This is the submitted version of a paper presented at ICRI Workshop on Wear and RCF.
Citation for the original published paper:
Casanueva, C., Dirks, B., Enblom, R., Hossein Nia, S., Shazamanian Shichani, M. (2016) Integrated simulation of damage: efficient contact modeling, wear-RCF interaction, and long- term evolution.
In: ICRI Workshop on Wear and RCF
N.B. When citing this work, cite the original published paper.
Permanent link to this version:
http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-190893
interaction, and long-term evolution
Carlos Casanueva
Assistant Professor in Rail Vehicle Technology KTH, Stockholm, Sweden
Carlos Casanueva, PhD (KTH Rail Vehicles)
Babette Dirks, PhD (Bombardier Transportation) Roger Enblom, PhD (BT, KTH Rail Vehicles)
Saeed Hossein Nia, MSc (KTH Rail Vehicles)
Matin Sh. Shichani, PhD (KTH, MiW Rail Technology)
KTH Railway Group
Key activities:
• Research and postgraduate education
• Graduate education
• Courses for professional engineers
• Seminars
• Consulting engineers
KTH Railway Group
0 115
Eskilstuna-Stockholm
105 90 83 80 75 67 50 36 15
Flemingsberg Södertälje syd
Nykvarn Läggesta
Grundbro Malmby Strängnäs Härad Kjula
Eskilstuna C
Åkers
styckebruk Järna
Flen
Almnäs
43 v ö
73 Barva
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Traffic and Logistics
Cost effective bridges
soil-steel composite
railway bridges Structural Engineering and Bridges
Machine design
Rail Vehicles Electric Energy
Conversion (Light and with good
dynamic and acoustic comfort)
3
Wheel and rail damage simulation at KTH
Multiscale analysis
Contact Patch Modelling
Vehicle Dynamics
Wear/RCF
interaction
Wheel and rail damage simulation at KTH
Multiscale analysis
Contact Patch Modelling
Vehicle Dynamics
Wear/RCF interaction
5
Vehicle Dynamics
Wear/RCF interaction
Multiscale analysis
Large scale
Small scale
SNCF
Contact
Patch
Modelling
Wheel and rail damage simulation at KTH
Multiscale analysis
Contact Patch Modelling
Vehicle Dynamics
Wear/RCF interaction
7
Contact patch modelling
Important for precise damage calculation
Hertz+FASTSIM CONTACT code (most precise)
~ 0.02 second
~ 20
seconds
Creep Force
Pure translational case
FaStrip :
FASTSIM:
M. S. Sichani, R. Enblom, and M. Berg, “A novel method to model wheel–rail normal contact in vehicle dynamics simulation,” Vehicle System Dynamics, vol. 52, no. 12, pp. 1752–1764, Dec. 2014.
M. S. Sichani, R. Enblom, and M. Berg, “Comparison of non-elliptic contact models: Towards fast and accurate modelling of wheel–rail contact,” Wear, vol. 314, no. 1–2, pp. 111–117, Jun. 2014.
9
ANALYN+FaStrip
y = 0 mm y = -11 mm
Results
ANALYN+FaStrip
Hertz+FASTSIM CONTACT code
~ 0.02 second
~ 20 seconds
~ 0.12 second
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Energy index in the patch
Wheel and rail damage simulation at KTH
Multiscale analysis
Contact Patch Modelling
Vehicle Dynamics
Wear/RCF interaction
13
Basic damage prediction modelling
Wear RCF
Initial wheel profile Contact data generation
Transient simulations Wear calculation
Wheel profile updating Scaling to step limit
Rail profiles Simulation set
Wear map
- Traction and braking - Lubrication
- Friction coefficient - Track irregularities - …
- Metro wheels - Tram rails
- Commuter wheels
- Freight wagon wheels
- Freight loco wheels
Damage prediction modelling application
Wear RCF
44 45
46 47
48 49
−0.06
−0.04
−0.02
0 0.02
0.04 0.06 0
0.5 1 1.5
x 10−8
Turnout’s Longitudinal Dimension [m] Lateral Dim
ension of W
heel Profile [m]
Wear [m]
Wing rail
Crossing Nose
C. Casanueva, E. Doulgerakis, P.-A. Jönsson, and S. Stichel, “Influence of switches and crossings on wheel profile evolution in freight vehicles,” Vehicle System Dynamics, vol. 52, no. sup1, pp. 317–337, 2014.
S. Hossein Nia, P.-A. Jönsson, and S. Stichel, “Wheel damage on the Swedish iron ore line investigated via multibody simulation,”
Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, vol. 228, no. 6, pp. 652–662, Aug.
2014.
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Wear-RCF interaction
Crack growth model +
Archard
B. Dirks, R. Enblom, and M. Berg, “Prediction of wheel profile wear and crack growth – comparisons with measurements,” Wear. In
Validation – Wear
t f = flange thickness h f = flange height q r = flange inclination ΔA = worn-off area
o = measurements = simulation
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Validation – Crack growth
c pe = predicted crack length, wear excluded
c pi = predicted crack length, wear included
c m = measured crack length
Wear-RCF interaction
Surface Fatigue Index +
Archard
S. Hossein Nia, C. Casanueva, and S. Stichel, “Prediction of RCF and wear evolution of iron-ore locomotive wheels,” Wear, vol. 338–
339, pp. 62–72, Sep. 2015.
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Wear-RCF interaction
Validation – Long Term Development
Lubricated Non-Lubricated
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Validation – Long Term Development
Lubricated Non-Lubricated
Bombardier Transportation
Wheel and rail damage simulation at KTH
Multiscale analysis
Contact Patch Modelling
Vehicle Dynamics
Wear/RCF interaction
Crack growth + Archard Surface Fatigue + Archard Uniform wheel wear development
Tangential contact Normal contact
RCF long term development
Subsurface fatigue
Lubrication tribology Improved wear maps Software homogenization
MBS coding
Statistical wear calculation
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