Optimal design of wheel profiles for high-speed trains

The high maintenance cost of high-speed wheels due to wear and rolling contact fatigue is a major problem in the commercial operation of high-speed trains in China. In order to understand the wear behavior of high-speed wheels and its influence on the motion stability of high-speed trains, the worn profiles and the work-hardening of the wheels of the CRH3 high-speed trains that operate on the Wuhan–Guangzhou line were monitored in different periods during service; in particular, the influence of hollow wear of the wheel on the lateral acceleration of the bearing-box was investigated in detail. A new wheel profile design method was suggested to reduce the hollow wear by seeking an optimization match of the wheel profiles, the vehicle’s suspension systems, and the wear behavior of wheels in service. The feasibility of the method was verified by numerical simulation using the operation conditions of CRH3 high-speed trains on the Wuhan–Guangzhou line. A new wheel profile was designed using this method. The wheel/rail contact performance and the vehicle’s dynamic behavior resulting from the designed new wheel were investigated in detail and compared with those of the original wheel. The wear behavior of the designed new wheel profile was predicted based on wear data measured on the original wheel. The results show that compared with the original wheel profile, the designed new wheel profile can improve the wheel/rail contact state, reduce the contact stress level, and lower the friction power of wheel and rail. The extent of hollow wear on the new wheel is significantly decreased and the vehicle has improved dynamic behavior when wheelsets with the designed new profile are used. Thus, the period before re-profiling is required can be effectively extended.