Paper Effects of Wear and Service Conditions on Residual Stresses in Commuter Car Wheels Paper 1-12

Transcription

1 Table of Contents The Behavio of Wheelsets in Sevice Pape. - Analysis of Pobable Causes and the Consequences of the Appeaance of Defects in Wheel Running Sufaces fo the Design and Monitoing of Running Gea Jean-Claude TOURRADE, Jean-Claude FORTMANN, Roland MÜLLER, Hatmut KOCH, AND Jean-Jacques VIET Pape. - Development of seviceability citeia fo solid wheels of feight cas Andey RAZUMOV, Igo PASHLOLOK, Vladimi TSURENKO Pape.3 - Factue Modeling of a Noth Ameican Locomotive Wheel B.S. MANJUNATHA and A.W. GIAMMARISE Pape.4 - The Measuement of Wheel/Rail Foces to Detemine Wheel and Ca Pefomance Scott CUMMINGS and Hay TOURNEY Pape.5 - An Oveview of Raiload Wheel Rim Failue Modes unde Heavy Axle Loads Johannes MARAIS and J. S. VAN DER WALT Pape.6 Failue Investigations Dudley HADDINOTT Pape.7 - Status of the Investigation on the Wheel Tead Spalling in China Railway Rolling Stock Bin ZHANG Pape.8 - Evaluation of Feight Ca Wheelset Components Removed fo High Wheel Impact Loads Geoffey E. DAHLMAN, Cameon P. LONSDALE, and Lay D. GARDNER Pape.9 - Effects of New Bake System Requiements on Feight Ca Bake Shoes and Wheels Cameon P. LONSDALE, Tom McCABE and James PILCH Pape.0 - The Influence of Ceep Foces on Rolling Contact Fatigue of Wheels Eic E. MAGEL and Joe KALOUSEK

2 Pape. - Effects of Wea and Sevice Conditions on Residual Stesses in Commute Ca Wheels Jeff GORDON AND Benjamin PERLMAN Pape - A Study of Cuving Pefomance by Impoving Ac Wheel Pofile Yoshonoi MINAMI Pape -3 - Expeimental and Numeical Study of TGV Bake Disc Damage Mechanisms Fedeic BUMBIELER, Phillipe DUFRENOY, Rami HAMAM, Sylvie POMMIER, and Jean-Jacques VIET Pape -4 - Theoy and Reseach of Composite Bae Shoe M. SITARZ, A. MANKA and a. H$ELKA Pape -5-0 Yeas of Low Floos in Light Rail Vehicles The Somewhat Diffeent Kind of Wheelsets Andeas BRINKMANN Pape -6 - Paametic Analysis of Semi-Radial Thee-Piece Tuck on Cuved Tack Rolling Resistance Pefomance Amond TALLION and Giuseppe SAMMARTINO Pape AAR Ca Repai Billing Removal Analysis Richad SULLIVAN, Cameon LONSDALE, John OLIVER and Jean IORIO Impoving Wheels though Alloying and Impoved Cleanliness Pape. - Complex Influence of Selenium and Telluium on the Quality and Popeties of Wheel Steel Yu. S. PROYDAK, M.I. STAROSELET KYY and S. I. GUBENKO Pape. - The Quest fo Impoved Wheel Steels Entes the Matensitic Phase Tim CONSTABLE, E. V. PERELOMA, and R. BOLEN Pape.3 - Raiload Wheel Alloy Developed to Inhibit Spall Fomation as a Result of Wheel Slide Joseph KRISTAN AND Daniel STONE Pape.4 - Steel cleanliness in ailway wheels: Application to high-speed tains. J. J. VIET, J. BOUVY, F. DEMILLY, and T. INGOUF Pape.5 - High Mico-cleanliness Wheels Peventing Shatteed-im Factue Tomoaki YAMAMOTO, Myuki YAMAMOTO, Taizo MAKINO and Takashi FUJIMURA Pape.6 - Reseach of the Stuctue Changes Close to the Tead Suface of the Railway Wheels duing Opeation V. ESAULOV, S. GUBENKO, A. SLADKOVS KYY, Y. PROIDAKA, and M. ISKOV

3 Pape -7 - Stating a New Heat-Teatment Plant fo Railway Solid Wheels Tyes: Aims, Methodologies and Results Andea GHIDINI, Gianluca BELOTTI, Luca PATRIOLI, Renato BIANCHI, and Alessando GOGLIO Towad Impoved Wheelset Manufactuing and Specifications Pape 3. - Integity of Cast Wheels Detemined by Solidification Softwae Matt ERICKSON Pape 3. Numeical Expeimental Stength Analysis of Wheels of Railway Wheelsets M. SITARZ, K. BIZON and K. CHURZIK Pape Mechanical Compaison between Ameican and Euopean Mateials fo Railway Wought Solid Wheels, in Tems of RCF Resistance Andea GHIDINI and Stefano CANTINI Pape A New Wheelset Design Tool (A New CAE Pocedue fo Railway Wheel Tibological Design) R. LEWIS, R.S. DWYER-JOYCE, S. BRUNI, A. EKBERG, M. CAVALETTI, K. BEL KNANI Pape Altenative Micocleanliness Measuement Methods fo Wheel Steel Jay GALBREAITH, Cameon LONSDALE, Bad COOLEY, Jean-Mac BOHLEN and Paul MEYER Pape A Study of the Coefficient of Fiction between Rail Gage Cone and Wheel Flange Focusing on Wheel Machining Takami BAN, Hideshi KAKISHIMA, Kohei IIDA, Eiichi MAEBASHI, and Hioaki Ishida and Makoto Ishida Pape 3.7 The Mateial Stength Veification of Wheel sets Influence of Diffeent Evaluation Pocedues on the Dimensioning Fanz MURAWA Pape 3.8 Stating an Innovative Line fo Heat Teatment of Railways Solid Wheels and Tyes Andea GHIDINI, Gianluca BILOTTI, Luca PATRIOLI, Rinato BIANCHI and Alessando GOGLIO Pape New Design of Rubbe Wheel VAMPOLA, Pet MATUSEK, ZIMA, FAJKOS, and VALJENT Pape Moden Wheelset Design fo Naow Gauge Railways Jog VILLMANN, Hans-Otto HOLLAND, and Matthias SCHWARTZE Pape 3- - Optimizing Design of Wheel fo High Speed Passenge Wagon Huying LIU, Nansen LI, Weixing HOU, and Fengzhou WANG Impoved Non-Destuctive Inspection Applications Pape 4. Wheel Pofile Wea Check on Passing Vehicles Diete HOFFMANN

4 Pape 4. - Steel Cleanliness in Railway Wheels: Application to High Speed Tains Jean-Jacques VIET, Fancous DEMILLY, Jacques BOUVEY and Thiey INGOUF Pape Monitoing of Round-motion Matthias JELINSKI and SIEFER Pape Cack Detection in Pess fit Railway Axle Using New concept Induced Cuent Focusing Potential Dop Technique Seok Jin KWON, Jin Woo PARK, Kazuhio OGAWA and Tetsuo SHOJI Pape Cacked Wheel Dynamic Detection System using the Lase to Ai-Hybid Ultasonic Technique Kai GONZALES, Richad MORGAN, Geg GARCIA and Shant KENDARIAN Pape Stess Evaluation on Class-C Foged Wheels by Ultasonic Testing Domingos MINICUCCI, Autelinao ANTUNES DOS SANTOS FILHO, Macillo ANDRINO Pape New Method of UT Inspection fo Hollow Axles G BELOTTI, A. GOGLIO and F. REBOA Pape Measuements of Wheelset Loads. Testing Facilities to Impove Load Calibation of Instumented Wheelsets F. LOMBARDO and S. CAVELLO Pape Measuing Wheel/Rail Contact Stesses using Ultasound M. B. MARSHALL, R. LEWIS, R.S. DWYER-JOYCE, S. BJORKLUND, and U. OLOFSSON Pape Inail Installed Wheelset Diagnostic System H. J. NAUMAN Pape 4- Ultasonic Detection of Contact Anomalies Massimiliano PAU and Buno LEBAN Advances in Axle and Beaing Technology Pape 5. Pedicting Resistance to Fetting Fatigue Cacking in Aeas of the Axle Located Unde Wheel Seats A. YAMEOGO, A. M. MARECHAL, F. DEMILLY, F. PRIOUL, and J. J. VIET Pape 5. - Factos Woking Axle Fatigue Pet MATUŠEK, FÜRBACHER, LINHART, NOVOSAD, FAJKOS AND KUNZ Pape Hub/Axle Fit Pessues (Ultasonic Chaacteisation of Wheel Hub/Axle Intefeence Fit Pessues) M.B. MARSHALL, R. LEWIS, R.S. DWYER-JOYCE, F. DEMILLY, AND Y. FLAMENT Pape Safe Life Inspection intevals of Railways Axles: a Compaison of Cack Gowth Popeties of Diffeent Steel Gades S. CANTINI, A. GHIDINI, and S. BERETTA Pape Cone Ceep of a Raiload Axle Jounal Beaing Takafumi NAGATOMO and David G. Toth

5 Pape Beaing Degadation Studies Uwe KOPKE, David RENNISON, Caolyne SOUTHERN and Keith BLADON Pape 5-7 Compact TGU Field Expeience Gottfied KURE, Mauizio MARTINELLI, and Paul PRICE Pape 5-8 Undestanding Rail Jounal Beaing Cage Design Chaacteistics fo Successful Beaing Pefomance Stephen E. BRISTER ans David G. TOTH Pevention of Wheelset Wea and Noise Pape 6. - Influential Factos on Wea Makoto ISHIDA, Jin YING, Fusayoshi AOKI, and Mitsunobu TAKIKAEA Pape 6. - Wheel Wea Modeling Including Disc Baking and Contact Envionment Roge ENBLOM and Mats BERG Pape WEAR of Wheel Mateials (Wheel Mateial Wea Mechanisms and Tansitions) R. LEWIS, R.S. DWYER-JOYCE, and U. OLOFSSON Pape Reducing the Rolling Noise fom Tains The Wheel-Composite Bake Block Combination The Wheel s Behaviou. Jean-Jacques VIET, Jean-Claude FORTMANN, Roland MULLER and Jacques RAISON Pape 6.5 Wheel/Rail Noise Emmission Monitoing System Caolyne SOUTHERN, Uwe KOPKE, and David RENNISON Pape Development of a Modula Damping System against Wheel Noise Emission fo Feight and Uban Tanspot Vehicles F. LOMBARDO AND S. CERVELLO Pape Upgade and Retofit of Easten Wheel Flange by Fine Paticle Shot Peening Motohide MATSUI Pape Wheel Life Extension with On-Boad Solid Stick Flange Lubication Donald T. EADIE and HUI Resisting Fatigue in Wheelsets Pape 7. - Multi-axial Fatigue Analysis of The Web Plate LIU Degang, LIU Huiying, WANG Fengzhou, and HU Hongtao Pape 7.- Integated Analysis of the Dynamic Tain-Tack Inteaction on Rolling Contact Fatigue Jens NIELSEN, Andes EKBERG, Elena KABO, and Roge LUNDÉN Pape The Fatigue Design Method of High-speed Railway Wheel Yoshinoi OKAGATA, YAMAMOTO, YAMAMURA and Kenji HIRAKAWA Pape Towad the Wheels Calculation and Validation in Multi-Axial Fatigue Y. FLAMENT, F. COCHETEUX, and J. J. VIET

6 Pape Failue Analysis of Coosion Fatigue Cack on Loading Relieving Gove of Wagon RD Axle Lixian XING and Xuewen LIU Pape 7-6- Fatigue Stength Veification of Wheels fo High-Speed Tains acc. to the Euopean UIC Leaflet 50-5 in Consideation of the Centifugal- Foces and othe Influence Paametes Thomas GERLACH AND Andeas HOVELS

7 Numeical - expeimntal stenght analysis of wheels of ailway wheelsets M. Sitaz, K. Bizoń, K. Chuzik Depatment of Railway Engineeing, Silesian Univesity of Technology, Cente of Excellence TRANSMEC, Poland Summay: At pesent, the design pocess can be simplified and acceleated, if compute simulation basing on finite element method (FEM) is used. FEM numeical calculations of diffeent wheels of ailway wheelsets ae investigated in Depatment of Railway Engineeing. The justification fo undetaking this issue is that the methodology of design of ailway wheelsets both in Poland and aboad is absent; thee is no possibility of optimising wheelsets constuction chaacteistics depending on manufactuing pocess and sevice paametes. The analysis of this poblem has made possible: compaison of softwae used so fa in stain calculation of ailway wheelsets; elaboation of design methodology fo ailway wheelsets; incease in duability of ailway wheelsets; incease in the safety of ail tanspot; decease in manufactuing and sevice costs of ailway wheelsets. Index Tems: finite elements method, numeical analysis, wheelsets.. NOTATION AND UNITS c coefficient c coefficient D coefficient E Young s modulus h mesh thickness M() bending moment P foce inne adius of mesh a wheel oute adius of mesh a wheel T pessing foce T coefficient W() displacements distibution σ max maximum stain in adial diection µ Lame coefficient y pe-set displacement in y diection z pe-set displacement in z diection κ Lame coefficient ν Poisson s atio τ φ max maximum stain in cicumfeential diection ς tosion of inne contou ϑ tosion length in cicumfeential diection σ stain in adial diection η coefficient µ fiction coefficient

8 . INTRODUCTION In spite of gowing competitiveness of the oad tanspot, the ail tanspot is still the pincipal longdistance tanspot system. In some counties (Fance, UK, Gemany) the ail tanspot expeiences its enaissance in city agglomeations (tams, ail bus, meto) and in long-distance tavel (high-speed tains). Inceased sevice demands as well as envionmental and taffic safety equiements set on ail vehicles in the majoity of Euopean states explain the necessity of manufactuing olling stock fulfilling high quality standads. The moden tains should be faste, cheape and safe. The tavel conditions, i.e. passenges comfot, should also be impoved. All these factos depend most of all on the design of ail vehicle. The demands set on fast moden ail vehicles and thei pats, including the ailway wheelsets, can be enumeated as follows [,]: deceasing weight; inceasing vehicle elements mechanical stength; lessening the noise and vibations level; inceasing tavel comfot; deceasing dynamical inteaction between vehicle and the tack. The development of computes and softwae povides possibilities of modelling new designs of diffeent stuctual elements of ail vehicles. The phenomena occuing duing the vehicle sevice can be adequately descibed, The eo geneated duing design o pototype tests can lead to tagic occuences duing the sevice itself. These may be elated to additional financial outlay and lengthening the pototype testing time, but they may also cause incalculable loss of human health o life. Accoding to the expets, the ail tanspot is one of the most ecological (Table ) and safe (Table ) eans of tanspot. Still, accidents happen [3]. They ae not vey fequent, but they ae highlighted by the media. The most famous accident to date happened in Eschede, Gemany, on 3d June, 998. Incoectly designed ailway wheelset has caused a tagic deailment and death of 0 pesons (Fig. [4]). Simila, though less tagic accidents happened lately all ove Euope [3]: Rickescote, 8 Mach 996, Sandy, 7 June 998, Hatfield, 7 Octobe 000, Pottes Ba, 0 May 00. Table. Compaison of diffeent means of tanspot Tanspot means Enegy consumption in Cabon dioxide emission in kcal/passenge-km g of cabon /passenge-km Ca Bus 96 9 Tain 06 5 Aiplane Table. Motality of the passenges pe a hunded million Tanspot means Kilometes Tavels Hous Ca 0,3 4 3 Bus 0,06 0,5 Tain 0,08 4 Aiplane 0, Fig.. Deailment of tain in Gemany - Eschede, 3 June 998.

9 The advancement in the computes computational speed and the elaboation of complex softwae based on finite element method (FEM) and devoted to the ailway industy demands, esults in unning calculations and simulations, which have not been peviously possible. Thee ae many issues, which so fa have been only expeimentally/analytically investigated. The use of numeical methods limits o wholly eliminates the need fo some tests o calculations. The investigation time is theefoe deceased, the complex test stands can be eplaced with suitable softwae; hence, financial advantages ae gained. On the basis of the above analysis elated to state-of-the-at in the ailway wheelsets subject matte, conclusion may be dawn that computation by numeical methods might play significant ole in each of the above issues. It is cetain that numeical calculations should be the stating point in the design, assembly and sevice stess analysis and themal analysis of the mateial. Howeve, the numeical methods ae saddled with eos due to the impefect tansfomation of the eal model into the vitual model. Still, if the investigation methods ae used jointly, i.e. expeimental tests ae backed by numeical analysis, the esults obtained may be close to eality. Basing on the efeences, the pesent state-of-the-at of the numeical calculations of the ailway wheelset wheels can be summaised as follows: lack of univesally accepted computational algoithm of ailway wheels, inadequate expeimental confimation of the coectness of computational pocedues used at pesent, absence of compaison of numeical calculations of ailway wheels done with the help of diffeent softwae, discepancies in set bounday conditions, absence of pecise algoithm fo ceating FEM model fo ailway wheels (type, distibution and size of element) complexity of stess calculation method, when the stess is due to assembly-time intefeence, lack of UIC cetification fo calculations of themal stess due to baking. 3. NUMERICAL ANALYSIS OF THE WHEELSETS WHEELS The ailway wheelset is a constuctional element influencing diectly the vehicle motion as well as passenges safety. That is why the axle, wheel and the wheelset itself must be chaacteised by adequate mechanical stength duing the sevice peiod. Nowadays the ailway wheelsets designs used ae the effect of sevice expeience and pocess engineeing. Lately, the numeical analyses of stess and stain done in the wheelset design phase ae also utilised. At pesent, the design pocess can be simplified and acceleated, if compute simulation basing on finite element method (FEM) is used. FEM numeical calculations of diffeent wheels of ailway wheelsets ae investigated in Depatment of Railway Engineeing. Thee softwae packages ae used ANSYS, NASTRAN and COSMOS. This divesity of softwae should make possible the compaison of convegence of esults (toleance, computation time), povided that input data ae identical (e.g. wheel geomety, mateial. bounday conditions, FEM mesh). Befoe the calculations ae stated, these data must be established, if the esults ae to be compaable. The justification fo undetaking this issue is that the methodology of design of ailway wheelsets both in Poland and aboad is absent; thee is no possibility of optimising wheelsets constuction chaacteistics depending on manufactuing pocess and sevice paametes. The analysis of this poblem has made possible: compaison of softwae used so fa in stain calculation of ailway wheelsets; elaboation of design methodology fo ailway wheelsets; incease in duability of ailway wheelsets; incease in the safety of ail tanspot; decease in manufactuing and sevice costs of ailway wheelsets.

10 3.. Initial investigations mesh of a wheel model In ode to make FEM calculations moe accuate, the compaison of analytical and numeical methods of calculations has been conducted on the basis of mesh of a wheel model. Figue shows the mesh of a wheel model and physical and discete models geneated by the softwae. a) physical model b) discete model Fig.. Model of the mesh of a wheel Thee possible loads have been consideed see Fig.3. In case of the fist load, the initial displacements of the nodes of inne suface geneato paallel to y-axis of the global Catesian co-odinate system have been defined (Fig. 3.a). In the case of second load, the initial displacement of the nodes has been alongside T-angle of pola co-odinate system Fig. 3.b. In the case of thid load, the nodes have been linealy displaced paallel to the z-axis of Catesian co-odinate system Fig.3.c. The maximum stains fo the pesented loads have been calculated analytically. The data: mesh thickness h = 0,0 [m], inne adius outline = 0,09 [m] and oute adius = 0,36 [mm] [5]: a) b) c) Fig. 3. Load models fo the mesh a wheel Case #. σ max µ = c y 3 κ ( + ) κ ( + ) + + κ whee µ and κ ae Lame coefficients, calculated fom the fomulas: E µ = ( + ν) 3 ν κ = + ν () ( )

11 E Young s modulus ν Poisson s constant y pe-set displacement = 0,000 [m] Coefficient c has been detemined with the help of fomula: c + = κ ( ) ln ( 3) Fo this equation σ 43,9 MPa ( 4) max = Case # max µ = ς τ φ ( 5) whee ς - tosion of inne contou, tosion angle is ϑ ς = fo ϑ = 0,000 [m] 0,5 MPa τ φ max = Case # 3 () M = 6 h σ ( 8) whee bending moment at mesh coss-section, deived fom fomula: d d ν d () = D w() + w() M () d depends on the displacements distibution of the mesh T = 8πD ( η ) + ln η ( η) + ln( η ) + ( η ) ln w ( 0) Bending igidity and axial foces have been calculated fom the fomulas: Eh D = z T = c c η = σ ( ν ) 3 η ( η) + ln( ) ( ) η + η 8πD( η ) + ln = max = 60,5 MPa ln ( 6) ( 7) ( 9) ( ) ( )

12 At the same time, meshes have been geneated, diffeing one fom the othe by the size and distibution of elements as well as the type of element used. The investigation has esulted in detemination of the pecentage eo of numeical analysis, which depends on the size and distibution of the elements and on type of element used. Figue 4a illustates gaphically the computation eo fo the thid and most typical load; computation time is shown in Fig.4b. The analysis shows that the minimum numbe of elements along the lateal coss-section of the wheel mesh should be equal to six. These investigations have led to geneating an optimum mesh fo the mesh with espect to computation accuacy and time. a) Numeical analysis case # 3 80,0 70,0 Eo[%] 60,0 50,0 40,0 30,0 0,0 0,0 Nastan Heksagonal Cosmos Heksagonal Ansys Heksagonal Nastan Tetagonal Cosmos Tetagonal Ansys Tetagonal Log. (Nastan Heksagonal) Log. (Cosmos Heksagonal) Log. (Ansys Heksagonal) Log. (Nastan Tetagonal) Log. (Cosmos Tetagonal) Log. (Ansys Tetagonal) 0,0 3x5x0 3x0x 6x0x 6x0x 6x40x 6x0x4 0x40x 0x40x4 Distibution of Elements Thickness x Height x Cicumfeence of wheeld b) Calculation time Time [s] Heksagonal mesh Tetagonal mesh x5x0 3x0x0 6x0x0 6x0x0 6x40x0 6x0x40 0x40x0 0x40x40 Distibution of Elements Thickness x Height x Cicumfeence of wheel Fig.4. Results of compaison of analytical and numeical calculations - case #3

13 3.. Subject of investigation wheel design of ailway wheelset The wok was pincipally aimed at elaboating methods of selection of constuctional paametes fo the ailway wheelset wheels. The conducted calculations of ailway wheelsets stains should impove the accuacy of pesently used numeical methods and should also be helpful in woking out the guidelines fo designes, since the calculation algoithm and FEM softwae ae detemined. The numeical investigation has been un fo ten diffeent geometical designs of wheels Ø 90 and Ø 90 h (won out), diffeing by geometical paametes of the mesh, hub and wheel seat diamete. The geneated FE mesh fo these wheels has been shown in Fig. 5. Fig. 5. Discete models of the investigated monoblock wheels

14 Fig. 6. Wheel loads of the ailway wheelset Next, assembly loads and sevice loads of the ailway wheelset wheel have been detemined. These have been used in subsequent eseach Fig.6. These ae static, dynamic and themal loads. The static loads ae due to intefeential fit duing the assembly and to caiage weight. The dynamic loads ae elated to the vehicle un ove the tack and centifugal foces esulting fom un speed. The themal loads occu in the wheel duing baking. The numeical analysis has been conducted fo P5 mateial (R7 accoding to UIC classification), which is used fo ailway wheels in Poland Static loads of the ailway wheels Remaks and conclusions numeical analysis of the wheelsets wheels Afte the numeical analysis of ten diffeent wheel designs has been conducted with the help of thee FEM softwae packages, the obtained esults of educed stess have been compaed with espect to: mesh type and patten, value-dependent stess distibution, wheel constuction, degee of wea, used softwae. The following conclusions may be dawn: mesh type and patten have geat impact on the tempeatue, displacement and stess fields values; geomety of the wheel mesh and hub bea influence on the distibution and values of the stesses. If the sevice conditions ae known, the appopiate wheel geomety can be selected. analysis of the degee of wea of the wheel on the distibution and values of the stesses has shown that the influence is significant only in case of loads due to baking; compaison of softwae used has shown significant diffeences in computation of tempeatue field caused by baking; the conducted analysis has clealy demonstated the impotance of a coect FEM model numeical analysis has made possible compaison o softwae used in calculations. The conducted analysis has shown the supemacy of moden-design wheels with espect to the mechanical stength (Italian wheel. Czech wheels and ). 4. EKSPERIMENTAL INVESTIGATION OF DEFORMATION AND TEMPERATURE FIELDS OF RAILWAY WHEELS 4.. Static expeimental investigation of a Geman wheel The expeimental tests have been conducted in the Bohumin Plant a.s. in Czech Republic. Test stand fo stain measuements of ailway wheels defomation has been used Fig. 7. Stain gauges have been placed on the intenal and extenal suface of the web of a wheel in the axial and adial diections (Fig. 8).

15 The maximum load geneated by hydaulic actuato has coesponded to static load in the wheel-ail system. The stain gauges have been placed at the points of maximum stesses caused by static load due to caiage weight. Stain gauges of KM0 type have been used, k=,0. The conducted investigations have esulted in obtaining the defomation values of the web of a wheel of a ailway wheel. The wheel has been loaded with axial and adial foces at the same time fo 50 seconds (Fig. 8). The maximum steady-state foce values have been: adial foce 60 kn, axial foce 60 kn (Fig. 9), which coesponds to the axle load of 3 T pe axle. The maximum foce values have also been adopted in the second stage of investigations, when FEM has been used. In ode to compae the esults of expeimental tests with FEM numeical analysis esults, the defomation values measued by stain gauges T3 and T5 have been selected. These gauges have been placed adially at both sides of the wheel and the defomation values measued by these gauges have been the highest of all. Defomation values in the adial diection have been pe-dominant; they have been of a highe ode than defomations in the axial diection. The maximum measued value of axial defomation of the web of a wheel at the intenal side (T3 stain gauge) has been equal to 0,0004, and at the extenal side (T5 stain gauge) it has been equal to 0, Fig. 0. Fig. 7. Stain test stand fo investigation of ailway wheelsets wheels defomations Fig. 8. Loading diagam fo a wheel placed in the test stand; stain gauges placed on the wheel

16 80 F adial F axial -6,7-9,3-60,5-30, -60,5-34,9-60,5-39,7-60,6-44,8-60,6-49,8-60, , , -54,7-6, -49,8-6, -44,9-6, -39,8-6, -34,9-6, -30, -8,5-0, Foce [kn] F adial F axial time [s] Fig. 9. Time cycles of foces loading the wheel at the test stand Defomation [µm/m] T3 T4 T5 (-) T6 (-) Time [s] Fig.0. Time cycles of wheelset wheel defomation measued at the test stand Afte the FEM numeical analysis, the wheel defomation has been detemined Fig. b. The lowest diffeence in the esult as elates to expeimental investigation has been geneated in case of manual hexagonal mesh. Figue shows compaison of the esults. The compaison confims the coectness of the poposed model of loading the wheel with two foces axial and adial.

17 a) , , Displacement value [3m/m] , , 473, 00 0 T5 Test Cosmos Results Ansys Nastan T3 Stain guage # b) 6 3,9 4,95 4,9 4 Measuement diffeence [%] , 8, 7,5 4 0 Cosmos Results Ansys Nastan T5 T3 Stain guage # Fig.. Compaison of esults of numeical analysis and expeimental tests; load is due to caiage weight; a) defomation, b) esults discepancy

18 4.. Expeimental themal investigation of a Geman wheel A Geman wheel has been investigated (Technical Specification No. FWG ); its initial diamete has been equal to 90 mm. In ode to simulate the effects of wea, this diamete has been machined down to 854 mm. The wheel has been subjected to baking in 3 cycles at the test stand of Machine Faculty of Univesity of Zilina (Fig.). The investigation has been aimed at the tempeatue measuement in the ailway wheel duing baking. Test stand scheme is shown in Fig.3. The stand consists of a measuement fame affixed to the wheel shaft. Two bake sets ae located on the fame. The baking foce is detemined by the ai pessue measued with mechanical foce gauge duing calibation; this mete has been inseted between the wheel and bake casing. Tempeatue in the wheel of the web has been measued with the help of themosensos of K type, manufactued by Ameican company Omega. The sensos and ceamic casing have been symmetically affixed at evey 90º along the cicumfeence, and 9 mm away fom the wheel s olling suface Fig.4. The themosenso signal is amplified and tansfeed to data acquisition compute cad. The tests have been un in cycles in accodance with UIC 50-5: - baking at 60 km/h, baking powe of 60 kw, time inteval 45 minutes one cycle - baking at 60 km/h, baking powe of 30 kw, time inteval 45 minutes one cycle - baking at 60 km/h, baking powe of 40 kw, time inteval 45 minutes one cycle - baking at 60 km/h, baking powe of 60 kw, time inteval 45 minutes ten cycles. 03-P0-type shoe bakes have been used in the investigations. These ae widely used in Czech ail tanspot. They ae made of cast ion with pe cent phosphous admixtue. The shoes have been placed 0 mm away fom the extenal face of wheel s olling suface (30 x 80 mm). Fig.. Test stand fo defomation and tempeatue investigation of ailway wheelsets wheels Fig. 3. Test stand fo investigation of defomation and tempeatue of ailway wheelsets wheels:

19 Electic moto ( P = 65 kw, P max = 400 kw, n = 300 pm ) Toothed gea ( i =,5, esp. i =,7 o i = 4 ) 3 Coupling 4 Flywheel 400 kgm = kgm ( x5+3x0+4x5 ) 5 Flywheel 600 kgm 6 Flywheel 900 kgm 7 Stand casing 8 Wheel with ailway shoe bake Fig. 4. Placing of themocouples along the wheel cicumfeence (9 mm away fom the olling suface) Duing baking the wheel has been cooled by the ai flowing at 30 km/h (half the un speed). The cooling afte baking has been done with foced ai ventilation, ai has been heated to 50 ºC. Lowe tempeatues have been obtained by using wate spinkling both sides of the wheel hub at 6 km/h. The wate has been able to flow feely ove the web and wheel s olling suface. Total amount of wate used has been equal to 65 l/h. The initial wheel tempeatue in each cycle has been equal to max. 50º C. Investigations have esulted in a eading of aveage tempeatue duing the whole cycle (themocouples measuement). In ode to veify the coectness of the used calculation algoithm fo tempeatue field a compaison of numeical calculations with esults of expeimental tests has been conducted (baking cycle in accodance with UIC 50-5). The numeical themal analysis has been conducted accoding to UIC Repot [6,7], fo a wheel with the maximum wea of the olling suface. The themal flux has been detemined fo each baking phase. Between the baking pocesses the wheel has been left without any incoming themal flux. The convection simulating cooling pocesses lasting 4400 seconds has been taken into account. Afte each baking, the tempeatues in the points, whee themocouples have been placed in eal life, have been calculated. As a esult, the aveage values of the tempeatues fo selected nodes have been detemined fo seveal baking cycles - Fig. 5) as well as tempeatue fields of the wheel. The compaison of expeimental investigation and numeical calculation of baking cycles leads to following conclusions: - fo NASTRAN and ANSYS softwae the discepancy has been as %.

20 Tempeatue Testing NASTRAN [ C ] ANSYS [ C ] Cycle Fig.5. Tempeatue diagam fo nodes coesponding to themocouples placing 5. REMARKS AND CONCLUSIONS On the basis of web of a wheel model a ational mathematical numeical model has been established (ationality hee is undestood as easonable accuacy and computation time). This model has made possible the compaison of numeical calculations with unshakeable analytical esults. The wheel model, which has been ceated, has made possible the subsequent ceation of ational discete models of selected ailway wheels designs. These have been analysed with espect to loads aising duing manufactue and opeation. In addition, simulation of ailway wheel stain fo diffeent mesh types and pattens geneated by diffeent softwae has been conducted in ode to establish possible esults discepancy. The analysis has shown the impotance of accuate modelling of the load couse and wheel mesh. In ode to check out the calculation model the expeimental tests of static loads (due to caiage weight) and themal loads (due to baking) have been un. The esults of these tests have been compaed with esults of numeical analysis. The poposed calculation model has been compaed with esults of test stand investigation. Compaison of the esults has confimed the coectness of the poposed discete model and calculation algoithm. Additionally, the influence of wheel geomety (olling suface diamete, hub geomety, web geomety) and technological paametes (diffeence of intefeences between wheel and axle) on the distibution of displacements and stesses has been investigated. The following pincipal conclusions have been dawn as a esult of the investigation:. Using Finite Element Method (FEM) the computation pocedues fo tempeatue, displacement and stess fields in ailway wheelsets have been elaboated. This method takes into account eal wheel geomety, complex loads of the wheelset and mateial popeties.. New pocedues fo solving the wheel-axle contact poblems have been woked out. 3. The numeical computation esults have been compaed to the analytical computation esults. Results of this compaison justified selection of FEM mesh.

21 4. The numeical computation esults of the wheelset designs have been compaed with the esults of expeimental investigations. This should veify the adequacy of algoithm method used. Until now, the discepancies between numeical computation and field investigation esults could be as high as 50 pe cent. Fo the method poposed in this pape the diffeence was not highe than pe cent in case of themal loads and 5 pe cent fo static loads. 5. The elaboated pocedues of design and selection of wheelsets wheels using FEM have made possible a complex stength analysis of ten diffeent wheel designs; conclusions as to thei design and sevice have been woked out. 6. The conducted numeical analysis of the influence of the most significant geometical and sevice paametes of wheels of ailway wheelsets should enable the designes to optimise and select the wheels accoding to thei pocess engineeing paametes and constuction. 7. Futhe investigation will be diected at moe pecise definition of bounday condition fo themal loads in ode to achieve less discepancy in the esults; eal calculations of dynamic loads ae also planned. REFERENCES. Gąsowski W.: Wagony kolejowe. Waszawa: WKŁ, 988. Podemski J., Maczewski R., Majchzak Z.: Zestawy kołowe i maźnice. Waszawa: WKiŁ, Smith R. A.: Fatigue & the ailways: Why thee ae still unesolved poblems. W: Mateiały Seminaium Szkoleniowego Poblemy mechaniki w tanspocie szynowym ze szczególnym uwzględnieniem kolejowych zestawów kołowych, TRANSMEC, lipiec Feme M.: Optymization of a ailway Feight ca wheel by use of a factional design method. Division of Solid Mechanics, Chelmes Univesity of Technology, Gotebog Sweden Esaułow B.P., Sładkowski A.W.: K asczietu napażiennovo sostojania diskov kolies. Izwiestia WUZow. Maszinostwojenie 989, N, s Rapot ERRI B69.. Entwuf zum UIC-mekblatt Rapot ERRI B 69. Temische genzen de aden und bemsklotze. MTEL P 98005, Utecht