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Wear
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a r t i c l e
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Article history:
Accepted 21 February 2008
Available online 23 May 2008
Keywords:
Vehicle-track interaction
Instrumented wheelset
Wheel at
Rail corrugation
Vehicle/track modelling
a b s t r a c t
The computer program DIFF, which is being developed at CHARMEC since the late 1980s, is used to simulate
vertical vehicletrack interaction at high frequencies, from about 20 Hz to at least 2000 Hz. Measured
results from two eld test campaigns are used to validate the vehicletrack interaction model. The rst
test case involves impact loads from a wheel at, while the other case studies the inuence of a corrugated
rail on dynamic vertical wheelrail contact forces. Four vehicle models and two visco-elastic track models
are compared. The track models are calibrated versus test data from laboratory and eld tests. Input data
on rail and wheel roughness are taken from eld measurements. Good agreement between calculated
and measured vertical contact forces is observed, both with respect to magnitude and frequency content,
for most frequencies below 2000 Hz. The best agreement is obtained when using a vehicle model that
accounts for both wheelsets in a bogie, instead of using a single wheelset model.
2008 Jens C.O. Nielsen. Published by Elsevier B.V. All rights reserved.
1. Introduction
Small amplitude undulations (roughness, waviness) with a
broad spectrum of wavelengths are present on the running surfaces
of wheels and rails. Such roughness leads to a broadband relative
displacement excitation of wheel and rail, inducing high-frequency
vertical wheelrail contact forces together with vibrations and
rolling noise. Wheel corrugation due to tread braking with cast
iron brake blocks, and rail corrugation that for example may
develop in situations with uniform trafc in track sections where
high levels of traction are present, will increase the excitation
level [1]. In Sweden, dominating wavelengths for corrugation on
tangent tracks are usually in the interval 48 cm, see Fig. 1. Amplitudes of the corrugation are in the order of 10 m. Cast iron
tread brakes lead to similar wavelengths and amplitudes on the
wheels.
Wheel ats and insulating rail joints are examples of discrete irregularities leading to severe impact loads with signicant
force contributions at high frequencies. Such loads exacerbate
deterioration of wheelset and track components and lead to
increased maintenance costs. The high-frequency contents of vertical wheelrail contact forces generated by these different forms
of wheelrail irregularities are often of signicant magnitudes and
must not be ignored [2]. Common examples of associated damage
0043-1648/$ see front matter 2008 Jens C.O. Nielsen. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2008.02.038
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Fig. 2. Strain gauges are glued to the wheel disc. Locations of 16 strain gauges for
measurement of Q-force are shown.
Fig. 1. Rail corrugation with wavelengths in the interval 48 cm. Photo: Lennart
Lundfeldt, Banverket.
StockholmGoteborg.
The extensive test campaign was performed
in October 2002. Measurement wheels from Intereet Technology
Sweden, instrumented with strain gauge bridges on each side of
the wheel disc, were employed, see Fig. 2. The wheels were calibrated for vertical (Q) and lateral (Y) static wheelrail contact forces,
respectively. At measurements in-eld, the signals from the strain
gauge bridges are processed to give the Q- and Y-forces from the
rolling wheel. The signals were recorded on data loggers on board
the train. Also GPS-signals, pulses from reference locations along
the track and train speed were recorded.
The standard approach for data processing used by Intereet
Technology includes a low-pass ltering of the measured signals with cut-off frequency 90 Hz. A major challenge has been to
extend the frequency range in the force measurements. However,
the wheelset has several eigenmodes in the frequency range that
are excited by the short-pitch wheelrail irregularities, and the
inuence of these modes could lead to inaccurate results when
transforming the measured strains to forces in the wheelrail contact. From an experimental modal analysis, it was concluded that
the most signicant source of error is the radial wheel mode
with two nodal diameters at 1712 Hz, see Fig. 3. The error con-
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wheel curvature = 0, rail curvature = 0 and transverse rail curvature = 1/0.3 m1 as input data.
Fig. 5. Magnitude and phase of dynamic rail pad stiffness. Comparison of rail pad
models A and B with data measured in a laboratory.
Fig. 6. Magnitude and phase of track receptance. Comparison of track models A and
B with data measured in the eld.
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4. Validation 1: wheel at
Before simulation and measurement are compared for the case
with the X2 trailer wheelset, results from a previous validation exercise will be repeated in brief [7]. Wheelrail impact loads calculated
using the model in Section 3 were compared with loads measured
during a eld test performed in 2000, see [8]. The impact loads
were generated by a wheel at with length 100 mm and depth
0.9 mm. A freight train with axle load 24 tonnes was used and train
speeds were in the interval 5100 km/h. Impact loads were measured using a wheel impact load detector that was based on strain
gauges mounted on the rail web in nine consecutive sleeper bays.
The impact load detector was calibrated against the quasi-static
wheel load that was measured when the train passed the test site
at a speed of 5 km/h.
In the calculations, a vehicle model of type B and a track model
of type A were used. Input data were similar to those used in the
present study [7]. Good agreement between measured and calculated impact loads was observed, see Fig. 8. The solid line was
generated by a numerical curve tting of the measured results to
a third-degree polynomial in order to provide an indication of the
inuence of train speed on measured impact loads. A local maximum is observed for train speed 40 km/h.
5. Rail and wheel roughness
Fig. 8. Impact load versus train speed for a wheel at with length 100 mm and
depth 0.9 mm. Axle load 24 tonnes, unsprung half wheelset mass Mw = 1185/2 kg.
Measured data: *; calculated data: . From Ref. [7].
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Fig. 10. DFT of vertical wheelrail contact force (average from left and right wheel)
measured in Vretstorp at two different train speeds.
Fig. 9. Measured roughness level spectra for corrugated rail in Vretstorp (average
of left and right rails) and X2 trailer wheelset (average of ve wheels). Comparison
with ISO 3095 spectrum (dashed line). Roughness level spectra are evaluated in 1/3
octave bands.
wheels had a minimum travelled distance of 100,000 km. The evaluated wheel roughness level spectrum is shown in Fig. 9. It is
observed that the X2 trailer wheels are very smooth compared
to the rail in Vretstorp (at least in the studied wavelength interval 2250 cm). The inuence of wheel roughness on the combined
wheelrail roughness could therefore be neglected in this validation exercise. A ltering of the roughness prole to account for the
size of the wheelrail contact patch was performed. This leads to
an attenuation of roughness magnitudes for shorter wavelengths.
The adopted contact lter is based on the moving average of the
irregularity that has been summed over the length of the contact
patch. The irregularity prole is assumed to be constant over the
width of the contact patch.
It should be noted that several of the peaks in the DFT spectra are
frequency-constant. This means that these peaks do not shift with
train speed. The so-called P2 resonance (wheelset, rail and sleepers
moving in phase on the sleeper support stiffness) is observed as a
wide peak at around 100 Hz. The other frequency-constant peaks
can be distinguished at around 570, 830 and 1100 Hz. It was concluded in Ref. [13] that these latter peaks are caused by bending
modes in the rail that occur between the two wheels in a bogie. A
comparison with a RayleighTimoshenko beam model of the rail,
with length corresponding to the bogie wheelbase and pinnedpinned boundary conditions, conrm that these modes correspond
to three (570 Hz), four (830 Hz) and ve (1100 Hz) half wavelengths
between the wheels of the bogie. It has also been shown that such
modes are important in the generation of rail corrugation [13,14].
Results (power spectral density, PSD) from simulations of the
conditions in Vretstorp are compared with the corresponding eld
tests in Figs. 11 and 12. Two samples of rail irregularity prole
were generated based on the (narrowband) rail roughness spec-
Fig. 11. PSD of vertical wheelrail contact force in Vretstorp. Comparison of measured and calculated contact forces along a distance of 100 sleeper bays. Train speed
160 km/h. Vehicle model D.
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Fig. 12. PSD of vertical wheelrail contact force in Vretstorp. Comparison of measured and calculated contact forces along a distance of 100 sleeper bays. Train speed
197 km/h. Vehicle model D.
The inuence of vehicle model on the calculated vertical contact force is illustrated in Fig. 14. Four different vehicle models are
studied, see Section 3. One of the sample rail irregularity proles
described in Section 6 was used again.
All four vehicle models lead to similar results, but there are some
important differences. The inuence of the local rail bending modes
can only be captured by model D since the other three vehicle models only contain one wheelset. The inuence of several eigenmodes
of the wheelset, which are only covered by vehicle model C, leads
to distinct peaks and troughs in the PSD spectrum. Note that the
inuence of the radial mode with two nodal diameters at 1712 Hz
leads to a reduction in contact force. Vehicle model A generates the
highest contact forces at frequencies above 1000 Hz.
8. Inuence of track model
The inuence of track model on the calculated vertical contact
force is illustrated in Fig. 15. Two different track models are studied,
see Section 3. One of the sample rail irregularity proles described
Fig. 14. PSD of vertical wheelrail contact force in Vretstorp. Train speed 160 km/h.
Inuence of vehicle model.
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Fig. 15. PSD of vertical wheelrail contact force in Vretstorp. Train speed 160 km/h.
Vehicle model D. Inuence of track model.