Optimisation of grease application to railway track

Trackside lubricators are designed to deliver grease to passing wheel flanges to reduce wheel and rail wear on curves. Ensuring that they are set up to deliver sufficient grease for the range of vehicles passing a site can be a challenge. For example, vehicle dynamics modelling and site investigations have shown that the wheels of passenger vehicles do not run as close to the rail face as those of freight vehicles, meaning that they are less likely to contact the grease and lubricate subsequent curves. To investigate the effects of different trackside devices, and the influence of parameters governing grease pickup, including lateral wheel displacement and pump durations, a bespoke test rig was built at the University of Sheffield. The rig used a scaled wheel, a short section of rail and a modern trackside lubricator set-up. Experiments involving different lateral wheel displacements and pumping durations were carried out, in addition to the visualisation of the size of the grease bulb. This showed how a grease bulb grows. It also indicated that a worn profile is likely to require greater wheel displacement to make contact with grease bulbs when compared to a new wheel profile. The experimental results showed that increasing pickup of grease can be expected when an additional component called a GreaseGuide™ was fitted to a regular grease delivery unit (GDU) on the rail. The efficiency of grease pickup was investigated, and test results exploring increasing pump durations have indicated a relationship between pickup and bulb size. To validate the use of the scaled rig, similar tests were carried out using a full-scale test rig. The full-scale results were compared to the experimental results of the scaled wheel rig. This showed that whilst there were differences between the two test rigs in absolute values and anomalous results, overall trends were the same on both test scales. The effect of temperature on bulb size and pumpability of grease was also investigated. This work can be extended further by using the same method to investigate other parameters that affect the lubrication of curves. This can lead to optimised lubricator set-up to ensure that the track is fully lubricated all the time.