Scaling Strategy of a New Experimental Rig for Wheel-Rail Contact
A new small–scale test rig developed for rolling
contact fatigue (RCF) investigations in wheel–rail material. This
paper presents the scaling strategy of the rig based on dimensional
analysis and mechanical modelling. The new experimental rig is
indeed a spinning frame structure with multiple wheel components
over a fixed rail-track ring, capable of simulating continuous wheelrail
contact in a laboratory scale. This paper describes the
dimensional design of the rig, to derive its overall scaling strategy
and to determine the key elements’ specifications. Finite element
(FE) modelling is used to simulate the mechanical behavior of the rig
with two sample scale factors of 1/5 and 1/7. The results of FE
models are compared with the actual railway system to observe the
effectiveness of the chosen scales. The mechanical properties of the
components and variables of the system are finally determined
through the design process.
[1] C. Esveld, “Modern railway track”, Second ed., MTR-Productions,
Zaltbommel, The Netherlands 2001.
[2] U. Zerbst, R. Lundén, K.O. Edel, R.A. Smith, “Introduction to the
damage tolerance behaviour of railway rails – a review”, Engineering
Fracture Mechanics, vol. 76 (2009) pp. 2563-2601.
[3] J.J. Kalker, “Wheel Rail Rolling Contact Theory”, Wear, vol. 144
(1991) pp. 243-261.
[4] S. Bogdanski, M. Olzak, J. Stupnicki, “Numerical stress analysis of rail
rolling contact fatigue cracks”, Wear, vol. 191 (1996) pp. 14-24.
[5] S. Bogdanski, M. Olzak, J. Stupnicki, “Influence of liquid interaction on
propagation of rail rolling contact fatigue cracks”, in: Proceedings from
the Second Mini Conference on Contact Mechanics and Wear of
Rail/Wheel Systems, Budapest, Hungary, 1996, pp. 134-143.
[6] S. Grassie, J. Kalousek, “Rolling contact fatigue of rails: characteristics,
causes and treatments”, in: Proceedings of 6th International Heavy Haul
Conference, The International Heavy Haul Association, Cape Town,
South Africa, 1997, pp. 381-404.
[7] J. Seo, S. Kwon, H. Jun, D. Lee, “Numerical stress analysis and rolling
contact fatigue of White Etching Layer on rail steel”, International
Journal of Fatigue, vol. 33 (2011) pp. 203-211.
[8] Z.F. Wen, L. Wu, W. Li, X.S. Jin, M.H. Zhu, “Three-dimensional
elastic-plastic stress analysis of wheel-rail rolling contact”, Wear, vol.
271 (2011) pp. 426-436.
[9] M.R. Aalami, A. Anari, T. Shafighfard, S. Talatahari, “A robust finite
element analysis of the rail-wheel rolling contact”, Adv Mech Eng,
(2013).
[10] X. Zhao, Z.L. Li, R. Dollevoet, “The vertical and the longitudinal
dynamic responses of the vehicle-track system to squat-type short
wavelength irregularity”, Vehicle System Dynamics, vol. 51 (2013) pp.
1918-1937.
[11] P. Clayton, “Tribological aspects of wheel-rail contact: a review of
recent experimental research”, Wear, vol. 191 (1996) pp. 170-183.
[12] P. Clayton, D. Danks, “Effect of interlamellar spacing on the wear
resistance of eutectoid steels under rolling-sliding conditions”, Wear,
vol. 135 (1990) pp. 369-389.
[13] P. Clayton, D.N. Hill, “Rolling contact fatigue of a rail steel”, Wear, vol.
117 (1987) pp. 319-334.
[14] P. Clayton, X. Su, “Surface initiated fatigue of pearlitic and bainitic
steels under water lubricated rolling/sliding contact”, Wear, vol. 200
(1996) pp. 63-73.
[15] V. Dikshit, P. Clayton, D. Christensen, “Investigation of rolling contact
fatigue in a head-hardened rail”, Wear, vol. 144 (1991) pp. 89-102.
[16] P. Allen, “Chapter 15, Scale Testing, in Handbook of railway vehicle
dynamics”, in: S. Iwnicki (Ed.), CRC Press, Boca Raton FL (USA),
2006.
[17] C. Heliot, “Small-scale test method for railway dynamics”, Vehicle
System Dynamics, vol. 15 (1986) pp. 197-207.
[18] A. Jaschinski, H. Chollet, S. Iwnicki, A. Wickens, J. Würzen, “The
application of roller rigs to railway vehicle dynamics”, Vehicle System
Dynamics, vol. 31 (1999) pp. 345-392.
[19] B.G. Eom, B.B. Kang, H.S. Lee, “Design of small-scaled derailment
simulator for investigating bogie dynamics”, International Journal of
Railway, vol. 4 (2011) pp. 50-55.
[20] M. Gretzschel, A. Jaschinski, “Design of an active wheelset on a scaled
roller rig”, Vehicle System Dynamics, 41 (2004) pp. 365-381.
[21] A. Jaschinski, F. Grupp, H. Netter, “Parameter identification and
experimental investigations of unconventional railway wheelset designs
on a scaled roller rig”, Vehicle System Dynamics, vol. 25 (1996) pp. 293-
316.
[22] T. Armstrong, D. Thompson, “Use of a reduced scale model for the
study of wheel/rail interaction”, in Proceedings of the Institution of
Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, vol.
220 (2006) pp. 235-246.
[23] J. Koch, N. Vincent, H. Chollet, O. Chiello, “Curve squeal of urban
rolling stock—Part 2: Parametric study on a 1/4 scale test rig”, J Sound
Vib, vol. 293 (2006) pp. 701-709.
[24] D.J. Thompson, A.D. Monk-Steel, C.J.C. Jones, P.D. Allen, S.S. Hsu,
S.D. Iwnicki, “Railway noise: curve squeal, roughness growth, friction
and wear”, Real Research UK, Report: RRUK A, 3 (2003).
[25] X. Zhao, Z. Li, “The solution of frictional wheel–rail rolling contact
with a 3D transient finite element model: Validation and error analysis”,
Wear, vol. 271 (2011) pp. 444-452.
[1] C. Esveld, “Modern railway track”, Second ed., MTR-Productions,
Zaltbommel, The Netherlands 2001.
[2] U. Zerbst, R. Lundén, K.O. Edel, R.A. Smith, “Introduction to the
damage tolerance behaviour of railway rails – a review”, Engineering
Fracture Mechanics, vol. 76 (2009) pp. 2563-2601.
[3] J.J. Kalker, “Wheel Rail Rolling Contact Theory”, Wear, vol. 144
(1991) pp. 243-261.
[4] S. Bogdanski, M. Olzak, J. Stupnicki, “Numerical stress analysis of rail
rolling contact fatigue cracks”, Wear, vol. 191 (1996) pp. 14-24.
[5] S. Bogdanski, M. Olzak, J. Stupnicki, “Influence of liquid interaction on
propagation of rail rolling contact fatigue cracks”, in: Proceedings from
the Second Mini Conference on Contact Mechanics and Wear of
Rail/Wheel Systems, Budapest, Hungary, 1996, pp. 134-143.
[6] S. Grassie, J. Kalousek, “Rolling contact fatigue of rails: characteristics,
causes and treatments”, in: Proceedings of 6th International Heavy Haul
Conference, The International Heavy Haul Association, Cape Town,
South Africa, 1997, pp. 381-404.
[7] J. Seo, S. Kwon, H. Jun, D. Lee, “Numerical stress analysis and rolling
contact fatigue of White Etching Layer on rail steel”, International
Journal of Fatigue, vol. 33 (2011) pp. 203-211.
[8] Z.F. Wen, L. Wu, W. Li, X.S. Jin, M.H. Zhu, “Three-dimensional
elastic-plastic stress analysis of wheel-rail rolling contact”, Wear, vol.
271 (2011) pp. 426-436.
[9] M.R. Aalami, A. Anari, T. Shafighfard, S. Talatahari, “A robust finite
element analysis of the rail-wheel rolling contact”, Adv Mech Eng,
(2013).
[10] X. Zhao, Z.L. Li, R. Dollevoet, “The vertical and the longitudinal
dynamic responses of the vehicle-track system to squat-type short
wavelength irregularity”, Vehicle System Dynamics, vol. 51 (2013) pp.
1918-1937.
[11] P. Clayton, “Tribological aspects of wheel-rail contact: a review of
recent experimental research”, Wear, vol. 191 (1996) pp. 170-183.
[12] P. Clayton, D. Danks, “Effect of interlamellar spacing on the wear
resistance of eutectoid steels under rolling-sliding conditions”, Wear,
vol. 135 (1990) pp. 369-389.
[13] P. Clayton, D.N. Hill, “Rolling contact fatigue of a rail steel”, Wear, vol.
117 (1987) pp. 319-334.
[14] P. Clayton, X. Su, “Surface initiated fatigue of pearlitic and bainitic
steels under water lubricated rolling/sliding contact”, Wear, vol. 200
(1996) pp. 63-73.
[15] V. Dikshit, P. Clayton, D. Christensen, “Investigation of rolling contact
fatigue in a head-hardened rail”, Wear, vol. 144 (1991) pp. 89-102.
[16] P. Allen, “Chapter 15, Scale Testing, in Handbook of railway vehicle
dynamics”, in: S. Iwnicki (Ed.), CRC Press, Boca Raton FL (USA),
2006.
[17] C. Heliot, “Small-scale test method for railway dynamics”, Vehicle
System Dynamics, vol. 15 (1986) pp. 197-207.
[18] A. Jaschinski, H. Chollet, S. Iwnicki, A. Wickens, J. Würzen, “The
application of roller rigs to railway vehicle dynamics”, Vehicle System
Dynamics, vol. 31 (1999) pp. 345-392.
[19] B.G. Eom, B.B. Kang, H.S. Lee, “Design of small-scaled derailment
simulator for investigating bogie dynamics”, International Journal of
Railway, vol. 4 (2011) pp. 50-55.
[20] M. Gretzschel, A. Jaschinski, “Design of an active wheelset on a scaled
roller rig”, Vehicle System Dynamics, 41 (2004) pp. 365-381.
[21] A. Jaschinski, F. Grupp, H. Netter, “Parameter identification and
experimental investigations of unconventional railway wheelset designs
on a scaled roller rig”, Vehicle System Dynamics, vol. 25 (1996) pp. 293-
316.
[22] T. Armstrong, D. Thompson, “Use of a reduced scale model for the
study of wheel/rail interaction”, in Proceedings of the Institution of
Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, vol.
220 (2006) pp. 235-246.
[23] J. Koch, N. Vincent, H. Chollet, O. Chiello, “Curve squeal of urban
rolling stock—Part 2: Parametric study on a 1/4 scale test rig”, J Sound
Vib, vol. 293 (2006) pp. 701-709.
[24] D.J. Thompson, A.D. Monk-Steel, C.J.C. Jones, P.D. Allen, S.S. Hsu,
S.D. Iwnicki, “Railway noise: curve squeal, roughness growth, friction
and wear”, Real Research UK, Report: RRUK A, 3 (2003).
[25] X. Zhao, Z. Li, “The solution of frictional wheel–rail rolling contact
with a 3D transient finite element model: Validation and error analysis”,
Wear, vol. 271 (2011) pp. 444-452.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:68445", author = "Meysam Naeimi and Zili Li and Rolf Dollevoet", title = "Scaling Strategy of a New Experimental Rig for Wheel-Rail Contact", abstract = "A new small–scale test rig developed for rolling
contact fatigue (RCF) investigations in wheel–rail material. This
paper presents the scaling strategy of the rig based on dimensional
analysis and mechanical modelling. The new experimental rig is
indeed a spinning frame structure with multiple wheel components
over a fixed rail-track ring, capable of simulating continuous wheelrail
contact in a laboratory scale. This paper describes the
dimensional design of the rig, to derive its overall scaling strategy
and to determine the key elements’ specifications. Finite element
(FE) modelling is used to simulate the mechanical behavior of the rig
with two sample scale factors of 1/5 and 1/7. The results of FE
models are compared with the actual railway system to observe the
effectiveness of the chosen scales. The mechanical properties of the
components and variables of the system are finally determined
through the design process.
", keywords = "New test rig, rolling contact fatigue, rail, small scale.", volume = "8", number = "12", pages = "1984-8", }
