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.
Abstract: The effect of the discontinuity of the rail ends and the
presence of lower modulus insulation material at the gap to the
variations of stresses in the insulated rail joint (IRJ) is presented. A
three-dimensional wheel – rail contact model in the finite element
framework is used for the analysis. It is shown that the maximum stress
occurs in the subsurface of the railhead when the wheel contact occurs
far away from the rail end and migrates to the railhead surface as the
wheel approaches the rail end; under this condition, the interface
between the rail ends and the insulation material has suffered
significantly increased levels of stress concentration. The ratio of the
elastic modulus of the railhead and insulation material is found to alter
the levels of stress concentration. Numerical result indicates that a
higher elastic modulus insulating material can reduce the stress
concentration in the railhead but will generate higher stresses in the
insulation material, leading to earlier failure of the insulation material