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ABSTRACT
1. INTRODUCTION
y
x
FX
MZ
FY
FN
k + 0.25k 2
FT
=
FN
sign( )
k 2
k 2
(1)
A
FIGURE 2. CONTACT FORCES FROM AN MBSSIMULATION.
Damage mechanisms such as surface cracks, plastic
deformation and wear, see for example Kalousek et al. (1999) for
a survey, can significantly reduce the service life of railway track
and rolling stock. Furthermore, they can have a negative impact
on the rolling noise as well as on the riding comfort. A proper
understanding of these mechanisms require a detailed knowledge
of the wheel and rail interaction. Five theories of rolling are
presently in use: the two-dimensional theory of Carter (1926), the
linear theory (Kalker, 1967), the complete contact theory (Kalker,
1983), the theory of Shen et al. (1984), and the simplified theory
(Kalker, 1982b). All of these theories have limitations and they
can be viewed as complementary.
Continuum rolling contact theory started with a publication
by Carter (1926), where he approximated the wheel by a cylinder
and the rail by an infinite half-space. The analysis was twodimensional and the exact solution was found. Carter showed that
the difference between the circumferential velocity VC of a driven
wheel and the translational velocity VT of the wheel has a nonzero value as soon as an accelerating or a braking couple is
applied to the wheel. This difference increases with increasing
couple until the maximum value according to Coulomb is
height (mm)
30
20
10
plastic
deformation
0
0
20
40
60
length (mm)
B
30
height (mm)
20
10
wear
plastic
deformation
0
0
20
40
60
length (mm)
FIGURE 4. FORM CHANGE OF AN UIC HIGH RAIL IN A
NARROW CURVE. THREE YEAR OLD RAIL AT START
(A). NEW RAIL AT START (B).
To overcome the limitations inherent in the traditional
approaches, a tool for FE-based quasi-static wheel-rail contact
modeling and simulations has been developed. The tool is a
library of macro routines for configuring, meshing and loading a
parametric wheel-rail model. The routines are written in the
Ansys programming language. The meshing can be based on
measured wheel and rail profiles, i.e. worn profiles. The
kinematic constraints are enforced with the Ansys contact element
Contac49 (Ansys, 1997). The material models are treated as
elastic-plastic with kinematic hardening. By controlling the
values of the configuration parameters, representations of various
driving cases can be generated. The quasi-static loads are
obtained from train dynamic calculations with special purpose
MBS software. Interaction phenomena such as rolling, spinning
and sliding can be included. In order to reduce the size of the
computational model, the superelement technique is utilized for
the linear model features.
The modeling and simulation tool and a methodology are
described below, and simulation results are compared with
solutions obtained with traditional methods.
Center node
Superelement
Wheel
Contact region
Superelement
Rail
600 mm
The main parts of the wheel and rail bodies are meshed with
degenerated linear isoparametric elements. The hub surface is
covered with shell elements. These two submodels are condensed
to superelements. The size of a typical wheel-rail model is given
in table 1. The nodes on the hub surface are connected to a center
node with constraint equations (see figure 10).
800
Rolling direction
640
A
10
480
320
160
50 mm
Contact region
Wheel
0
0.0
Contact region
Rail
Number of
elements
35131
284
52785
Number
of nodes
14796
212741
171
Master
DOFs
1701
2709
0
Contact region
Rail
SOLID45
Wheel
SOLID45
Center MASS21
Contact CONTAC49
4560
5920
1
2978
5439
7056
1
1391
16317
21168
6
0
0.2
0.4
0.6
0.8
1.0
(%)
3. A METHODOLOGY
Contact region
Rail
Angel 1/30
Wheel
FIGURE 10. THE WHEEL HUB IS CONNECTED TO THE CENTER NODE WITH CONSTRAINT EQUATIONS.
Contact forces
Motion simulation
Wheel location
Gensys/
Medyna
Simulation
condition
definition
Boundary
conditions
Macros
Rail profile
Rail measurement
FE modeling
of wheel-rail
interaction
Miniprof
Wheel measurement
Simulation control
Wheel profile
Ansys,
Macros
FE model
FE simulation
Ansys,
Macros
Miniprof
measurement
Salient
tribometer
Stress-strain curves
Case 1
Case 2
FIGURE 12. CONTACT POINT LOCATION FOR THE TWO TEST CASES.
Method
Case 1
Case 2
FEM with plasticity 606 MPa
577 MPa
Contact
3057 MPa
715 MPa
Hertzian max stress
1080 MPa
TABLE 2. MAXIMUM CONTACT PRESSURE
WITH THE FE AND TRADITIONAL METHODS.
The main scope for this work was to enhance the knowledge
of the contact pressure and the maximum stresses in bulk
material. This should give an appropriate basis to study the
degradation mechanism along with the wear simulation. The
results in case 1 could not be compared with the Hertz method
assuming one-point contact. The Hertzian solution showed
approximately twice the contact length in y-direction compared
with the other methods. This remained the same for the regions of
the surface radii of curvature in the range of 0.01 .. 0.015m for
the rail and -0.02.. -0.1m for the wheel. So, the normal force was
split similar way as in program Contact to three parts. After that
the results were very similar for these two classical methods (see
figure 13). Compared to Ansys, the difference was approximately
300% for the contact area and more than 200% for the maximum
pressure. For case 2 the result show that the difference in the
maximum contact pressure and the size of the contact area was
small when the minimum contact radius is large compared with
the significant dimensions of the contact area, i.e. the half space
assumption is valid.
Using the linear-elastic model the differences in results are
significant in regards especially to the relatively new wheel and
rail shapes. Significant flattening of the contact pressure profile
was found with increasing plastic deformation. The maximum
pressure and plastic work moved outward in the direction of the
contact edge along with the increase of friction coefficient.
The distribution of the equivalent vonMises stress shows that,
even with the three contact patches, significant yielding will
occur (see figure 14).
7. ACKNOWLEDGEMENT
This work was performed within the Swedish research
programme SAMBA. The work was financially supported by the
Swedish National Board for Industrial an d Technical
Development (NUTEK), Adtranz Sweden AB, Stockholm Local
Traffic, the Swedish National Rail Administration and the
Swedish State Railways.
8. REFERENCES
5. CONCLUSIONS
A tool for contact mechanics modeling and simulation of the
wheel rail contact has been developed. The geometry of the
contact can easily be changed. The model can be generated from
measured wheel and rail profiles. Traditional methods and
computational tools are limited by an half space assumption and a
linear material model. The results from two test cases show that
the difference in maximum equivalent stress between traditional
methods and the FE model is small when the minimum contact
radius is large compared to the significant dimensions of the
contact area, i.e. when the half space assumptions is valid.
However, in the test case where the minimum contact radius was
of the same order as the significant dimensions of the contact area
the difference between the FE results and results obtained with
traditional Hertzian and BE methods was as large as 3GPa. This
large difference was probably due to limitations in both the half
space assumption and the linear elastic material model in the
traditional methods.
Mechanics,
Cambridge
pp. 243-261.
Knothe, K.L., Strzyakowski, Z., and Willner, K., 1994, "Rail
vibrations in the high frequency range", Journal of Sound and
Vibration, 169(1), pp. 111-123.
Knothe K., Theiler A. and Gney S., 1999, Investigation of
contact stresses on the wheel/rail system at steady-state curving,
16th IAVSD Conference, Pretoria RSA, 30 August- 3 Sept.
Lim, S.C., Ashby, M.F.,1987, Wear mechanism maps. Acta
metall. Vol. 35, No. 1 , pp. 1-24.
Nilsson R., 2000, Wheel and rail wear measured profiles and
hardness changes during 2.5 years for Stockholm commuter
traffic, Hannover EUROMECH 409 Colloquium 6-9 mars,
2000.
Olofsson, U. and Nilsson, R., 1998, Initial wear of a commuter
train track, Nordtrib98, June 8-10, Ebeltoft, Denmark.
Kalker, J.J., 1982, The contact between wheel and rail. Report
of the Department of Mathematics and Informatics No. 82/27, TH
Delft.
Olofsson, U., 1999, on the form change due to wear and plastic
deformation in narrow curves on a commuter train track,
submitted for publication.