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

Yunfan Yang1,2, Feifan Chai1, Pengfei Liu2, Liang Ling1, Kaiyun Wang1, Wanming Zhai1
1State Key Laboratory of Rail Transit Vehicle System, Southwest Jiaotong University, Chengdu, China
2State Key Laboratory of Mechanical Behavior and System Safety of Traffic Engineering Structures, Shijiazhuang Tiedao University, Shijiazhuang, China

Tóm tắt

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 multi-cut 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.

Từ khóa


Tài liệu tham khảo

W M Zhai, X S Jin, Z F Wen, et al. Wear problems of high-speed wheel/rail systems: Observations, causes, and countermeasures in China. Applied Mechanics Reviews, 2020, 72(6): 060801. Y F Yang, L Ling, C Wang, et al. Wheel/rail dynamic interaction induced by polygonal wear of locomotive wheels. Vehicle System Dynamics, 2022, 60(1): 211-235. P F Liu, S P Yang, Y Q Liu. Full-scale test and numerical simulation of wheelset-gear box vibration excited by wheel polygon wear and track irregularity. Mechanical Systems and Signal Processing, 2022, 167:108515. H Wu, P B Wu, F S Li, et al. Fatigue analysis of the gearbox housing in high-speed trains under wheel polygonization using a multibody dynamics algorithm. Engineering Failure Analysis, 2019, 100: 351-364. Y G Ye, B Zhu, P Huang, et al. OORNet: A deep learning model for on-board condition monitoring and fault diagnosis of out-of-round wheels of high-speed trains. Measurement, 2022, 199: 111268. G Q Tao, Z F Wen, X S Jin, et al. Polygonisation of railway wheels: A critical review. Railway Engineering Science, 2020, 28(4): 317-345. Y F Yang, L Ling, P F Liu, et al. Experimental investigation of essential feature of polygonal wear of locomotive wheels. Measurement, 2020, 166: 108199. G Q Tao, L F Wang, Z F Wen, et al. Measurement and assessment of out-of-round electric locomotive wheels. Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, 2018, 232(1): 275-287. J C O Nielsen, R Lundén, A Johansson. Train-track interaction and mechanisms of irregular wear on wheel and rail surfaces. Vehicle System Dynamics, 2003, 40(1-3): 3-54. W B Cai, X W Wu, M R Chi, et al. High-order wheel polygonal wear growth and mitigation: A parametric study. Mechanical Systems and Signal Processing, 2023, 186: 109917. Y Wu, X Du, J Han, et al. Experimental analysis of the mechanism of high-order polygonal wear of wheels of a high-speed train. Journal of Zhejiang University-Science A, 2017, 18(8): 579-592. Y Wu, J N Wang, M K Liu, et al. Polygonal wear mechanism of high-speed wheels based on full-size wheel-rail roller test rig. Wear, 2022, 494-495: 204234. S Qu, B Zhu, J Zeng, et al. Experimental investigation for wheel polygonisation of high-speed trains. Vehicle System Dynamics, 2021, 59(10): 1573-1586. C Z Ma, L Gao, R X Cui, et al. The initiation mechanism and distribution rule of wheel high-order polygonal wear on high-speed railway. Engineering Failure Analysis, 2021, 119: 104937. X Zhao, G X Chen, J Z Lyv, et al. Study on the mechanism for the wheel polygonal wear of high-speed trains in terms of the frictional self-excited vibration theory. Wear, 2019, 426-427: 1820-1827. B W Wu, Z Y Shang, J B Pan, et al. Analysis on the formation cause for the high-order wheel polygonization of the high-speed trains based on the finite element method. Vehicle System Dynamics, 2023, 61(1): 1-18. X S Jin, L Wu, J Y Fang, et al. An investigation into the mechanism of the polygonal wear of metro train wheels and its effect on the dynamic behaviour of a wheel/rail system. Vehicle System Dynamics, 2012, 50(12): 1817-1834. G Q Tao, C X Xie, H Y Wang, et al. An investigation into the mechanism of high-order polygonal wear of metro train wheels and its mitigation measures. Vehicle System Dynamics, 2021, 59(10): 1557-1572. G Q Tao, Z F Wen, X R Liang, et al. An investigation into the mechanism of the out-of- round wheels of metro train and its mitigation measures. Vehicle System Dynamics, 2019, 57(1): 1-16. B Fu, S Bruni, S H Luo. Study on wheel polygonization of a metro vehicle based on polygonal wear simulation. Wear, 2019, 438-439: 203071. R Fröhling, U Spangenberg, E Reitmann. Root cause analysis of locomotive wheel tread polygonization. Wear, 2019, 432-433: 102911. U Spangenberg. Variable frequency drive harmonics and interharmonics exciting axle torsional vibration resulting in railway wheel polygonization. Vehicle System Dynamics, 2020, 58(3): 404-424. G Q Tao, L F Wang, Z F Wen, et al. Experimental investigation into the mechanism of the polygonal wear of electric locomotive wheels. Vehicle System Dynamics, 2018, 56(6): 883-899. G Q Tao, Z F Wen, G S Chen, et al. Locomotive wheel polygonisation due to discrete irregularities: simulation and mechanism. Vehicle System Dynamics, 2021, 59(6): 872-889. Y G Ye, D C Shi, P Krause, et al. Wheel flat can cause or exacerbate wheel polygonization. Vehicle System Dynamics, 2020, 58(10): 1575-1604. B Peng, S Iwnicki, P Shackleton, et al. General conditions for railway wheel polygonal wear to evolve. Vehicle System Dynamics, 2021, 59(4): 568-587. D B Cui, B Y An, P Allen, et al. Effect of the turning characteristics of underfloor wheel lathes on the evolution of wheel polygonization. Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, 2019, 233(5): 479-488. G Q Tao, X L Liu, Z F Wen, et al. Formation process, key influencing factors, and countermeasures of high-order polygonal wear of locomotive wheels. Journal of Zhejiang University-Science A, 2021, 22(1): 70-84. W B Cai, M R Chi, X W Wu, et al. Experimental and numerical analysis of the polygonal wear of high-speed trains. Wear, 2019, 440-441: 203079. X W Wu, S Rakheja, W B Cai, et al. A study of formation of high order wheel polygonalization. Wear, 2019, 424-425: 1-14. Y F Yang, M K Xu, L Ling, et al. Polygonal wear evolution of locomotive wheels subjected to anti-slip control. Wear, 2022, 500-501: 204348. U Spangenberg, R Fröhling. Solving locomotive wheel polygonisation by reducing variable frequency drive interharmonics. Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, 2021, 235(1): 73-82. C Y Chang, G Li, Y H Zhang, et al. Experimental study on influence of wheel-rail material hardness matching on wheel polygonal wear. China Railway Science, 2018, 39(2): 87-93. (in Chinese) B Morys. Enlargement of out-of-round wheel profiles on high-speed trains. Journal of Sound and Vibration, 1999, 227(5): 965-978. A Johansson, C Andersson. Out-of-round railway wheels—a study of wheel polygonalization through simulation of three-dimensional wheel–rail interaction and wear. Vehicle System Dynamics, 2005, 43(8): 539-559. F Braghin, R Lewis, R S Dwyer-Joyce, et al. A mathematical model to predict railway wheel profile evolution due to wear. Wear, 2016, 261(11): 1253-1264. W M Zhai. Vehicle-track coupled dynamics: Theory and applications. Springer, Singapore, 2020. W M Zhai, K Y Wang, C B Cai. Fundamentals of vehicle-track coupled dynamics. Vehicle System Dynamics, 2009, 47(11): 1349-1376. Y F Yang, L Ling, Y F Yang, et al. Effects of wheelset flexibility on locomotive-track interaction due to rail weld irregularities. Vehicle System Dynamics, 2022, 60(9): 3088-3108. P Vila, L Baeza, J Martínez-Casas, et al. Rail corrugation growth accounting for the flexibility and rotation of the wheelset and the non-Hertzian and non-steady-state effects at contact patch. Vehicle System Dynamics, 2014, 52(S1): 92-108. L Baeza, J Giner-Navarro, D J Thompson, et al. Eulerian models of the rotating flexible wheelset for high frequency railway dynamics. Journal of Sound and Vibration, 2019, 449: 300-314. Y Sun, W M Zhai, Y G Ye, et al. A simplified model for solving wheel/rail non-Hertzian normal contact problem under the influence of yaw angle. International Journal of Mechanical Sciences, 2020, 174: 105554. Y F Yang, L Ling, J C Wang, et al. A numerical study on tread wear and fatigue damage of railway wheels subjected to anti-slip control. Friction, 2023, 11: 1470-1492. R Lewis, U Olofsson. Wheel-rail interface handbook. Woodhead Publishing Limited, Oxford, 2009. B Peng, S Iwnicki, P Shackleton, et al. Comparison of wear models for simulation of railway wheel polygonization. Wear, 2019, 436-437: 203010. M H Sichani, R Enblom, M Berg. A fast wheel/rail contact model for application to damage analysis in vehicle dynamics simulation. Wear, 2016, 366-367: 123-130. X X Yang, G Q Tao, W Li, et al. On the formation mechanism of high-order polygonal wear of metro train wheels: Experiment and simulation. Engineering Failure Analysis, 2021, 127: 105512.