A new CAE procedure for railway wheel tribological design

New demands are being imposed on railway wheel wear and reliability to increase the time between wheel reprofiling, improve safety and reduce total wheelset lifecycle costs. In parallel with these requirements, changes in railway vehicle missions are also occurring. These have led to the need to operate rolling stock on track with low as well as high radius curves; increase speeds and axle loads; and contend with a decrease in track quality due to a reduction in maintenance. These changes are leading to an increase in the severity of the wheel/rail contact conditions, which may increase the likelihood of wear or damage occurring.

The aim of this work was to develop a new CAE design methodology to deal with these demands. The model should integrate advanced numerical tools for modelling of railway vehicle dynamics and suitable models to predict wheelset durability under typical operating conditions. This will help in designing wheels for minimum wheel and rail wear; optimising railway vehicle suspensions and wheel profiles; maintenance scheduling and the evaluation of new wheel materials. This work was carried out as part of the project HIPERWheel, funded by the European Community within the Vth Framework Programme.