Comparison study on measurement of rail weld joint between inertial reference method and multi-point chord reference method

Purpose – Straightness measurement of rail weld joint is of essential importance to railway maintenance. Dueto the lack of efficient measurement equipment, there has been limited in-depth research on rail weld joint with a5-m wavelength range, leaving a significant knowledge gap in this field.Design/methodology/approach – In this study, the authors used the well-established inertial referencemethod (IR-method), and the state-of-the-art multi-point chord reference method (MCR-method). Two methodshave been applied in different types of rail straightness measurement trollies, respectively. These instrumentswere tested in a high-speed rail section within a certain region of China. The test results were ultimatelyvalidated through using traditional straightedge and feeler gauge methods as reference data to evaluate the railweld joint straightness within the 5-m wavelength range.Findings – The research reveals that IR-method and MCR-method produce reasonably similar measurementresults for wavelengths below 1 m. However, MCR-method outperforms IR-method in terms of accuracy forwavelengths exceeding 3 m. Furthermore, it was observed that IR-method, while operating at a slower speed,carries the risk of derailing and is incapable of detecting rail weld joints and low joints within the track.Originality/value – The research compare two methods’ measurement effects in a longer wavelength rangeand demonstrate the superiority of MCR-method.

Track dynamic behavior at rail welds at high speed

As a vehicle passing through a track with different weld irregularities, the dynamic performance of track com- ponents is investigated in detail by using a coupled vehi- cle-track model. In the model, the vehicle is modeled as a multi-body system with 35 degrees of freedom, and a Timoshenko beam is used to model the rails which are dis- cretely supported by sleepers. In the track model, the sleepers are modeled as rigid bodies accounting for their vertical, lat- eral and rolling motions and assumed to move backward at a constant speed to simulate the vehicle running along the track at the same speed. In the study of the coupled vehicle and track dynamics, the Hertizian contact theory and the theory proposed by Shen-Hedrick-Elkins are, respectively, used to calculate normal and creep forces between the wheel and the rails. In the calculation of the normal forces, the coefficient of the normal contact stiffness is determined by transient contact condition of the wheel and rail surface. In the calcu- lation of the creepages, the lateral, roll-over motions of the rail and the fact that the relative velocity between the wheel and rail in their common normal direction is equal to zero are simultaneously taken into account. The motion equations of the vehicle and track are solved by means of an explicit integration method, in which the rail weld irregularities are modeled as local track vertical deviations described by some ideal cosine functions. The effects of the train speed, the axle load, the wavelength and depth of the irregularities, and the weld center position in a sleeper span on the wheel-rail impact loading are analyzed. The numerical results obtained are greatly useful in the tolerance design of welded rail pro- file irregularity caused by hand-grinding after rail welding and track maintenances.

Mechanical deformation properties of Continuous Welded Rail on kilometer-span suspension bridge for high-speed railway

The complex bridge-track interaction between kilometer-span bridges and continuous Welded Rail(CWR)brings great challenges to CWR designing.Taking a suspension bridge with laying CWR as a case,the mechanical properties of CWR on the bridge are analyzed to reveal the sensitive areas of the track,and the design method of CWR and track structures on the beam ends are proposed.The results show that the unidirectional Rail Expansion Joints(REJ)need to be installed on the beam end of the kilometer-span bridge to reduce rail longitudinal force.Due to the bridge characteristics,there is no CWR fixed area on the kilometer-span bridge,and rail longitudinal force on the main span caused by bending loads needs to be concerned.The deformation of track on the beam end is complex,which is the weak area on the kilometer bridge,the large relative displacement between the stock rail of REJ and the main beam can cause poor stability of ballast bed on beam end,small resistance fasteners need to be laid on the sides of stock rail on the main beam to increase the stability of ballast and fasteners on the beam end.To improve the driving safety and comfort of beam end,the Sleeper-Supporting Apparatus(SSA)should be specially designed to ensure the uniform transition of track on beam ends.Temperature and wind loads have a significant impact on track regularity on the kilometer span bridge,the dynamic response of trains and bridges under those loads needs to be attended to.

Longitudinal force in continuously welded rail on long-span tied arch continuous bridge carrying multiple tracks

Considering arch rib, lateral brace, suspender, girder, pier and track position, the model for the interaction between long-span tied arch continuous bridge and multiple tracks was established by using steel-concrete composite section beam element to simulate concrete-filled steel tube(CFST) arch rib, using the beam element with rigid arm to simulate the prestressed concrete girder and using nonlinear bar element to simulate longitudinal constraint between track and bridge. Taking a(77+3×156.8+77) m tied arch continuous bridge with four tracks on the Harbin-Qiqihar Passenger Dedicated Line as an example, the arrangement of continuously welded rail(CWR) was explored. The longitudinal force in CWR on the tied arch continuous bridge, the pier top horizontal force and torque due to the unbalance load case, were analyzed under the action of temperature, vertical live load, train braking and wind load.Studies show that, it can significantly reduce track displacement to set the track expansion devices at main span arch springing on both sides; the track stress due to arch temperature variation can reach 40.8 MPa; the track stress, pier top horizontal force and torque are related to the number of loaded tracks and train running direction, and the bending force applied to unloaded track is close to the loaded track, while the braking force applied to unloaded track is 1/4 to 1/2 of the loaded track; the longitudinal force of track due to the wind load is up to 12.4 MPa, which should be considered.

Mechanical properties and fracture toughness of rail steels and thermite welds at low temperature

Brittle fracture occurs frequently in rails and thermite welded joints, which intimidates the security and reliability of railway ser- vice. Railways in cold regions, such as Qinghai-Tibet Railway, make the problem of brittle fi＇acture in rails even worse. A series of tests such as uniaxial tensile tests, Charpy impact tests, and three-point bending tests were carried out at low temperature to investigate the mechanical properties and fracture toughness of U71Mn and U75V rail steels and their thermite welds. Fracture micromechanisms were analyzed by scanning electron microscopy （SEM） on the fracture surfaces of the tested specimens. The ductility indices （percentage elongation aider frac- ture and percentage reduction of area） and the toughness indices （Charpy impact energy Ak and plane-strain fracture toughness Kic） of the two kinds of rail steels and the corresponding thermite welds all decrease as the temperature decreases. The thermite welds are more critical to fracture than the rail steel base metals, as indicated by a higher yield-to-ultimate ratio and a much lower Charpy impact energy. U71Mn rail steel is relatively higher in toughness than U75V, as demonstrated by larger Ak and Klc values. Therefore, U71Mn rail steel and the corresponding thermite weld are recommended in railway construction and maintenance in cold regions.

Mechanics model of additional longitudinal force transmission between bridges and continuously welded rails with small resistance fasteners

A new mechanics model, which reveals additional longitudinal force transmission between the continuously welded rails and the bridges, is established on the fact that the influence of the mutual relative displacement (among) the rail, the sleeper and the beam is taken into account. An example is presented and numerical results are compared. The results show that the additional longitudinal forces calculated with the new model are less than those of the previous, especially in the case of the flexible pier bridges. The new model is also suitable for the analysis of the additional longitudinal force transmission between rails and bridges of ballastless track with small resistance fasteners without taking the sleeper displacement into account, and compared with the ballast bridges, the ballastless bridges have a much stronger additional longitudinal force transmission between the continuously welded rails and the bridges.

Effect of Preheating Temperature on the Mechanical and Fracture Properties of Welded Pearlitic Rail Steels

The effect of preheating temperature on the mechanical and fracture behavior, hardness, and the microstructure of slot welded pearlitic rail steel were studied. Railhead sections with slots were preheated to 200℃, 300℃, 350℃ and 400℃?before gas metal arc filling to simulate defects repair. Another sample, welded at room temperature (RT) with no preheat, was studied in comparison. The parent rail steel has ultimate strength, yield strength and strain to failure of 1146 MPa, 717 MPa and 9.3%, respectively. Optimum values of these properties for the welded rail steels were found to be 1023 MPa, 655 MPa and 4.7%, respectively, for the 200℃ preheat temperature. On this basis, the optimum weld efficiency was found to be 89.2%. The average apparent fracture toughness KI for the parent rail was 127 MPa.m0.5, while that for the optimum welded joint (200℃ preheat) was 116.5 MPa.m0.5. In addition, the average hardness values of the weld, fusion zone, and heat affected zone (HAZ) were 313.5, 332 and 313.6 HB, respectively, while that for parent rail steel was about 360 HB. Dominance of bainite and acicular ferrite phase in the weld microstructure was observed at 200℃ preheat.

Application of Programmable Controller in a Rail Welding Machine

An innovation is conducted on a K190πK rail auto welding machine because of its poor stability in quality of welding joints. A new control system based on a programmable controller is designed to replace the old one. The new control system is of higher accuracy in controlling sequence and good ability in anti disturbance, and is convenient to operate. The comparison tests are carried out. The experimental results show that the quality of welded joints is greatly increased by the improved welding mechine.

Stability issues of the continuous welded rail track on the concrete sleepers on the curves with radius R ≤ 300 m

This paper describes the economic and technological benefits of installing continuous welded rail （CWR） track on sharp （radius≤300 m） railway curves. A new form of prestressed concrete sleepers developed by the V. Lazaryan Dniprope- trovsk National University of Railway Transport is shown to improve the lateral shift resistance of CWR track in sharp curves and the use of anchor sleepers on tangents is shown to make it possible to lower the fastening temperature of the CWR track in order to increase the rail lifespan.

Application of heat treatment technology for thermit welds at Da-qin railway

A kind of heat treatment technology of thermit welds was introduced in this paper. Through the heal treatment not only the mechanical properties are improved, but the hardness of head was redistributed. Heat treatreatment alleviated the soften of the quenched rail clue to welding. The technology has been successfully applied to lay the lines and crosses at Da-qin continuous line.

公铁两用大跨度斜拉桥-无砟轨道体系变形适应性研究

高速铁路大跨度斜拉桥结构变形受其复杂服役环境影响显著,而无砟轨道对工后变形的调整能力有限,因此大跨度斜拉桥的复杂变形条件将直接影响其上无砟轨道结构的适应性。以沪渝蓉高铁长江北支公铁两用大跨度斜拉桥应用无砟轨道为工程背景,建立无砟轨道-大跨度斜拉桥一体化精细空间有限元模型,分析铁路、公路以及温度等多种荷载联合作用下大跨度斜拉桥-无砟轨道体系平顺性、无缝线路稳定性和无砟轨道层间变形协调性,从而对大跨度公铁两用钢桁梁斜拉桥-无砟轨道体系变形适应性开展深入研究。结果表明:在运营荷载及温度荷载最不利组合作用下,大跨度斜拉桥主梁线形平顺,变形平缓,桥梁整体刚度较好,桥上无砟轨道几何形位可以满足静态验收标准;大跨度斜拉桥上无缝线路的强度和稳定性满足要求,扣件工作性能良好,钢轨伸缩调节器的设置可有效释放梁端钢轨的纵向应力;无砟轨道层间设置橡胶隔离层且不跨主梁桁架节间的布置方式可提高大跨度斜拉桥上无砟轨道的变形协调性能,使得桥上无砟轨道层间始终处于受压状态,达到“隔而不离”的桥上轨道层间理想服役状态;大跨度公铁两用钢桁梁斜拉桥-无砟轨道体系变形适应性良好。本文研究成果可为公铁两用大跨度钢桁梁斜拉桥上无砟轨道的应用提供技术参考。

考虑加载历史的小半径曲线桥梁梁轨相互作用分析

目前,大部分考虑加载历史的梁轨相互作用研究都集中在直线桥梁上,针对曲线桥梁,尤其是小半径曲线桥梁,梁轨相互作用的研究相对较少。采用理想弹塑性滞回阻力模型模拟扣件纵向阻力,运用有限元软件,建立以城东特大桥为研究对象的钢轨-桥梁-墩台三维有限元空间力学计算模型,研究曲线半径对于梁轨相互作用的影响,探究了多荷载耦合作用、往复荷载作用以及循环荷载作用下考虑加载历史效应的曲线桥梁梁轨相互作用情况,并提出“拉力百分比”以及“压力百分比”的概念以便分析曲线半径对传统线性叠加法误差的影响。结果表明,曲线桥梁中梁轨纵、横向相互作用分别与曲线半径成正、反比,相关数据改变幅度与曲线半径成反比且当曲线半径超过800 m时基本收敛,此时可采用“以直代曲”的简化算法;曲线半径对于横向梁轨相互作用影响程度大于纵向,相较于挠曲、制动工况,伸缩工况受曲线半径影响更加显著;多荷载耦合作用下,采用传统线性叠加法相较于考虑加载历史更为保守且温度荷载起主要贡献;考虑加载历史时钢轨在往复荷载作用下会产生不可忽视的残余内力,且在循环荷载作用下将会产生收敛于第1次往复荷载下的残余内力,这是扣件纵向阻力的弹塑性滞回特性决定的;线性叠加法误差与曲线半径具有相关性,相较于挠曲、制动工况,伸缩工况下对其更为敏感。研究结果可为考虑加载历史下曲线桥梁结构设计提供参考。

重载铁路钢轨焊接不平顺对道床动力特性的影响

在车轮反复碾压作用下,钢轨接头区域易出现马鞍形不平顺、低塌等缺陷。为分析重载铁路钢轨焊接不平顺对有砟道床动力特性的影响,首先建立车辆-轨道耦合动力学模型,计算钢轨焊接不平顺影响下的轨枕上动压力;然后采用离散元分析方法,建立有砟轨道结构二维模型,将焊接不平顺影响下的轨枕上动压力作为荷载输入,模拟分析钢轨焊接不平顺对有砟轨道结构道床动力特性的影响。结果表明:钢轨焊接不平顺显著增加了接头两侧轨枕上动压力,且不平顺短波波长越长,影响范围越大,当波长为0.2 m、波深为0.7 mm时,接头两侧轨枕上动压力增加显著,最大值相较于随机不平顺时增加了50.52%;随着焊接不平顺短波波长的减小及波深的增加,道床垂向加速度、摩擦耗能以及累积变形均随之增加;道砟颗粒间最大接触力受焊接不平顺影响较为显著,尤其当短波波深大于0.5 mm时,最大接触力随波深增加而显著增大;当短波波长为0.1 m、波深为0.7 mm时,相较于随机不平顺,道床应力增加55.89%,距道床顶面0.15 m深度处的道砟颗粒加速度增加了449.42%。

连续刚构系杆拱桥-无缝线路体系适应性研究

为确定连续刚构系杆拱桥上无缝线路铺设方案,基于梁轨相互作用原理,建立无缝线路-无砟轨道-连续刚构系杆拱桥空间耦合模型,针对温度、列车荷载作用下连续刚构系杆拱桥-无缝线路体系适应性开展研究,探明了连续刚构系杆拱桥上无缝线路纵向力分布规律,提出适宜不同区域的连续刚构系杆拱桥上无缝线路铺设方案。研究表明:相较于相同梁跨布置的连续梁桥,连续刚构系杆拱桥温度跨度明显减小,温度作用下钢轨纵向力关于跨中对称分布,峰值出现在主桥梁端;跨中系杆拱区域钢轨纵向力分布发生突变,主梁产生较大的压弯上拱变形;拱肋和吊杆温差对桥梁主跨上的无缝线路纵向力分布有明显影响,随着拱肋降温幅度的增大,主梁跨中钢轨压力增大;随着吊杆降温幅度的增大,主梁跨中钢轨压力线性减小;连续刚构系杆拱桥钢轨伸缩力明显大于钢轨挠曲力,故在无缝线路检算中,主力应采用基本温度力与伸缩力组合;连续刚构系杆拱桥结构铺设方案优先采用全桥铺设常阻力扣件方案,当该方案无法满足钢轨强度要求时,可以通过铺设小阻力扣件和设置钢轨伸缩调节器等措施解决钢轨纵向力过大的问题;当该刚构拱桥位于寒冷、温暖和炎热地区时,分别推荐采用梁端设置调节器方案、边跨铺设小阻力扣件方案和全桥铺设常阻力扣件方案。研究成果可为连续刚构系杆拱桥上无缝线路的设计、重点区域检测监测及养护维修提供借鉴。

高原地区无缝道岔健康监测研究

研究目的:无缝道岔是无缝线路的关键技术之一,高原地区的气候复杂使其受力更为复杂,为保证列车的安全运营,有必要对其进行长期实时健康监测。本文针对高原地区无缝道岔构建实时健康监测系统,并对一组道岔进行为期2个月的在线监测,对监测期内的轨温、尖轨尖端位移及尖轨断轨进行相应分析。研究结论:(1)钢轨温度变化趋势与气温变化趋势相同,最高轨温始终高于日最高气温,平均差值为11.75℃,其出现时间总体来讲早于气温出现3 h左右;(2)最低轨温与气温值基本相同,其出现时间也基本相近,大致于早上7:00—8:00出现;(3)钢轨温度和大气温度之间存在较好的一次线性关系,当气温变化1℃时轨温变化约为1.5℃;(4)尖轨尖端的纵向位移变化趋势与气温和轨温变化趋势相同,与气温间呈一次线性关系;(5)本文研究可为高原地区无缝道岔的养护维修提供数据支撑。

地铁连续刚构桥上无砟轨道无缝线路纵向力分析

【目的】为研究地铁连续刚构桥上无砟轨道无缝线路纵向受力与变形规律,对地铁连续刚构桥上无砟轨道无缝线路设计改进、运营养护维修提供理论指导。【方法】根据梁-板-轨相互作用原理,建立地铁连续刚构桥上整体道床式无砟轨道无缝线路空间耦合模型,计算伸缩、挠曲、制动、断轨工况下轨道结构和桥梁纵向力及位移,并对轨道结构静力特性进行对比分析,为地铁连续刚构桥上无缝线路轨道结构设计提供参考。【结果】结果表明:双线列车荷载中点与中部梁端处重合时为列车垂向荷载最不利工况,此时钢轨纵向力与钢轨、桥梁纵向位移均为最大,均出现在中部梁端附近,数值分别为70.3 kN与0.6,0.8 mm;双线制动荷载列车尾部位于两侧梁端时为列车制动荷载最不利工况,此时钢轨纵向力与钢轨、桥梁纵向位移均为最大,数值分别为107.8 kN与1.6,1.7 mm。【结论】伸缩力作用下各个端部桥缝处为薄弱部位,在平时养护中应特别注意梁端部桥缝处轨道结构,防止因伸缩力过大而产生断轨;钢轨发生断轨时,在断缝处纵向力、纵向位移均发生突变,严重影响线路行车安全。

城市轨道交通轨面短波不平顺谱实测研究

针对城市轨道交通诱发的振动噪声问题,对轨面短波不平顺进行研究.首先,对上海市轨道交通线路轨面短波不平顺实测数据进行零均值化、剔除异常值、消除趋势项等预处理.其次,利用改进的协方差法计算得到轨面短波不平顺功率谱,分析轨道类型、曲线半径及钢轨接头对轨面短波不平顺功率谱分布规律的影响.然后,基于非线性最小二乘法对轨面短波不平顺谱进行拟合.最后,提出我国城市轨道交通轨面短波不平顺统计谱表达式.研究结果表明:直线段接头区轨面短波不平顺功率谱密度曲线在整个分析波长范围内具有较多特征峰值;直线段接头区上、下行短波不平顺功率谱密度值随波长的分布特征和数值相差不大,说明上、下行的轨面不平顺状态基本相同;钢轨的磨耗程度与曲线半径呈负相关,内、外轨面不平顺功率谱密度的差异随曲线半径的增大而减小,曲线半径是影响轨面不平顺状态的主要因素之一;线路类型对轨面短波不平顺功率谱的影响不大,不同曲线半径、焊接接头影响明显,在对轨道进行维护和养护时需关注小曲线半径区段以及焊接接头区段的不平顺状态.

基于轨道不平顺的无缝线路稳定性统计分析

为弥补现有无缝线路稳定性设计未区分轨道平顺性等级的不足,基于轨道不平顺数值模拟方法和无缝线路稳定性有限元分析方法,提出考虑轨道不平顺和道床横向阻力随机性的无缝线路稳定性概率统计分析方法。针对不同半径的铁路线路,研究轨道不平顺、道床横向阻力大小及位置分布随机性对钢轨允许温升分布规律的影响,并与现有无缝线路稳定性分析方法计算结果进行对比。研究结果表明:当道床横向阻力服从正态分布时,单独考虑道床横向阻力大小随机性时,钢轨允许温升近似服从极值I型分布;单独考虑轨道不平顺随机性、同时考虑道床横向阻力大小及位置分布随机性或综合考虑上述3个因素随机性时,钢轨允许温升均服从正态分布;以不少于95%保证率定义的钢轨允许温升标准值及均值随着线路平顺性的改善而增加;不同曲线半径条件下,现有“等波长-有限元”确定的钢轨允许温升与美国五级谱对应钢轨允许温升标准值相近,与其他轨道谱对应结果则存在较大差异;在综合考虑轨道不平顺、道床横向阻力大小及位置分布三因素随机性条件下,建立表征钢轨允许温升分布的均值、标准差及标准值与曲线半径间的显式映射关系,使无缝线路稳定性分析中考虑线路平顺性等级成为了可能。研究结果为进一步优化铁路无缝线路极限状态法设计提供了参考。

变摩擦条件下高速钢轨焊缝处轮轨滚动接触-冲击行为研究

采用变摩擦系数能够较为准确地刻画轮轨滚动接触行为。为研究变摩擦系数对钢轨焊缝处轮轨滚动接触行为的影响,建立三种不同钢轨焊缝工况的三维轮轨瞬态滚动接触有限元模型,通过对比库伦型摩擦系数的结果,计算分析变摩擦系数对轮轨力、接触斑内的微滑以及黏滑分布等接触行为的影响。结果表明:变摩擦系数接触斑内的滑动区域占比会更大且在滑动区域会引起黏滑振荡现象,当轮轨界面滑动现象越明显时,黏滑振荡越剧烈;变摩擦系数对法向接触解的影响不大,切向接触解会因接触状态的改变显著受到影响,造成凸形1焊缝的不均匀磨耗;变摩擦系数会影响von Mises应力分布,其最大von Mises应力发生的位置会向轨底移动,对伤损出现的位置产生影响。

基于3m波长地铁钢轨焊缝接头不平顺的轮轨响应分析

相对于1 m弦测值的焊缝接头动力学评估与管理,基于3 m波长范围的焊缝接头不平顺轮轨响应分析对其服役状态评估与管理具有重要意义。首先,基于车辆-轨道垂向耦合动力学理论建立车辆-轨道垂向耦合模型;然后,借助基于一弦N点弦测法研制的钢轨短波不平顺测量小车,对地铁线路焊缝接头不平顺进行精确测量,并根据传统弦测理论得到1 m弦测值;接着,将实测3 m波长焊缝接头不平顺和1 m弦测值作为车辆-轨道垂向耦合模型的不平顺激励输入,对比3 m波长焊缝接头不平顺和1 m弦测值激扰下的轮轨响应;最后,研究了车速和焊缝位置对轮轨动力响应的影响。结果表明:相比1 m弦测值激扰下的轮轨动力响应结果,3 m波长焊缝接头不平顺激扰下的轮轨力幅值变化不明显,轮重减载率幅值增大11.52%,钢轨加速度幅值增大54.05%,轮对振动加速度幅值增大37.67%;车速提高会导致轮轨力和轮重减载率幅值增大;焊缝中心与轨枕间的距离增加,轮轨力幅值先增加后减小,当焊缝中心距离轨枕0.1 m时,轮轨力幅值最大。