The existing multi-objective wheel profile optimization methods mainly consist of three sub-modules: (1) wheel profile generation, (2) multi-body dynamics simulation, and (3) an optimization algorithm. For the first module, a comparably conservative rotary-scaling finetuning (RSFT) method, which introduces two design variables and an empirical formula, is proposed to fine-tune the traditional wheel profiles for improving their engineering applicability. For the second module, for the TRAXX locomotives serving on the Blankenburg-Rübeland line, an optimization function representing the relationship between the wheel profile and the wheel-rail wear number is established based on Kriging surrogate model (KSM). For the third module, a method combining the regression capability of KSM with the iterative computing power of particle swarm optimization (PSO) is proposed to quickly and reliably implement the task of optimizing wheel profiles. Finally, with the RSFT-KSM-PSO method, we propose two wear-resistant wheel profiles for the TRAXX locomotives serving on the Blankenburg-Rübeland line, namely S1002-S and S1002-M. The S1002-S profile minimizes the total wear number by 30%, while the S1002-M profile makes the wear distribution more uniform through a proper sacrifice of the tread wear number, and the total wear number is reduced by 21%. The quasi-static and hunting stability tests further demonstrate that the profile designed by the RSFT-KSM-PSO method is promising for practical engineering applications.
As high-speed trains operate at a higher speed, the problem of rail wear is more serious. In this paper, a new Gaussian function correction (GFC) method is proposed to design the new rail profile, two parameters are introduced to control the removal area. Then a high-speed train vehicle dynamic model is established, the Kriging surrogate model (KSM) is used to reduce the number of simulations and the Non dominated sorting genetic algorithm-II (NSGA-II) algorithm is used to optimize the rail profile. Finally, the dynamic characteristics and wheel/rail wear evolution of the optimized profile are analyzed. The results show that the dynamic performance of the optimized rail profile has been improved. The maximum wear depth of the optimized rail profile is reduced by 15.63% when passing a total weight of 16 Mt. The wheel wear depth of S1002CN profile contact with CHN60OPT is reduced by 4.8%. The proposed GFC method can quickly generate a new rail profile and has good engineering significance for rail grinding. The GFC-KSM-NSGA- II method can be used to optimize the rail profiles for high-speed lines, and it can further guide the operation and maintenance.
With the increase of train speed, the harmonic torque of the traction motor of a high-speed train is not a negligible source of excitation. In order to explore the influence of the harmonic torque of the motor on wheel wear, a high-speed EMU vehicle model was established based on the multibody dynamics theory. FASTSIM was used to calculate the wear parameters, and the Zobory wear model was used to calculate the depth of the wheel wear. The influence of the harmonic torque of the motor on the wear parameters and wear depth of high-speed trains under straight and curve conditions is calculated, respectively. The simulation results show that the harmonic torque has a large influence on the wheel rail vertical force and the longitudinal creep force and has little influence on the lateral creep force. With the 30% harmonic torque, the wheel rail vertical force increases by 7.6%, the longitudinal creep force increases by 15%, and the lateral creep force increases by 4%. The amplitude of the longitudinal creepage increases by 14.2% when the harmonic torque is 10%, and increases by 34.4% when the harmonic torque is 30%. When the harmonic torque increases, the wheel wear depth increases, the 10% harmonic torque increases by 3% and the 30% harmonic torque increases by 8%, and the increase of the motor harmonic component accelerates the wheel wear. At the same time, small longitudinal positioning stiffness can help to reduce the influence of the harmonic torque, and the selection of the longitudinal positioning stiffness needs to consider the dynamic performance of the vehicle.
The rail was considered as double Timoshenko beam in this paper, applied to the vehicle track coupling dynamics model; the Hertz nonlinear method is used to calculate the wheel rail contact force. Wheel rail vertical force and response of vehicle are calculated by using the model under random irregularity and single harmonic excitation; at the same time, wheel rail force and vertical acceleration response of 3-order, 10-order, and 19-order wheel polygon were calculated. The results show that, under the excitation of random irregularity, the wheel rail vertical force of two models was very close in the low frequency band, and the response of the double beam model in the high frequency band of 200–1000 Hz is larger than the single beam model, and the acceleration and displacement responses of the double beam model are relatively close. Under a single harmonic excitation, the double beam model has a shorter wheel rail force attenuation time than that of the single beam model. And wheel rail force peak value of double beam model is 9% larger than that of single beam model. Similarly, the vertical displacement of the double beam model increased by 2.6%. Under the 3-order and 10-order wheel polygon excitation, vertical wheel rail peak force of double beam is, respectively, 37.5% and 50% larger than single beam model; the vertical frame acceleration amplitude is 1 g and 1.7 g; under the 19-order polygon wheel excitation, the difference of the wheel rail force between two models is very small, and the amplitude of acceleration of bogie is 2.3 g. And double beam model has more advantage in analyzing high frequency problems such as wheel polygonization.
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