude de stabilité est réalisée avec le code de dynamique ferroviaire VOCO dans lequel des facteurs de réduction des coefficients de Kalker ont été appliqués / The calculation of normal and tangential forces is important for the dynamic modeling of the railway vehicle-track interaction. To determine the tangential forces at the wheel-rail contact level, the Kalker’s coefficients of stiffness are used in most of computer codes for different contact models. These coefficients were measured on bench several times in the 80s. A survey of these works, conducted by Hobbs, shows a decrease of up to 50 % in value compared to Kalker’s theory. The aim of this thesis is first to identify the real causes of the dispersion observed between the various measurements, usually attributed to the surface contamination, then to develop a model taking into account some of them.The numerical modeling of the wheel-rail contact is presented in two parts. In the first part, a direct boundary element method based on Boussinesq-Cerruti solution is developed to study the normal and sliding contact between two elastic bodies, and then extended to the resolution of rolling contact problem. Successfully applied to the wheel-rail contact for non-Hertzian situation, this method is a promising tool for studying the parameters influencing Kalker’s coefficients which combines both precision and speed.In the second part, a finite element model for rolling contact between wheel and rail is developed to study the normal and the tangential contact problems using the explicit and the implicit integration schemes. The elastic solution is compared with the solution of the CONTACT software. The three-dimensional finite element model takes into account the elastoplastic behavior of the bodies in contact as well as the existence of a third body layer at the interface between the wheel and the rail. Finally, a correction of Kalker’s coefficients is estimated from the results of the numerical simulations.To study the impact of this correction on the critical speed of the vehicle, a stability analysis is performed using the multibody dynamics software VOCO in which the reduced factors of Kalker’s coefficients are considered