Development of a wear model for the wheel profile optimisation on railway vehicles

The modelling and the reduction of wear due to wheel–rail interaction is a fundamental aspect in the railway field, mainly correlated to safety, maintenance interventions and costs. In this work, the authors present two innovative wheel profiles, specifically designed with the aim of improving the wear and stability behaviour of the standard ORE S1002 wheel profile matched with the UIC60 rail profile canted at 1/20 rad, which represents the wheel–rail combination adopted in the Italian railway line. The two wheel profiles, conventionally named CD1 and DR2, have been developed by the authors in collaboration with Trenitalia S.p.A. The CD1 profile has been designed with the purpose of spreading the contact points in the flange zone on a larger area in order to reduce wear phenomena and having a constant equivalent conicity for small lateral displacements of the wheelset with respect to the centred position in the track. The DR2 wheel profile is instead designed to guarantee the same kinematic characteristics of the matching formed by ORE S1002 wheel profile and UIC60 rail profile with laying angle αp equal to 1/40 rad, widely common in European railways and characterised by good performances in both wear and kinematic behaviour. The evolution of wheel profiles due to wear has been evaluated through a wear model developed and validated by the authors in previous works. The wear model comprises two mutually interactive units: a vehicle model for the dynamic simulations and a model for the wear assessment. The whole model is based on a discrete process: each discrete step consists in one dynamic simulation and one profile update by means of the wear model while, within the discrete step, the profiles are supposed to be constant. The choice of an appropriate step is crucial in terms of precision and computational effort: the particular strategy adopted in the current work has been chosen for its capacity in representing the nonlinear wear evolution and for the low computational time required. In the present research, the investigated trainset is the passenger vehicle ALSTOM ALn 501 ‘Minuetto’, which is usually equipped with the standard ORE S1002 wheel profile in Italian railways. The entire model has been simulated on a virtual track specifically developed to represent a statistical description of the whole Italian line. The data necessary to build the virtual track and the vehicle model were provided by Trenitalia S.p.A. and Rete Ferroviaria Italiana. The CD1 and DR2 wheel profiles, matched to the UIC60 rail with cant 1/20 rad, have shown a good behaviour in terms of wear resistance if compared with the old ORE S1002 wheel profile, consequently assuring a more uniform distribution of the removed material and a prolongation of the mean time between two subsequent re-profiling interventions.