Dynamic response and wear analysis of a swing nose crossing in heavy haul railways

Abstract

Swing nose crossings (SNXs) have been widely used in heavy haul railways to create a smoother load transfer and hence reduced impact load. However, the current design of SNXs hasn’t been fully examined under heavy haul operating conditions. Additionally, maintenance guidelines for SNX wear-related issues in Australian heavy haul railways are relatively lacking. As such, this study aims to investigate the dynamic response of the wheel–rail contact and analyse the wear performance of an SNX currently used in Australian heavy haul railways. Dynamic implicit–explicit finite element analysis was conducted to simulate the wheel–rail contact along the SNX. The distribution of the wear intensity over the SNX was identified by using a local contact-based wear model. The influence of various scenarios on wear was also explored. The results verify the improved dynamic performance of the SNX, as the increased contact force after load transfer remains below 1.2 times the static load. The findings also indicate that the decrease in relative height and increase in nose rail inclination result in greater wear on the nose rail. Notably, the SNX considered in the current study exhibits better wear performance when used with moderately worn wheels.

Keywords

Wear / Heavy haul railways / Swing nose crossing / Finite element method / Wheel–rail contact

References

[1.] Pun J, Welsby D, Kassa E et al (2022) An approach to improve wheel-rail contact conditions in heavy-haul turnouts. Paper presented at the 12th International Conference on Contact Mechanics and Wear of Rail/Wheel Systems, Melbourne, Australia, 4–7 Sept. 2022

[2.] Markine VL, Steenbergen MJMM, Shevtsov IY. Combatting RCF on switch points by tuning elastic track properties. Wear, 2011, 271(1–2):158-167.

[3.] Wiedorn J, Daves W, Ossberger U, et al. Finite element model for predicting the initiation of subsurface damage in railway crossings: a parametric study. Proc Inst Mech Eng Part F J Rail Rapid Transit, 2019, 233(6):614-628.

[4.] ARTC (2020) Detailed inspection of swing nose crossings. In: Inspection of points and crossings: procedure. https://extranet.artc.com.au/docs/eng/track-civil/procedures/pc/ETE-03-01.pdf. Accessed 14 May 2024

[5.] NSW (2013). Track inspection. https://www.transport.nsw.gov.au/industry/asset-standards-authority/find-a-standard/track-inspection-53. Accessed 12 May 2024

[6.] Lau A, Hoff I. Simulation of train-turnout coupled dynamics using a multibody simulation software. Model Simul Eng, 2018, 2018: 8578272.

[7.] Pålsson BA, Nielsen JCO. Dynamic vehicle–track interaction in switches and crossings and the influence of rail pad stiffness–field measurements and validation of a simulation model. Veh Syst Dyn, 2015, 53(6):734-755.

[8.] Kassa E, Andersson C, Nielsen JCO. Simulation of dynamic interaction between train and railway turnout. Veh Syst Dyn, 2006, 44(3):247-258.

[9.] Liu X, Markine VL. MBS vehicle-crossing model for crossing structural health monitoring. Sensors (Basel), 2020, 20(10):2880.

[10.] Wan C, Markine V, Shevtsov I. Optimisation of the elastic track properties of turnout crossings. Proc Inst Mech Eng Part F J Rail Rapid Transit, 2016, 230(2):360-373.

[11.] Wan C, Markine VL, Shevtsov IY. Improvement of vehicle–turnout interaction by optimising the shape of crossing nose. Veh Syst Dyn, 2014, 52(11):1517-1540.

[12.] Wan C (2016) Optimisation of vehicle-track interaction at railway crossings. Dissertation, Delft University of Technology

[13.] Wan C, Markine V, Dollevoet R. Robust optimisation of railway crossing geometry. Veh Syst Dyn, 2016, 54(5):617-637.

[14.] Cao Y, Zhao W, Lin Y, et al. Dynamic optimization of the rail-crown geometry in the rigid frog area by controlling the position of the wheel-load transition. Proc Inst Mech Eng Part F J Rail Rapid Transit, 2020, 234(9):1017-1028.

[15.] Wang P, Ma X, Wang J, et al. (2017) Optimization of rail profiles to improve vehicle running stability in switch panel of high-speed railway turnouts. Math Probl Eng, 2017, 1: 856030.

[16.] Fang J, Chen R, Chen J, et al. A multi-objective optimisation method of rail combination profile in high-speed turnout switch panel. Veh Syst Dyn, 2023, 61(1):336-355.

[17.] Yan W, Fischer FD. Applicability of the Hertz contact theory to rail-wheel contact problems. Arch Appl Mech, 2000, 70(4):255-268.

[18.] Pletz M, Daves W, Ossberger H. A wheel set/crossing model regarding impact, sliding and deformation: explicit finite element approach. Wear, 2012, 294: 446-456.

[19.] Wei Z, Núñez A, Boogaard A, et al. Method for evaluating the performance of railway crossing rails after long-term service. Tribol Int, 2018, 123: 337-348.

[20.] Wei Z, Núñez A, Liu X, et al. Multi-criteria evaluation of wheel/rail degradation at railway crossings. Tribol Int, 2020, 144: 106107.

[21.] Ma Y, Mashal AA, Markine VL. Modelling and experimental validation of dynamic impact in 1:9 railway crossing panel. Tribol Int, 2018, 118: 208-226.

[22.] Wei W, Yuan C, Wu R, et al. Wear of a crossing under dynamic wheel impact. Wear, 2019, 436: 202997.

[23.] Johansson A, Pålsson B, Ekh M, et al. Simulation of wheel–rail contact and damage in switches & crossings. Wear, 2011, 271(1–2):472-481.

[24.] Skrypnyk R, Ekh M, Nielsen JCO, et al. Prediction of plastic deformation and wear in railway crossings–comparing the performance of two rail steel grades. Wear, 2019, 428: 302-314.

[25.] Skrypnyk R, Pålsson BA, Nielsen JCO, et al. On the influence of crossing angle on long-term rail damage evolution in railway crossings. Int J Rail Transp, 2021, 9(6):503-519.

[26.] Skrypnyk R, Ossberger U, Pålsson BA, et al. Long-term rail profile damage in a railway crossing: field measurements and numerical simulations. Wear, 2021, 472: 203331.

[27.] Chen R, Chen J, Wang P, et al. Impact of wheel profile evolution on wheel-rail dynamic interaction and surface initiated rolling contact fatigue in turnouts. Wear, 2019, 438: 203109.

[28.] Shih JY, Weston P, Entezami M, et al. Dynamic characteristics of a switch and crossing on the west coast main line in the UK. Railw Eng Sci, 2022, 30(2):183-203.

[29.] Wang S, Wang H, Jing G. Experimental analysis of profile degradation of high-speed turnouts: a case study in China. Tribol Int, 2023, 178: 108035.

[30.] Burstow M C (2006) A model to predict and understand rolling contact fatigue in wheels and rails. Paper presented at the the 7th World Congress on Railway Research (WCRR 2006), Montreal, Canada, 4–8 June 2006

[31.] Gao Y, Wang P, Liu Y, et al. (2019) Investigation on wheel-rail contact and damage behavior in a flange bearing frog with explicit finite element method. Math Probl Eng, 2019, 1: 1209352.

[32.] Wan C, Markine VL. Parametric study of wheel transitions at railway crossings. Veh Syst Dyn, 2015, 53(12):1876-1901.

[33.] Archard JF. Contact and rubbing of flat surfaces. J Appl Phys, 1953, 24(8):981-988.

[34.] Ma X, Wang P, Xu J, et al. Assessment of non-Hertzian wheel-rail contact models for numerical simulation of rail damages in switch panel of railway turnout. Wear, 2019, 432: 102912.

[35.] Wang P, Xu J, Xie K, et al. Numerical simulation of rail profiles evolution in the switch panel of a railway turnout. Wear, 2016, 366: 105-115.

[36.] Pereira MP, Duncan JL, Yan W, et al. Contact pressure evolution at the die radius in sheet metal stamping. J Mater Process Technol, 2009, 209(7):3532-3541.

[37.] Pereira MP, Yan W, Rolfe BF. Contact pressure evolution and its relation to wear in sheet metal forming. Wear, 2008, 265(11–12):1687-1699.

[38.] Pereira MP, Yan W, Rolfe BF. Sliding distance, contact pressure and wear in sheet metal stamping. Wear, 2010, 268(11–12):1275-1284.

[39.] Pereira MP, Yan W, Rolfe BF. Wear at the die radius in sheet metal stamping. Wear, 2012, 274: 355-367.

[40.] Hsu SM, Shen MC, Ruff AW. Wear prediction for metals. Tribol Int, 1997, 30(5):377-383.

[41.] Yan W. Theoretical investigation of wear-resistance mechanism of superelastic shape memory alloy NiTi. Mater Sci Eng A, 2006, 427(1–2):348-355.

[42.] Yan W, Busso EP, O’Dowd NP. A micromechanics investigation of sliding wear in coated components. Proc R Soc Lond A, 2000, 456: 2387-2407.

[43.] Jin Q, Wang W, Jiang R, et al. A numerical study on contact condition and wear of roller in cold rolling. Metals, 2017, 7(9):376.

[44.] Hiew A, Pun CL, Su H, et al. A numerical study on dynamic interaction and wear of flange tip lift crossings in tramlines. Wear, 2023, 532: 205096.

[45.] Gao Y, Wang P, Wang K, et al. Damage tolerance of fractured rails on continuous welded rail track for high-speed railways. Railw Eng Sci, 2021, 29(1):59-73.

[46.] NEN (2006) EN 13232–7: Railway applications - Track - Switches and crossings for Vignole rails-Part 7: Crossings with moveable parts

[47.] Yang Z, Deng X, Li Z. Numerical modeling of dynamic frictional rolling contact with an explicit finite element method. Tribol Int, 2019, 129: 214-231.

[48.] Hamarat MZ, Kaewunruen S, Papaelias M. Contact conditions over turnout crossing noses. IOP Conf Ser: Mater Sci Eng, 2019, 471: 062027.

[49.] Federal Railroad Administration (2014) Broken Rims in Railroad Wheels. https://railroads.dot.gov/elibrary/broken-rims-railroad-wheels. Accessed 10 April 2024

Funding

Australian Research Council http://dx.doi.org/10.13039/501100000923(LP200100110)