Effect of Bogie Cavity End Wall Inclination on Flow Field and Aerodynamic Noise in the Bogie Region of High-Speed Trains

Combining the detached eddy simulation(DES)method and Ffowcs Williams-Hawkings(FW-H)equation,the effect of bogie cavity end wall inclination on the flow field and aerodynamic noise in the bogie region is numerically studied.First,the simulation is conducted based on a simplified cavity-bogie model,including five cases with different inclination angles of the front and rear walls of the cavity.By comparing and analyzing the flow field and acoustic results of the five cases,the influence of the regularity and mechanism of the bogie cavity end wall inclination on the flow field and the aerodynamic noise of the bogie region are revealed.Then,the noise reduction strategy determined by the results of the simplified cavity-bogie model is applied to a three-car marshaling train model to verify its effectiveness when applied to the real train.The results reveal that the forward inclination of the cavity front wall enlarges the influence area of shear vortex structures formed at the leading edge of the cavity and intensifies the interaction between the vortex structures and the front wheelset,frontmotor,and front gearbox,resulting in the increase of the aerodynamic noise generated by the bogie itself.The backward inclination of the cavity rear wall is conducive to guiding the vortex structures flow out of the cavity and weakening the interaction between the shear vortex structures and the cavity rear wall,leading to the reduction of the aerodynamic noise generated by the bogie cavity.Inclining the rear end wall of the foremost bogie cavity of the head car is a feasible aerodynamic noise reduction measure for high-speed trains.

A critical review of wheel/rail high frequency vibration-induced vibration fatigue of railway bogie in China

Purpose–This review aims to give a critical view of the wheel/rail high frequency vibration-induced vibration fatigue in railway bogie.Design/methodology/approach–Vibration fatigue of railway bogie arising from the wheel/rail high frequency vibration has become the main concern of railway operators.Previous reviews usually focused on the formation mechanism of wheel/rail high frequency vibration.This paper thus gives a critical review of the vibration fatigue of railway bogie owing to the short-pitch irregularities-induced high frequency vibration,including a brief introduction of short-pitch irregularities,associated high frequency vibration in railway bogie,typical vibration fatigue failure cases of railway bogie and methodologies used for the assessment of vibration fatigue and research gaps.Findings–The results showed that the resulting excitation frequencies of short-pitch irregularity vary substantially due to different track types and formation mechanisms.The axle box-mounted components are much more vulnerable to vibration fatigue compared with other components.The wheel polygonal wear and rail corrugation-induced high frequency vibration is the main driving force of fatigue failure,and the fatigue crack usually initiates from the defect of the weld seam.Vibration spectrum for attachments of railway bogie defined in the standard underestimates the vibration level arising from the short-pitch irregularities.The current investigations on vibration fatigue mainly focus on the methods to improve the accuracy of fatigue damage assessment,and a systematical design method for vibration fatigue remains a huge gap to improve the survival probability when the rail vehicle is subjected to vibration fatigue.Originality/value–The research can facilitate the development of a new methodology to improve the fatigue life of railway vehicles when subjected to wheel/rail high frequency vibration.

Theoretical research and experimental validation of quasi-static load spectra on bogie frame structures of high-speed trains

One of the major problems in structural fatigue life analysis is establishing structural load spectra under actual operating conditions.This study conducts theoretical research and experimental validation of quasi-static load spectra on bogie frame structures of high-speed trains.The quasistatic load series that corresponds to quasi-static deformation modes are identified according to the structural form and bearing conditions of high-speed train bogie frames.Moreover,a force-measuring frame is designed and manufactured based on the quasi-static load series.The load decoupling model of the quasi-static load series is then established via calibration tests.Quasi-static load–time histories,together with online tests and decoupling analysis,are obtained for the intermediate range of the Beijing—Shanghai dedicated passenger line.The damage consistency calibration of the quasi-static discrete load spectra is performed according to a damage consistency criterion and a genetic algorithm.The calibrated damage that corresponds with the quasi-static discrete load spectra satisfies the safety requirements of bogie frames.

Investigation into the Vibration of Metro Bogies Induced by Rail Corrugation

The current research of rail corrugation mainly focuses on the mechanisms of its formation and development. Compared with the root causes and development mechanisms, the wheel-rail impacts, the fatigue failure of vehicle-track parts, and the loss of ride comfort due to rail corrugation should also be taken into account. However, the influences of rail corrugation on vehicle and track vibration, and failure of vehicle and track structural parts are barely discussed in the literature. This paper presents an experimental and numerical investigation of the structural vibration of metro bogies caused by rail corrugation. Extensive experiments are conducted to investigate the effects of short-pitch rail corrugation on the vibration accelerations of metro bogies. A dynamic model of a metro vehicle coupled with a concrete track is established to study the influence of rail corrugation on the structural vibration of metro bogies. The field test results indicate that the short-pitch rail corrugation generates strong vibrations on the axle-boxes and the bogie frames, therefore, accelerates the fatigue failure of the bogie components. The numerical results show that short-pitch rail corrugation may largely reduce the fatigue life of the coil spring, and improving the damping value of the primary vertical dampers is likely to reduce the strong vibration induced by short-pitch rail corrugation. This research systematically studies the effect of rail corrugation on the vibration of metro bogies and proposes some remedies for mitigating strong vibrations of metro bogies and reducing the incidence of failure in primary coil springs, which would be helpful in developing new metro bogies and track maintenance procedures.

Damage Tolerance Assessment of a Brake Unit Bracket for High-Speed Railway Welded Bogie Frames

The brake unit bracket of a bogie frame is an important load-carrying component, particularly under emergency start/stop conditions. Conventional infinite/safe life approaches provide an over-conservative recommendation for the allowable strength and lifetime, which hinders the lightweight design of modern railway vehicles. In this study, to ensure the reliability and durability of a brake unit bracket, an attempt was made to integrate the nominal stress method and an advanced damage tolerance method. First, a complex bogie frame was modelled using solid elements instead of plate and beam elements. A hot spot stress region on the bracket was found under an eight-stage load spectrum obtained from the Wuhan–Guangzhou high-speed railway line. Based on the probability of foreign damage, a semi-elliptical surface crack was then assumed for residual life assessment. The results obtained by the cumulative damage and damage tolerance methods show that the brake unit bracket can operate for over 30 years. Moreover, even if a 2-mm depth crack exists, the brake unit bracket can be safely operated for more than 2.27 years, with the hope that the crack can be detected in subsequent maintenance procedures. Finally, an appropriate safety margin was suggested which provides a basis for the life prediction and durability assessment of brake unit brackets of high-speed railways.

Methodology to Evaluate Fatigue Damage of High-Speed Train Welded Bogie Frames Based on On-Track Dynamic Stress Test Data

The current method of estimating the fatigue life of railway structures is to calculating the equivalent stress amplitude based on the measured stress data. However, the random of the measured data is not considered. In this paper, a new method was established to compute the equivalent stress amplitude to evaluate the fatigue damage based on the measurable randomness, since the equivalent stress is the key parameter for assessment of structure fatigue life and load derivation. The equivalent stress amplitude of a high-speed train welded bogie frame was found to obey normal distribution under uniform operation route that verified by on-track dynamic stress data, and the proposed model is, in effect, an improved version of the mathematical model used to calculate the equivalent stress amplitude. The data of a long-term, on-track dynamic stress test program was analyzed to find that the normal distribution parameters of equivalent stress amplitude values differ across different operation route. Thus, the fatigue damage of the high-speed train welded bogie frame can be evaluated by the proposed method if the running schedule of the train is known a priori. The results also showed that the equivalent stress amplitude of the region connected to the power system is more random than in other regions of the bogie frame.

Comparative study on wheel-rail dynamic interactions of side-frame cross-bracing bogie and sub-frame radial bogie

Improving freight axle load is the most effective method to improve railway freight capability; based on the imported technologies of railway freight bogie, the 27 t axle load side-frame cross-bracing bogie and sub-frame radial bogie are developed in China. In order to analyze and compare dynamic interactions of the two newly developed heavy-haul freight bogies, we establish a vehi- cle-track coupling dynamic model and use numerical calculation methods for computer simulation. The dynamic performances of the two bogies are simulated separately at various conditions. The results show that at the dipped joint and straight line running conditions, the wheel-rail dynamic interactions of both bogies are basically the same, but at the curve negotiation condition, the wear and the lateral force of the side-frame cross-bracing bogie are much higher than that of the sub-frame radial bogie, and the advantages become more obvious when the curve radius is smaller. The results also indicate that the sub- frame radial bogie has better low-wheel-rail interaction characteristics.

Analysis of the Load-Stress Response Characteristics of the Bogie Frame in Intercity Electric Multiple Unit

Load spectra research for bogie frame requires establishing the load?stress relationship on working condition, which has been omitted by the researchers. With the load?stress of the bogie frame of an intercity Electric Multiple Unit(Hereinafter referred to as EMU) as the research object, an optimization model of the load?stress transfer relationship is established. The load?stress coe cient for EMU bogie frame was calibrated in the laboratory bench and online test was arranged on Dazhou?Chengdu line. Comparison of nonlinear and linear neural networks proves that the linear transitive relation between the load and stress of the bogie frame in the operating process is highly suitable. An optimization model of the load?stress transfer coe cient is obtained. The data calculated with the modified coe cient are closer to the dynamic stress results in the actual operating process than the data calculated with the calibration coe cient. The coe cient of the modified transitive relation is una ected by operating area, empty load, heavy load, or other conditions in the operating process of the intercity EMU. The real loads in actual situations are obtained. The model of online load?stress relationship that is highly suitable for line stress calculation is finally established. The research is helpful for further damage calculation and inferring the time history signal of the load in load spectra research.

Study on establishment of standardized load spectrum on bogie frames of high-speed trains

Establishing structural load spectrum under actual operating conditions is a major problem in structural fatigue life analysis. This study introduces the load measuring method for the bogie frame structure. The load-measuring frame based on quasi-static can measure different load systems synchronously. The t-test method is employed to evaluate the least test time of deducing the parent distribution. In order to fit the load spectrum distribution accurately, the kernel density estimation method is employed which is based on the sample characteristics. The expansion factor method is used to deduce the maximum load. The formula of standardized load spectrum derives from the deduced maximum load, the linear factor between operating condition length and cumulative frequency and the parent distribution of each load system. The damage consistency criterion is performed by solving the objective function with constraint conditions. The calibrated damage provides a suitable representation of the real damage under actual operating conditions. By processing and analyzing the load spectrum and stress spectrum data of the measured lines, it is verified that the standardized load spectrum established in this paper is superior to the European specification and the Japanese specification in evaluating the fatigue reliability of the structure.

Theoretical Research and Experimental Validation of Elastic Dynamic Load Spectra on Bogie Frame of High-speed Train

When a train runs at high speeds, the external exciting frequencies approach the natural frequencies of bogie critical components, thereby inducing strong elastic vibrations. The present international reliability test evaluation standard and design criteria of bogie frames are all based on the quasi-static deformation hypothesis. Structural fatigue damage generated by structural elastic vibrations has not yet been included. In this paper, theoretical research and experimental validation are done on elastic dynamic load spectra on bogie frame of high-speed train. The construction of the load series that correspond to elastic dynamic deformation modes is studied. The simplified form of the load series is obtained. A theory of simplified dynamic load–time histories is then deduced. Measured data from the Beijing–Shanghai Dedicated Passenger Line are introduced to derive the simplified dynamic load–time histories. The simplified dynamic discrete load spectra of bogie frame are established. Based on the damage consistency criterion and a genetic algorithm, damage consistency calibration of the simplified dynamic load spectra is finally performed. The computed result proves that the simplified load series is reasonable. The calibrated damage that corresponds to the elastic dynamic discrete load spectra can cover the actual damage at the operating conditions. The calibrated damage satisfies the safety requirement of damage consistency criterion for bogie frame. This research is helpful for investigating the standardized load spectra of bogie frame of high-speed train.

Design and Dynamics Analysis of Anti-skid Braking System for Aircraft with Four-wheel Bogie Landing Gears

In asymmetric conditions,the movement and loads of left/right wheels or front/back wheels of the aircraft with multi-wheel or four-wheel bogie landing gears are inconsistent.There are few open literatures related to anti-skid braking system for multi-wheels due to technology blockade.In China,the research on multi-channel control and non-equilibrium regulation has just started,and the design of multi-channel control system for anti-skid braking,the simulation of asymmetry taxiing under braking are not studied.In this paper,a dynamics model of ground movement for aircraft with four-wheel bogie landing gears is established for braking simulation, considering the six-degree-of-freedom aircraft body and the movement of bogies and wheels.A multi-channel anti-skid braking system is designed for the wheels of the main landing gears with four-wheel bogies.The eight wheels on left and right landing gears are divided into four groups,and each group is controlled via one channel.The cross protection and self-locked protection modules are added between different channels.A multi-channel anti-skid braking system with slip-ratio control or with slip-velocity control is established separately.Based on the aircraft dynamics model,aircraft braking to stop with anti-skid control on dry runway and on wet runway are simulated.The simulation results demonstrate that in asymmetric conditions,added with cross protection and self-locked protection modules,the slip-ratio-controlled braking system can automatically regulate brake torque to avoid deep slipping and correct aircraft course.The proposed research has reference value for improving brake control effect on wet runway.

Electric Multiple Unit Bogie Maintainability Allocation with Interval Analysis and Fuzzy Evaluation Method

Based on the failure rate and design features allocation method,considering the multiple influential factors which affect electric multiple unit( EMU) bogies,maintainability allocation on EMU bogie was presented by interval analytic hierarchy analysis and fuzzy comprehensive assessment. The maintainability allocation model was established. Weight based on the influence degree of each factor on maintenance was assigned. Fuzzy interval numbers were used to substitute real numbers and express uncertain information.The maintenance weighting factors for each subsystem were calculated by fuzzy comprehensive assessment. Then the allocation method was applied to EMU bogie. The results show that the method is feasible. The problem difficult to quantify for EMU bogie maintenance allocation is solved effectively.

Numerical Investigation of the Deposition Characteristics of Snow on the Bogie of a High-Speed Train

To investigate the deposition distribution of snow particles in the bogie surfaces of a high-speed train,a snow particle deposition model,based on the critical capture velocity and the critical shear velocity,was elaborated.Simulations based on the unsteady Reynolds-Averaged Navier-Stokes(RANS)approach coupled with Discrete Phase Model(DPM)were used to analyze the motion of snow particles.The results show that the cross beam of the bogie frame,the anti-snake damper,the intermediate brake clamps in the rear wheels,the traction rod and the anti-rolling torsion bar are prone to accumulate snow.The accumulation mass relating to the vertical surface in the rear region,horizontal surface in the front region and the corner area of the bogie is high.The average snow accumulation mass for each component ordered from high to low is as follow:traction rod,frame,bolster,brake clamp 2,anti-rolling torsion bar,brake clamp 1,transverse damper,axle box 2,axle box 1,air spring,anti-snake damper,tread cleaning device.The snow accumulation mass on the front components of the bogie is more significant than that relating to the rear components.Particularly,the average snow accumulation mass of rear brake clamp 2 and axle box 2 is about twice as high as that of the front brake clamp 1 and axle box 1.

Real-time multibody modeling and simulation of a scaled bogie test rig

In wheel–rail adhesion studies,most of the test rigs used are simplified designs such as a single wheel or wheelset,but the results may not be accurate.Alternatively,representing the complex system by using a full vehicle model provides accurate results but may incur complexity in design.To trade off accuracy over complexity,a bogie model can be the optimum selection.Furthermore,only a real-time model can replicate its physical counterpart in the time domain.Developing such a model requires broad expertise and appropriate software and hardware.A few published works are available which deal with real-time modeling.However,the influence of the control system has not been included in those works.To address these issues,a real-time scaled bogie test rig including the control system is essential.Therefore,a 1:4 scaled bogie roller rig is developed to study the adhesion between wheel and roller contact.To compare the performances obtained from the scaled bogie test rig and to expand the test applications,a numerical simulation model of that scaled bogie test rig is developed using Gensys multibody software.This model is the complete model of the test rig which delivers more precise results.To exactly represent the physical counterpart system in the time domain,a real-time scaled bogie test rig(RT-SBTR)is developed after four consecutive stages.Then,to simulate the RT-SBTR to solve the internal state equations and functions representing the physical counterpart system in rigs used are simplified designs such as a single wheel or wheelset,but the results may not be accurate.Alternatively,representing the complex system by using a full vehicle model provides accurate results but may incur complexity in design.To trade off accuracy over complexity,a bogie model can be the optimum selection.Furthermore,only a real-time model can replicate its physical counterpart in the time domain.Developing such a model requires broad expertise and appropriate software and hardware.A few published works are available which deal with real-time modeling.However,the influence of the control system has not been included in those works.To address these issues,a real-time scaled bogie test rig including the control system is essential.Therefore,a 1:4 scaled bogie roller rig is developed to study the adhesion between wheel and roller contact.To compare the performances obtained from the scaled bogie test rig and to expand the test applications,a numerical simulation model of that scaled bogie test rig is developed using Gensys multibody software.This model is the complete model of the test rig which delivers more precise results.To exactly represent the physical counterpart system in the time domain,a real-time scaled bogie test rig(RT-SBTR)is developed after four consecutive stages.Then,to simulate the RT-SBTR to solve the internal state equations and functions representing the physical counterpart system in equal or less than actual time,the real-time simulation environment is prepared in two stages.To such end,the computational time improved from 4 times slower than real time to 2 times faster than real time.Finally,the real-time scaled bogie model is also incorporated with the braking control system which slightly reduces the computational performances without affecting real-time capability.

Effect of Increasing Speed on Stress of Biaxial Bogie Frames

Increasing the trains’ speed has always been one of the goals of any railway industry and train manufacturers. Also, the influence of the train speed on bogie’s dynamics has an immense importance. Therefore, it is important to analyze the effect of train speed on the stress distribution in different parts of train structure. In this study the result of the increasing speed on the applied stresses of a biaxial bogie frame has been examined. For this purpose, a biaxial bogie frame has been modeled using finite element analysis. Static and dynamic forces applied on the bogie with biaxial frame have been obtained for different speeds and rail roughness. The Von Mises stresses are adopted as equivalent stresses in the strength calculation. The results show that maximum stress always has been induced in the bogie bowl also the increase in bogie’s speed has remarkable effect on the increment of applied stresses in the bogie frame.

Experimental Study on Rotation Resistance Coefficient of Motor Bogie for Type A Vehicle

Rotation resistance coefficient is an important operating parameter for vehicle bogies, which influences the dynamic behavior of vehicles directly. A research on the rotation resistance coefficient of type A vehicle motor bogies was conducted by means of theoretical calculation, dynamic simulation, test certification, and so on. Result of the simulation analysis shows that the rotation resistance coefficient relates to air springs stiffness and negotiated curve radii, and it varies proportionally with the change of air springs horizontal stiffness. The greater the rotation angle is, the greater the factor becomes. The certifications made under the operating conditions(e.g., different air spring status, different rotation speeds) indicate that the rotation resistance coefficient increases with the increase of the rotation speed. The anti-yaw dampers can contribute to the rotation resistance torque acted on bogie, and the greater the rotation speeds are, the greater the torque generated by the anti-yaw dampers is. The results suggest that the theoretical analysis and dynamics simulation are in accordance with the results from the bogie bench tests, which meet the requirements in EN14363 and the indicators in vehicles safe operation.

Bogie's Rotational Resistance Coefficient Analysis Based on Novel Parallel Mechanism

In this paper,a novel parallel mechanism which can be used to evaluate body-to-bogie yawtorque is proposed.It can satisfy experimental testing for rotation resistance coefficient(RRC) with various types of bogies,different rotational speeds,and different states of air spring.Aiming at the problem that computing speed of Newton iterative method for solving rotational angle is incompetence to meet the real-time requirements,and also that other methods adopting physical device such as laser displacement sensor to solve rotational angle possess larger measurement error,the analytical techniques method used for solving rotational angle is presented.Finally,by using the upper-single-6-DOF motion platform as an authentic urging mean to simulate a real vehicle,the test was carried out under the speeds of 0.2 and 1.0(°)/s,with the air spring at the inflated and deflated states,respectively.The results showthat the RRC of the bogie under various conditions is less than 0.06,which meets the standard requirement EN-14363.It was also found that the speed of vehicles moving along curves and the state of air spring were key factors influencing the RRC.The feasibilities of this model and test method are verified in this study.

An Experimental Study on Bogie Frame of a High Speed Electrical Locomotive

For the dynamics of wheel/rail and car body, lightweighting of bogie frames is one of main concerns of designers. Lightweighting of the bogie frames may reduce the fatigue strength and life, especially in heavy haul and high-speed conditions. In this work, full-scale fatigue and fracture experiments are performed to meet the design requirements of bogie frame of a high-speed electrical locomotive. Multi-axial stress-states of some dangerous points are found both in service and numerical calculation. The Von-Mises equivalent stress criterion is used to evaluate the strength. Then crack initiation and propagation detected during the test are described. The reason why the crack growth rate may become slow in the weld structure of the bogie frame is explained using a residual stress concept. Miner's accumulative damage rule and P-S-N curve are used to predict the life of the bogie frame under fatigue and fracture tests. The experimental approach and theoretical analysis give satisfactory results and design information.

Research on dent resistance of lightweight three-piece cans

An experimental apparatus and a numerical simulation model were built for investigating the dent resistance of lightweight three-piece cans.The dent resistance of raw materials 0.19 mm T4 and 0.17 mm DR7M was compared.It was found that when the thickness reduced from 0.19 to 0.17 mm,the dent resistance became about 80％ of that before thinning.This provides a guidance for the continuous thinning of three-piece cans.

Experimental prototyping of the adhesion braking control system design concept for a mechatronic bogie

The dynamic parameters of a roller rig vary as the adhesion level changes.The change in dynamics parameters needs to be analysed to estimate the adhesion level.One of these parameters is noise emanating from wheel–rail interaction.Most previous wheel–rail noise analysis has been conducted to mitigate those noises.However,in this paper,the noise is analysed to estimate the adhesion condition at the wheel–rail contact interface in combination with the other methodologies applied for this purpose.The adhesion level changes with changes in operational and environmental factors.To accurately estimate the adhesion level,the influence of those factors is included in this study.The testing and verification of the methodology required an accurate test prototype of the roller rig.In general,such testing and verification involve complex experimental works required by the intricate nature of the adhesion process and the integration of the different subsystems(i.e.controller,traction,braking).To this end,a new reduced-scale roller rig is developed to study the adhesion between wheel and rail roller contact.The various stages involved in the development of such a complex mechatronics system are described in this paper.Furthermore,the proposed brake control system was validated using the test rig under various adhesion conditions.The results indicate that the proposed brake controller has achieved a shorter stopping distance as compared to the conventional brake controller,and the brake control algorithm was able to maintain the operational condition even at the abrupt changes in adhesion condition.