On the Polygonal Wear Evolution of Heavy-Haul Locomotive Wheels due to Wheel/Rail Flexibility and Its Mitigation Measures

Wheel polygonal wear can immensely worsen wheel/rail interactions and vibration performances of the train and track,and ultimately,lead to the shortening of service life of railway components.At present,wheel/rail medium-or high-frequency frictional interactions are perceived as an essential reason of the high-order polygonal wear of railway wheels,which are potentially resulted by the flexible deformations of the train/track system or other external excitations.In this work,the effect of wheel/rail flexibility on polygonal wear evolution of heavy-haul locomotive wheels is explored with aid of the long-term wheel polygonal wear evolution simulations,in which different flexible modeling of the heavy-haul wheel/rail coupled system is implemented.Further,the mitigation measures for the polygonal wear of heavy-haul locomotive wheels are discussed.The results point out that the evolution of polygonal wear of heavy-haul locomotive wheels can be veritably simulated with consideration of the flexible effect of both wheelset and rails.Execution of mixed-line operation of heavy-haul trains and application of multicut wheel re-profiling can effectively reduce the development of wheel polygonal wear.This research can provide a deep-going understanding of polygonal wear evolution mechanism of heavy-haul locomotive wheels and its mitigation measures.

Experimental Study on Wear and Spalling Behaviors of Railway Wheel

The current researches of the wear and spalling behaviors of wheel/rail materials focus on the field investigation rather than the mechanism. However, it is necessary and significant for clarifying the mechanism and relationship between the wear and spalling damage of railway wheel to test and reproduce the wheel damages in laboratory. The objective of this paper is to investigate the wear and spalling damage behaviors of railway wheel using a JD-1 wheel/rail simulation facility, which consists of a small wheel serving as rolling stock wheel, and a larger wheel serving as rail. The damage process of wheel roller is explored in terms of the creep ratio, axle load, and carbon content by means of various microscopic examinations. The experimental results show that the wear volume growth of wheel roller is proved to be proportional to the increase of the creep ratio and normal load between simulating wheel and rail. The increase of carbon content of wheel material causes a linear reduction in the wear volume. The microscopic examinations indicate that the rolling wear mechanism transfers from abrasive wear to adhesive and fatigue wear with an increase of tangential friction force, which results in the initiation of fatigue crack, and then aggravates spalling damage on the wheel roller surface. The surface hardness of material depends strongly upon its carbon content. The decrease of the carbon content of wheel material may alleviate spalling damage, but can cause a significant growth in the wear volume of wheel roller. Therefore, there is a competitive relationship between the wear and spalling damage of wheel material. This research proposes an important measure for alleviating or preventing the wear and spalling damage of railway wheel material.

Interaction of subway LIM vehicle with ballasted track in polygonal wheel wear development

This paper develops a coupled dynamics model for a linear induction motor （LIM） vehicle and a subway track to investigate the influence of polygonal wheels of the vehicle on the dynamic behavior of the system. In the model, the vehicle is modeled as a multi-body system with 35 degrees of freedom. A Timoshenko beam is used to model the rails which are discretely supported by sleepers. The sleepers are modeled as rigid bodies with their vertical, lateral, and rolling motions being considered. In order to simulate the vehicle running along the track, a moving sleeper support model is introduced to simulate the excitation by the discrete sleeper supporters, in which the sleepers are assumed to move backward at a constant speed that is the same as the train speed. The Hertzian contact theory and the Shen– Hedrick–Elkins’ model are utilized to deal with the normal dynamic forces and the tangential forces between wheels and rails, respectively. In order to better characterize the linear metro system （LMS）, Euler beam theory based on modal superposition method is used to model LIM and RP. The vertical electric magnetic force and the lateral restoring force between the LIM and RP are also taken into consideration. The former has gap-varying nonlinear characteristics, whilst the latter is considered as a constant restoring force of 1 kN. The numerical analysis considers the effect of the excitation due to polygonal wheels on the dynamic behavior of the system at different wear stages, in which the used data regarding the polygonal wear on the wheel tread are directly measured at the subway site.

ONLINE GRINDING WHEEL WEAR COMPENSATION BY IMAGE BASED MEASURING TECHNIQUES

Automatic compensation of grinding wheel wear in dry grinding is accomplished by an image based online measurement method. A kind of PC-based charge-coupled device image recognition system is schemed out, which detects the topography changes of the grinding wheel surface. Profile data, which corresponds to the wear and the topography, is measured by using a digital image processing method. The grinding wheel wear is evalualed by analyzing the position deviation of the grinding wheel edge. The online wear compensation is achieved according to the measure results. The precise detection and automatic compensation system is integrated into an open structure CNC curve grinding machine. A practical application is carried out to fulfil the precision curve grinding. The experimental results confirm the benefits of the proposed techniques, and the online detection accuracy is less than 5 um. The grinding machine provides higher precision according to the in-process grinding wheel error compensation.

Simulation of wheel and rail profile wear:a review of numerical models

The development of numerical models able to compute the wheel and rail profile wear is essential to improve the scheduling of maintenance operations required to restore the original profile shapes.This work surveys the main numerical models in the literature for the evaluation of the uniform wear of wheel and rail profiles.The standard structure of these tools includes a multibody simulation of the wheel-track coupled dynamics and a wear module implementing an experimental wear law.Therefore,the models are classified according to the strategy adopted for the worn profile update,ranging from models performing a single computation to models based on an online communication between the dynamic and wear modules.Nevertheless,the most common strategy nowadays relies on an iteration of dynamic simulations in which the profiles are left unchanged,with co-simulation techniques often adopted to increase the computational performances.Work is still needed to improve the accuracy of the current models.New experimental campaigns should be carried out to obtain refined wear coefficients and models,while strategies for the evaluation of both longitudinal and transversal wear,also considering the effects of tread braking,should be implemented to obtain accurate damage models.

Deep learning-based fault diagnostic network of high-speed train secondary suspension systems for immunity to track irregularities and wheel wear

Fault detection and isolation of high-speed train suspension systems is of critical importance to guarantee train running safety. Firstly, the existing methods concerning fault detection or isolation of train suspension systems are briefly reviewed and divided into two categories, i.e., model-based and data-driven approaches. The advantages and disadvantages of these two categories of approaches are briefly summarized. Secondly, a 1D convolution network-based fault diagnostic method for highspeed train suspension systems is designed. To improve the robustness of the method, a Gaussian white noise strategy(GWN-strategy) for immunity to track irregularities and an edge sample training strategy(EST-strategy) for immunity to wheel wear are proposed. The whole network is called GWN-EST-1 DCNN method. Thirdly, to show the performance of this method, a multibody dynamics simulation model of a high-speed train is built to generate the lateral acceleration of a bogie frame corresponding to different track irregularities, wheel profiles, and secondary suspension faults. The simulated signals are then inputted into the diagnostic network, and the results show the correctness and superiority of the GWN-EST-1DCNN method. Finally,the 1DCNN method is further validated using tracking data of a CRH3 train running on a high-speed railway line.

Numerical simulation of wheel wear evolution for heavy haul railway

The prediction of the wheel wear is a fundamental problem in heavy haul railway. A numerical methodology is introduced to simulate the wheel wear evolution of heavy haul freight car. The methodology includes the spatial coupling dynamics of vehicle and track, the three-dimensional rolling contact analysis of wheel-rail, the Specht's material wear model, and the strategy for reproducing the actual operation conditions of railway. The freight vehicle is treated as a full 3D rigid multi-body model. Every component is built detailedly and various contact interactions between parts are accurately simulated, taking into account the real clearances. The wheel-rail rolling contact calculation is carried out based on Hertz's theory and Kalker's FASTSIM algorithm. The track model is built based on field measurements. The material loss due to wear is evaluated according to the Specht's model in which the wear coefficient varies with the wear intensity. In order to exactly reproduce the actual operating conditions of railway,dynamic simulations are performed separately for all possible track conditions and running velocities in each iterative step.Dimensionless weight coefficients are introduced that determine the ratios of different cases and are obtained through site survey. For the wheel profile updating, an adaptive step strategy based on the wear depth is introduced, which can effectively improve the reliability and stability of numerical calculation. At last, the wear evolution laws are studied by the numerical model for different wheels of heavy haul freight vehicle running in curves. The results show that the wear of the front wheelset is more serious than that of the rear wheelset for one bogie, and the difference is more obvious for the outer wheels. The wear of the outer wheels is severer than that of the inner wheels. The wear of outer wheels mainly distributes near the flange and the root; while the wear of inner wheels mainly distributes around the nominal rolling circle. For the outer wheel of front wheelset of each bogie, the development of wear is gradually concentrated on the flange and the developing speed increases continually with the increase of traveled distance.

Study on the fatigue and wear characteristics of four wheel materials

The fatigue and wear characteristics of four different steel wheel materials are investigated in detail by using rolling contact fatigue and wear bench tests on a JD-1 apparatus, analyzing chemical composition and hardness, and performing profile analysis and micro-morphology analysis. The wear and fatigue behavior of one of the materials under different operation speeds is also investigated. The results show that the wear resistance of the materials has a positive correlation with their carbon content, while fatigue resistance has a negative correlation. Based on hardness analysis as a function of depth into the specimen, the thickness of layers with a steep hardness gradient has a negative correlation with the initial surface hardness in the tests using different materials. The hardness increments, however, have a positive correlation with initial surface hardness. The rolling tests on one material using different rotation speeds show that the hardness increments and the thickness of layers with a steep hardness gradient increase with the rotation speed. The analyses and experimental results demonstrate that two of the four materials exhibit good wear resistance and rolling contact fatigue resistance, making them suitable for either highspeed or heavy axle railroad operations.

Wheel wear comparison between motor car and trailer of intercity train

To analyze wheel wear discrepancy between motor car and trailer of an intercity train,a novel wheel wear rates calculation model was proposed,which was composed of the intercity train dynamics model,wheel-rail three-dimensional rolling contact FEM model and the wear model.The simulated results were contrasted with measured results in field test.The simulated results showed the motor car wheels had larger rotation rate and longitudinal creepage than the trailer wheels.Meanwhile,the motor car wheels encountered larger vertical forces and longitudinal forces from bogie because of the heavier car body and the impact of traction torque.The traction torque acting on motor car wheel could increase the slip rates in the rear part of wheel contact patch and weaken the spinning phenomenon of relative slip.Larger contact pressure and slip rates caused the higher wear rates of motor car wheel than those of trailer wheel.The overall trends of wheel wear depth in simulated and tested results were similar.And they both showed the motor car wheel encountered the more serious wear than the trailer wheel.These models can be used to study the effect of the traction characteristics curves on the wear of wheel.

Research on Wheel Rail Wear for a 140 t Open Type Hot Metal Car

To maintain the safety of an open-type hot-metal car and to reduce wheel-rail wear during transportation, simulation models of the main components of such car were built using Pro/E software and then tested. In particular, the Pro/E models were imported into ADAMS/Rail for assembly and then used to construct a complete hot-metal car dynamic model. Locomotive wheel-rail attack angle, wheel-rail lateral force, and wear index were used as evaluation parameters during the simulation to analyze the effects of bogie parameter, rail parameter, and speed of the hot-metal car on wheel-rail wear. An improvement scheme for reducing wheel-rail wear was proposed based on the result of the dynamic simulation, wherein wheel-rail wear and curving performance were analyzed and compared. The simulation provided an important reference for evaluating and improving the dynamic performance of the hot-metal car. The applied effect showed that the improvement scheme is effective.

On－Line Identification of Grinding Burn and Wheel Wear Based on Grinding Chips Thermal Flow

The theoretical basis of the grinding chips thermal flow being regarded as the characteristic signal of on line identification is summarized. And on line identification of grinding burn and wheel wear based on the grinding chips thermal flow is introduc

Wear characteristics and prediction of wheel profiles in high-speed trains

Wheel/rail relationship is a fundamental problem of railway system. Wear of wheel profiles has great effect on vehicle performance. Thus, it is important not just for the analysis of wear characteristics but for its prediction. Actual wheel profiles of the high-speed trains on service were measured in the high-speed line and the wear characteristics were analyzed which came to the following results. The wear location was centralized from-15 mm to 25 mm. The maximum wear value appeared at the area of 5 mm from tread center far from wheel flange and it was less than 1.5 mm. Then, wheel wear was fitted to get the polynomial functions on different locations and operation mileages. A binary numerical prediction model was raised to predict wheel wear. The prediction model was proved by vehicle system dynamics and wheel/rail contact geometry. The results show that the prediction model can reflect wear characteristics of measured profiles and vehicle performances.

Parametric analysis of wheel wear in high-speed vehicles

In order to reduce the wheel profile wear of highspeed trains and extend the service life of wheels, a dynamic model for a high-speed vehicle was set up, in which the wheelset was regarded as flexible body, and the actual measured track irregularities and line conditions were considered. The wear depth of the wheel profile was calculated by the well-known Archard wear law. Through this model, the influence of the wheel profile, primary suspension stiffness, track gage, and rail cant on the wear of wheel profile were studied through multiple iterafive calculations. Numerical simulation results show that the type XP55 wheel profile has the smallest cumulative wear depth, and the type LM wheel profile has the largest wear depth. To reduce the wear of the wheel profile, the equivalent conicity of the wheel should not be too large or too small. On the other hand, a small primary vertical stiffness, a track gage around 1,435-1,438 mm, and a rail cant around 1：35-1：40 are beneficial for dynamic performance improvement and wheel wear alleviation.

Effect of Sliding Wear on Surface Microstructure and Wear Property of D2 Wheel Steel

In this paper, the surface microstructure and wear property of D2 wheel steel under sliding wear condition were studied by MRH-30 sliding wear tester. After testing, a transmission electron microscope (TEM), scanning electron microscope (SEM) with electron backscatter diffraction (EBSD), and micro-hardness testers were used to characterize the surface microstructure of samples with different cycles. The results show that the wear losss samples are increased as the increase of cycles, and the wear loss of wheel samples is higher than that of rail samples. The surface hardness and thickness of deformation layer of wheel samples are increased as the cycles increase. After sliding wear, the samples surfaces form the white etching layer with the thickness of several microns. Through the analysis of surface microstructure of sample with 12,000 cycles, the lamellar cementite in pearlite is fragment into cementite particles with the decrease of depth from surface, and the cementite is dissolved at surface to lead to the form of white etching layer. The ferrite grains are refined gradually and the fraction of high angle grain boundary is increased with the decrease of depth from surface. The nanosgrains layer of ferrite grains with 5 μm thickness is formed. According to the result of finite element simulation of contact surface temperature, the formation of surface nanograins and the dissolution of cementite are caused by the severe plastic deformation. The fiber structure of samples is formed after sliding wear, with direction of .

Influence of Angle of Attack and Lateral Force between Wheel and Rail on Wear of Rail ——a Laboratory Study

Angle of attack and lateral force are two important parameters influencing wheel rail wear. This paper deals with the question of influences of the angle of attack and the lateral force on the wear of rail. A series of experiments are conducted on 1/4 JD 1 Wheel/Rail Tribology Simulation Facility. The angles of attack selected in the tests are 0°16′30″, 0°37′40″ and 1°0′0″ respectively. The lateral forces selected in the tests are 0.694 kN, 1.250 kN and 2.083 kN, respectively corresponding to the lateral forces of 25 kN, 45 kN and 75 kN measured in the field, with the aim of keeping the same ratio of L/V between laboratory and field conditions. It is found that the larger the angle of attack is, the more serious the wear of rail is. The relation of rail wear rate versus angle of attack is non linear, and the relation of rail wear rate versus lateral force is approximately linear. The influence of angle of attack is more serious than that of lateral force. For the tractive wheelset, the wear index involving linear and quadratic function terms of angle of attack has good agreement with the limited experimental data. Some conclusions are given.

Microstructural Characteristics and Wear Performance of Plasma Sprayed Al_2O_3-13 wt. % TiO_2 Coating on the Surface of Extrusion Wheel

The conventional Al2O3-13 wt. % TiO2 composite ceramic coatings are fabricated by plasma spraying on the surface of extrusion wheel. The microstrueture, morphology and phase compositions of the substrate and coat- ing are investigated by using X-ray diffractometry （XRD） , scanning electron microsopy （SEM） and energy dis- persive spectroscopy （EDS）. Moreover, the microhardness of the substrate and the coating are investigated using Vickers mierohardness tester, the friction and wear behaviors of the substrate and the coating are investigated by using a block-on-ring tribometer under dry sliding conditions with the load of 245 N. The results show that both γ-Al2O3 and α-Al2O3 phases are observed in the as-sprayed coatings, the mian phase is γ-Al2O3. There are white particulates Al2O3 on its surface. The Al2O3-13 wt. % TiO2 coating possesses higher mierohardness which is about 1018HV and 1.6 times that of the substrate. The wear performance of coating is better than that of the substrate. In a practical application, the life of the extrusion wheel which is plasma sprayed Al2O3-13 wt. % TiO2 coating on the surface is 1.2 times that of the conventional extrusion wheel, and the life is about 330 h.

钢轨不平顺焊接区的磨耗及裂纹萌生预测

为探究钢轨焊接区的磨耗及裂纹萌生与轴重及摩擦因数的关系,通过对大量不平顺焊接区的实地测量,拟合了两种典型焊接区的不平顺数据,建立了上凸和下凹两类典型焊接区不平顺轮轨接触的有限元模型。结合摩擦功模型和Archard磨耗理论,对焊接区最大磨耗截面进行预测,基于Jiang-Sehitoglu模型对焊接区裂纹萌生寿命进行预测。发现随着轴重的增加,上凸及下凹焊接区的磨耗速率均增大;且轴重达到16 t时上凸型焊接区磨耗速率显著增大,而下凹型焊接区在轴重达到18 t时磨耗速率显著增大;摩擦因数从0.2增加到0.35,上凸和下凹两类焊接区最大磨耗量分别为1.93 mm、1.08 mm;且上凸型焊接区磨耗速率在摩擦因数为0.3时显著增大,而下凹型焊接区磨耗速率在摩擦因数为0.35时显著增大。轴重从12 t增加到18 t,上凸型焊接区服役寿命的衰减幅度较小,而下凹型焊接区服役寿命衰减幅度较大。此外,当摩擦因数从0.2增加至0.35时,其对上凸型焊接区服役寿命的影响明显小于轴重(12~18 t)的影响。然而,当摩擦因数从0.2增加至0.35时,其对下凹型焊接区服役寿命的影响与轴重(12~18 t)的影响相当。结果表明,随着轴重和摩擦因数的增加,对钢轨焊接区下凹型不平顺的寿命影响更加显著;在工务维护过程中,应着重关注下凹型焊接区的出现并及时标记和修复。

PERFORMANCE OF BRAZED DIAMOND CUP-TYPE WHEELS WITH DEFINED GRAIN PATTERN IN GRINDING CEMENTED CARBIDE

A new cup-type grinding wheel of the brazed monolayer diamond is developed with a defined grain pattern on the wheel surface. Grinding performance of the brazed wheel in the surface grinding of cemented carbide is studied. Experimental results show that when continuous dry grinding is employed, grits of the brazed diamond grinding wheel fail mainly in attritious wear and fracture modes and no pull-out ones are found in conventional electroplated and sintered diamond wheels. It indicates the strong retention of brazing alloy to diamond grits and the longer service life of the wheel. In addition, the ground surface has good roughness. The theoretical surface roughness agrees well with experimental results.

考虑车轮多边形磨损的机车轮轨动力特性研究

针对车轮的多边形磨损,建立了重载列车轨道三维耦合动力学模型,研究了机车车轮多边形磨损引起的轮轨动力相互作用。在动力学模型中嵌入了低粘着区(LAZ)和防滑控制算法,以分析在正常和低粘着条件下车轮多边形磨损对轮轨纵向和横向相互作用的影响。在两台不同磨损模式的机车上进行了对比试验,包括车轮周向磨损测量和机车振动试验,验证了模型的合理性。在此基础上分析了多边形磨损的动态响应,结果表明车轮多边形磨损不仅会加剧车轮/轨道的垂直力,还会加剧车轮与轨道之间的纵向相互作用。多边形磨损对机车前两轮对与后两轮对的纵向相互作用影响较大。

电梯曳引轮的轮槽磨损原因及其检验

曳引轮轮槽在电梯运行过程中承受着巨大的压力和摩擦力。由于多种因素的影响,轮槽可能会出现磨损现象。这种磨损不仅会影响电梯的运行效率,严重时可能会出现钢丝绳打滑等危险情况。通过对轮槽磨损原因进行分析,并研究检验方法,可以及时发现问题并采取相应的措施,从而延长曳引轮的使用寿命,保障电梯的安全可靠运行。对电梯曳引轮的轮槽磨损原因及其检验进行了探讨,以供参考。