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Abstract
The temperature rise of wheels and blocks due to frictional heating during railway tread braking along with the transfer
of heat through the wheel–rail contact is studied in this paper. In particular, heat partitioning between block, wheel and
rail for stop braking cycles is considered. The wheels are of interest because they are a limiting factor for railway tread
braking systems. Two types of thermal models are employed to investigate the maximum temperatures over the wheel
tread. In a circumferential (plane) model of wheel, block and rail, the heat transfer problem is studied by use of a finite
element formulation of the two-dimensional time-dependent convection–diffusion equation. The hot spot phenomenon
is simulated by introducing a prescribed wheel-fixed contact pressure distribution between wheel and block. In an
axisymmetric (axial) model of wheel, block and rail, the lateral movements of the wheel–rail contact are studied. A
general result is that the cooling effect provided by the rail is important when local temperatures on the tread are
considered, but not when studying bulk temperatures created in a single stop braking event. Furthermore, it is found
from the lateral movements of the wheel–rail contact that slow oscillations result in maximum temperatures over the
wheel tread that are somewhat lower than for travelling on straight track (rolling at the rolling circle).
Keywords
Frictional heating, finite element analysis, heat partition, hot spots, rail cooling effect, railway tread braking, temperature,
wheel–rail contact
The damage influences the life cycle cost of railway factors), where an increased propensity for TEI can
wheels and can also be a safety issue. Repeated stop be found for block materials that have a high stiffness,
braking (i.e. the initial speed of the train is reduced low conductivity and high coefficient of thermal
substantially, or the train is brought to rest), e.g. in expansion.12
metro applications, may cause both a substantial tem- Specific to tread braking is the phenomenon that
perature rise in the wheel rim and the creation of hot the frictionally heated wheel tread is in rolling contact
spots on the wheel tread. Moreover, excessive drag with the rail. This means that for each part of the
(downhill) braking (the potential increase in train tread passing through the wheel–rail contact ellipse,
speed is kept constant by braking with an approxi- heat will be conducted from the hot wheel to the cold
mately constant brake force for a relatively long rail. A model for heat transfer in wheel–rail contacts
time), may create a risk of a different wheel failure at perfect thermal contact (infinite contact conduct-
mode: global wheel fracture induced by residual stres- ance) was developed by Ertz and Knothe.15
ses when the wheel cools down. Vernersson and Lundén8 introduced the concept of
a finite thermal conductance at the wheel–rail contact
which may be the result of the existence of a thin
State-of-the-art
third-body layer in the contact. It has been found in
The high temperatures due to frictional heat during both numericall and experimental8 studies that the
braking are an important dimensioning factor for rail- cooling effect of the rail makes a considerable contri-
way wheels. Friction, material properties and the sub- bution to the overall cooling of the wheel at elevated
sequent thermal damage of the contacting bodies are contact temperatures.
also influenced by high temperatures.2 There is an
extensive literature that uses both numerical and
Aim of the present study
experimental techniques to understand the heat trans-
fer behaviour of railway tread brake systems.1,3–8 The The objective of this paper is to use a numerical mod-
thermal problem involves modelling of both the elling approach to study heat partitioning and the
block–wheel and the wheel–rail contacts. Of particu- cooling effect of the rail during railway tread braking.
lar interest is the partitioning of heat in the block– The finite element (FE) method is used to investigate
wheel contact and the transfer of thermal power at the influence of hot spots and banding. Two two-
the wheel–rail contact, which influence the build-up dimensional models are used, one circumferential
of the maximum wheel and block temperatures. and one axisymmetric. Hot spots with equally
Experimental research has shown that the thermo- spaced areas in the circumferential direction of the
mechanical interaction between brake block and wheel tread are studied using a plane model. In this
wheel tread during braking causes hot spots and circumferential problem the influences of both hot
crack arrays on the wheel tread, which evidently are spots on the wheel and brake block temperatures
harmful to the wheel life.3,9–11 When increasing axle are determined. Banding on the tread, that is, where
loads and train speeds, and consequently the required localized bands around the wheel tread have an ele-
braking power, high temperatures become an import- vated temperature, is studied using an axisymmetric
ant limiting parameter in the design of tread-braked model. The influence of the rail’s cooling effect is stu-
railway wheels. Therefore, the study of the effect of died using both models. The focus is on the wheel
localised cyclic heating created as a result of tread behaviour since the wheel is often the critical compo-
braking on a wheel tread is of considerable interest. nent when assessing the thermal capacity of the brak-
The mechanism which explains the development of ing system. The advantages and drawbacks of the two
hot spots during frictional sliding contact is called ‘fric- models are discussed. The influence of several param-
tionally excited thermo-elastic instability (TEI)’.12 In eters on heat partitioning and temperatures are
TEI, the contact area is reduced by a thermally induced demonstrated in numerical examples.
distortion which often gives rise to the load being con-
centrated in a relatively small part of the nominal con-
tact area, resulting in high local temperatures. Hot Thermal models
spots have been observed in experiments on both auto-
motive13 and railway11 braking.
Circumferential model
TEIs (and hot spots) are developed during sliding Geometry. The wheel–block–rail system is represented
contact if the sliding speed is higher than a critical in this study by the two-dimensional circumferential
sliding speed, above which small changes in the con- model shown in Figure 1. The wheel is modelled as a
tact start to grow. For railway wheels, the hot spots thin ring which represents the wheel tread and a shal-
induced on the treads of the wheels have been found low surface layer of the wheel rim. The brake block is
to generate waviness on the surface, which is respon- modelled as a sector of a ring having the same centre
sible for rolling noise emitted from the vehicle.14 The point as the wheel. The rail is modelled as a rectangle.
tendency to produce hot spots is related to the mater- Each component of the system is thermally conduct-
ial parameters of the friction material (and other ing. Note that the three components all have a
relatively thin planar geometry thickness; a fact which operator, c the specific heat, the massT density, T
makes a faster analysis possible but does not influence the temperature, v ¼ vx ðx, yÞ, vy ðx, yÞ the velocity
the results for the studied short periods of time. All vector of the spatial points (x , y) and t time. The
profile parameters pertaining to the wheel–block–rail equation is applied separately for each of the three
system are listed in Table 1. bodies. Note, however, that the heat conduction equa-
The formulation of the problem is performed in a tion for the brake block has no convection term.
reference frame with the spatial coordinates of the No convection or radiation of heat to the sur-
three components (wheel, block and rail) fixed. This roundings is considered which means that all surfaces,
is an Eulerian description in which the computational except for the contact interfaces are adiabatic
domain (with FE nodes) remains fixed.16 However, a (@T/@n ¼ 0, n denoting the coordinate perpendicular
mass flow rate is introduced for the wheel and rail to the domain surfaces). When introducing a numer-
parts to represent the rolling motion with constant ical FE solution, with typical mesh size l which is a
rotational speed in the anticlockwise direction of the characteristic element length in the heat flow direction
wheel ring and a constant translational motion of defined by Yu and Heinrich 17,18 the Péclet number
the rail.
The transient heat transfer problem can be cvl
Pe ¼ ð2Þ
described by a conduction–convection (convection– k
diffusion) equation of the form
! becomes very high (in the order of 106) for braking
@T applications. A conventional Galerkin approach
divðKrTÞ ¼ c vrT
þ |ffl{zffl} ð1Þ would then render spurious node-to-node oscillations.
|fflfflfflfflfflffl{zfflfflfflfflfflffl} @t
diffusion convection A solution to this problem is the streamline diffusion
method introduced by Brooks and Hughes.19
where div is the divergence vector operator, K ¼ k I The commercial FE package Abaqus/Standard was
the thermal conductivity matrix (with k being a scalar used in this study.20 This software implements the
and I a unit matrix), r the ‘del’ vector differential Petrov–Galerkin method in the solution of the multi-
dimensional time-dependent convection–diffusion
equation as described by Yu and Heinrich.17,18 The
model shown in Figure 1 was tested extensively by
studying the tread temperature history for one block
passage and rail cooling effect considering finite ther-
mal conductance at contact. Comparison with an ana-
lytical solution for a semi-infinite solid subjected to a
prescribed heat flux at the surface of the tread as dis-
cussed in Carslaw and Jaeger21 was done and also
used to find a suitable mesh density. The chosen
mesh typically gave results that closely matched the
analytical results for the case of constant heat flux
along brake block contact.
The average heat flux at the contact interface of the
wheel–block can be defined by
Table 1. Reference data for the wheel–block–rail system in the circumferential model.
Profile parameter for wheel and block Semi-axes of wheel–rail contact ellipse
Figure 4. The FE models of wheel, brake block and rail. Trailing edge of wheel–block contact is shown in the right picture. Thin rail is
illustrated below the wheel body in the left picture.
Figure 7. Assumed pressure variations with ¼ 1 for the study of banding during stop braking.
which required the block’s thermal properties to be The influence of banding during braking was stu-
modified to account for the actual length of the died by introducing stop braking cycles on a wheel
block. The influence of the cooling effect of the rail with an elevated temperature, where the brake heat
on the wheel tread was (in the present section) imple- input is non-uniform in the axial direction. The heat
mented by use of a convection-type boundary condi- generation was assumed to result from a block–wheel
tion. The wheel to rail heat transfer coefficient was contact pressure varying according to distributions
calculated assuming that the thermal contact conduct- given by (cf. circumferential model and equation (1))
ance between wheel and rail (see also the previous y y
section ‘Heat partioning’) was hwr ¼ 3 106 W/m2oC, p ¼ pm þ pm cos
t 0
þn ð9Þ
meaning that the heat transfer from wheel to rail is B
90% of the value for perfect thermal contact.8
The influence of rail cooling was implemented over where pm is the mean contact pressure (units: N/m2)
a (axial) width on the tread of 9.54 mm which is close and the second term represents the pressure perturb-
to the value calculated by Hertzian contact theory ations for which is a factor that determines the pres-
assuming a rail head radius of 300 mm (UIC 60 rail sure amplitude. Furthermore, yt is the coordinate
head profile). Thus, in the chosen axisymmetric starting from the field side of the rim, y0 is the dis-
model, the area exposed to the cooling from the rail tance from the field side of the rim to the brake block,
corresponds to a band around the wheel circumfer- B is wheel–block contact width and n was chosen to
ence. Also, the axial position of the simulated wheel have a value of zero or one to give the variations in
and rail contact, which on straight track is at the roll- Figure 7. The brake’s heat flux at the contact was
ing circle, was varied over the tread. Both the situ- calculated in accordance with equation (6) where for
ation when the contact moves periodically over the stop braking the speed decreases linearly from its
tread (assumed travel on curved tracks) and the case maximum down to zero.
when the contact has a stationary position shifted
away from the rolling circle were studied. The latter
case is somewhat academic (or could result from
travel along a long curve) but is presented to give an Parametric study
insight into the nature of the cooling effect of the rail.
The influence of the cooling effect of the rail on the
Plane (circumferential) model
heat partitioning and wheel temperatures was studied It is known from previous studies, see Teimourimanesh
by use of simulated drag braking cycles (constant et al.,1 that the temperature and heat partitioning
brake power over a long duration) which steadily during braking depend on several variables. In the pre-
pushes the wheel tread towards elevated temperatures. sent studies, a baseline was introduced and the devi-
The choice to study drag braking cycles can be seen as ation in results when different variables are varied was
a simplification of a scenario where a train is travel- studied.
ling on a route with multiple consecutive short stops In the baseline the wheel–block pressure distribu-
as for a metro train with short distances between the tion varies in a sinusoidal manner and the chosen set
stations. of parameters is given in Tables 1 and 2. The stop
Figure 8. Calculated wheel tread temperatures along the circumference after every revolution when stop braking with composite
brake block (1Bg) at 177.8 kW and 80 km/h. Sinusoidal pressure perturbation (up) and constant pressure (down). Baseline case is
shown in the upper left figure. Note, for identification of curves, that temperature increases with each revolution.
wheel–rail contact ellipse, it is clear that the cooling revolutions and that the braking power is decreased
effect of the rail is negligible when analysing bulk by 50%, resulting in lower temperatures for both
wheel temperatures. wheel and block. The alternative wheel diameter
The influence of different initial wheel and block gives a wheel–rail contact semi-axes a ¼ 5.93 mm and
temperatures was investigated. The results for initial b ¼ 5.15 mm which causes an increase in the maximum
temperatures of 0 C and 300 C both for the wheel wheel temperature (baseline case: a ¼ 6.31 mm,
and block show that the heat partition between the b ¼ 5.04 mm). The alternative pressure amplitude
two bodies remains relatively unaffected. The power was decreased to ¼ 1/3 in comparison with the ref-
from the wheel into the rail increases from 22% to erence case which means a more even distribution of
about 55% as the initial temperature is increased temperatures on both wheel and block. It is interest-
and is reduced to about 6% as the initial temperature ing to note that the heat partitioning between the
is decreased. wheel and block is only marginally changed by the
The influence of train speed, wheel diameter, alternative cases. However, the partition into the rail
wheel–rail contact semi-axis and pressure amplitude is increased for the lower train speed which is
is shown in Table 5. It should be noted that the alter- explained by the lower braking power. Furthermore,
native speed of 40 km/h gives a longer time for five the power to the rail is decreased by the smaller wheel
Figure 9. Calculated wheel tread and brake block temperatures (baseline) at the wheel–block trailing edge when stop braking with
composite brake block (1Bg) at 177.8 kW and 80 km/h.
Table 4. Calculated temperatures for the two contact pressure variation types. Summary of the calculated heat entering the wheel,
block and rail at the end of analysis for the case with and without cooling effect of the rail when stop braking with composite brake
block (1Bg) at 177.8 kW and 80 km/h.
Pressure Twmax ( C) Tbmax ( C) Twmin ( C) Qw/Qbrake (%) Qb/Qbrake (%) Qr/Qbrake (%) Qred
r /Q
brake
(%)
Table 5. Temperatures and calculated heat levels entering the wheel, block and rail at the end of the analysis of the four alternative
cases when stop braking with composite brake block (1Bg).
Cases Twmax ( C) Tbmax (C) Twmin ( C) Qw/Qbrake (%) Qb/Qbrake (%) Qr/Qbrake (%) Qred
r /Q
brake
(%)
diameter which means a smaller semi-axis of the sinter and cast iron, influence the temperature and
wheel–rail contact ellipse in the rolling direction of heat partitioning behaviour. Two important factors
5.93 mm. when considering the three different braking materials
The choice of brake block material is of great considered in this paper are the wavelength of the hot
importance for the performance of railway tread spot pattern which these materials induce3 and also
brakes. This paper investigates how the most the thermal resistances Rw and Rb between the wheel
common brake block materials, organic composite, and block as given in Vernersson7, see Table 6.
Another important aspect is the brake block config- The results listed in Table 7 show that composite
uration which can strongly affect both temperature and brake blocks create higher wheel temperatures than
heat partitioning. Figure 10 shows the wheel tread tem- the other studied materials. The reason for this behav-
peratures at the end of every revolution for the baseline iour is a combination of the material properties and
case but with a 2Bg configuration (left) and also with also thermal resistance values in comparison with
constant brake pressure (right), also here for the 2Bg sinter and cast iron. The lower temperatures for the
configuration. Comparison with Figure 8 (left) shows 2Bg block configuration are caused by the doubled
that the temperatures are generally reduced by the 2Bg braking contact area. The heat partitioning to the
configuration (two opposite blocks per wheel). wheel follows the same pattern as the wheel tempera-
tures. The case of a shorter hot spot wavelength of
Table 6. Hot spot wavelengths and values of the thermal 82.5 mm was also studied (not in the table) for com-
contact resistances Rw and Rb for the cast iron, sinter and posite and sinter brake blocks but no significant influ-
composite brake blocks. ence on the results was found.
The heat partitioning model, see equations (6) and
Block material Cast iron Sinter Composite (7), indicates that the thermal resistances of the wheel
Hot spot wavelength (mm) 62.8 165 165 and block play an important role. The model needed
Rw (m2 C/W) 440 10-6 250 106 170 106 to be tested using reduced thermal resistances for the
available materials. Thus, the thermal resistances in
Rb (m2 C/W) 350 10-6 570 106 720 106
Table 6 were scaled by a factor 0.001 and the obtained
Figure 10. Calculated tread temperatures along wheel circumference immediately after each of the five revolutions under stop
braking with composite brake blocks (2Bg) at 177.8 kW and 80 km/h. Assumed sinusoidal-varying block-tread pressure perturbation
(left) and constant pressure (right).
Table 7. Calculated temperatures and heat partitions for different brake block materials and block configurations.
Material Configuration Twmax ( C) Tbmax ( C) Twmin ( C) Qw/Qbrake (%) Qb/Qbrake (%) Qr/Qbrake (%) Qred
r /Q
brake
(%)
Cast iron 1Bg 183 441 59.1 49.9 50.1 19.7 1.95
Cast iron 2Bg 160 272 60.3 49.7 50.3 20.0 1.98
a
The brake block located on the left side of the wheel whereas baseline has block on right side, see Figure 1.
Table 8. Calculated temperatures and heat partitions for different brake block materials, brake pressure and thermal resistances.
The constant and sinusoidal brake pressures and thermal resistances based on Table 6 have been tested.
Cast iron Constant 1 141 440 60.2 49.9 50.1 19.5 1.93
Cast iron Constant 0.001 186 188 69.5 95.1 4.87 22.6 2.24
Cast iron Sinusoidal 1 183 441 59.1 49.9 50.1 19.7 1.95
Cast iron Sinusoidal 0.001 189 190 68.5 95.3 4.75 22.6 2.24
Table 9. Calculated temperatures and heat partitions for different brake block materials and pressure distributions.
Material Pressure Twmax ( C) Tbmax ( C) Twmin ( C) Qw/Qbrake (%) Qb/Qbrake (%) Qr/Qbrake (%) Qred
r /Q
brake
(%)
Cast iron Sinusoidal 183 441 59.1 49.9 50.1 19.7 1.95
Cast iron Square (/5) 310 440 50.3 49.9 50.1 20.2 1.99
Cast iron Square (/10) 493 432 50.3 50.0 50.1 20.6 2.04
results for temperature and heat partitioning are listed tread temperatures and banding. The cooling influ-
in Table 8. It can be seen that a reduction in the thermal ence of the rail was studied for two situations: first,
resistance level increases the heat partitioned into the the contact has a stationary axial position on the tread
wheel body. However, the wheel–block pressure distri- and second, the contact moves periodically over the
butions only marginally influence the heat partitions. tread to resemble travelling on curved track. A simu-
The temperatures and heat partitions for hot spots lated situation corresponding to drag braking power
obtained using a square wave instead of a sinusoidal Q ¼ 30 kW (to one wheel) at 100 km/h for 30 min
wave are listed in Table 9. The idea is to have more (long-period drag braking) was studied. The brake
concentrated pressure and areas of more elevated tem- block configuration was 2Bg and composite brake
peratures. The square wave amplitude was chosen to block material was assumed.
give the same average braking power, see Figure 2. All The influence of the cooling effect of the rail was
other parameter values were as for the baseline case. It investigated when the wheel–rail contact was located
can be seen that the temperature distributions are at different stationary positions ranging from a position
strongly affected by the calculated pressure but the towards the field side (yt ¼ 16 mm) to a position
heat partitioning is more or less unaffected. towards the flange side (yt ¼ 84 mm). Figure 11 shows
the wheel tread temperature with respect to time when
the wheel–rail contact position is at the rolling circle.
Axisymmetric (axial) model The influence of the cooling effect of the rail can be
The axisymmetric model was used to investigate the clearly seen as a local lowering of the temperature at
influence of the cooling effect of the rail on the wheel yt ¼ 65 mm. The maximum tread temperature at the
Figure 11. Calculated wheel tread temperature when the wheel–rail contact is located at the rolling circle (65 mm from the field
side of the wheel). The maximum temperature is 241 C and located 31.3 mm from the field side.
Figure 12. Calculated maximum tread temperatures for different wheel–rail contact positions along the wheel tread. The result
when the wheel–rail contact is located at the rolling diameter 65 mm from field side is shown by an arrow (left). Mean tread
temperature for a wheel–rail position at the rolling circle as well as the extreme cases that show the highest and lowest temperatures
respectively (right).
end of the simulated brake cycle as a function of the temperature 220 C occurs when the contact is located
wheel–rail contact position is shown in Figure 12. at 40 mm from the field side and the highest maximum
Also, the mean tread temperature for a wheel–rail pos- temperature (257 C) occurs when the contact is
ition at the rolling circle as well as the extreme cases towards the flange side of the tread (yt ¼ 85 mm).
that give highest and lowest temperatures, respectively, The amount of heat that goes from the wheel to the
are illustrated in Figure 12. The lowest maximum rail varies from 21% when the wheel–rail contact is at
Figure 13. Calculated wheel tread temperature when the wheel–rail contact moves periodically with amplitude 20.0 mm and period
8 min. The maximum temperature is 237 C at a position 31.8 mm from the field side.
the flange side up to 27 % when the wheel–rail contact illustrates the tread temperatures as a function of
is at yt ¼ 40 mm. time for non-uniform pressure distribution along the
Furthermore, the influence of the vehicle’s periodic wheel–block contact with n ¼ 0 (see Figure 7) during a
lateral movement was studied by simulating different single stop braking cycle. Table 10 shows the highest
amplitudes and time periods for sinusoidal wheel–rail tread temperature of the wheel for a wheel–rail con-
contact movements with the same drag braking con- tact (and rail cooling effect) positioned at the rolling
dition as previously considered. In general it is found circle. It can be clearly seen that a non-uniform pres-
that long time periods, see the example in Figure 13, sure distribution increases the maximum tread tem-
give a higher maximum tread temperature than do perature. For comparison, the same information is
short ones. The time period of the lateral movement also included for the case where the cooling effect of
was tested for magnitudes between 10 min and 10 s. the rail is not considered. The comparison shows that
For example, time periods in the range 4–10 min have the maximum tread temperature is not significantly
a highest maximum temperature of about 240 C, changed for these cases.
whereas really short time periods have a highest max-
imum temperature of about 226 C. Moreover, the
Discussion
amplitude of the wheel-rail contact movement over
the wheel tread was varied from 29.2 mm down to The circumferential model, which only allows simulat-
10 mm. ing effects over a short period of time due to compu-
The influence of banding during braking was stu- tational constraints, shows that hot spots (tread
died by introducing stop braking cycles on a wheel temperature oscillations in the circumferential direc-
with an elevated temperature. For these simulations, tion) have a negligible influence on the heat partition-
the wheel and brake blocks were assumed to have a ing in the wheel–rail–block system, see Table 4. Even
constant initial temperature of 100 C while the rail though the maximum tread temperatures (for simu-
temperature was taken to be 0 C. Three alternatives lated braking with composite brake blocks) increase
for brake heat input distribution in the axial direc- substantially due to the temperature perturbations
tion were tested, see Figure 7. The simulated case superimposed on the bulk temperature, the global
corresponds to initial stop braking power Q ¼ mav ¼ heat input to the wheel (Qw) does not change.
7500 kg 1 m/s2 100/3.6 m/s ¼ 208 kW and braking Moreover, the wheel–rail contact (rail cooling effect)
time 27.8 s to a standstill. Correspondingly, the is found to reduce the maximum tread temperatures.
brake power is ramped down to zero. Figure 14 After five simulated revolutions of the wheel, the rail
Figure 14. Calculated tread temperatures for non-uniform pressure distribution with n ¼ 0, see Figure 7. The maximum tread
temperature and the corresponding distance from field side are 358 C and 17.8 mm, respectively.
this can be seen as a decrease in the maximum tem- and it was shown that the temperature differences
peratures when simulating hot spots with the resist- were small.
ances scaled by 0.001 (Table 8). The same effect is
present when braking with the cast iron brake
Concluding remarks
blocks, i.e. the temperature differences on the tread
are suppressed. However, since the block in the The generated temperatures and heat partitioning
normal case takes such a large part of the heat and between wheel, block and rail during tread braking
since the block temperature is now substantially have been studied. First, by use of a circumferential
reduced, the maximum wheel temperature neverthe- model, the effects of short time period braking at
less increases for this case (but with eliminated tem- powers typical for a stop braking cycle were analysed
perature variations). under the assumption that hot spots appear on the
The simulations with the axisymmetric model high- tread. Second, by use of an axisymmetric model, the
lighted two phenomena: first, the influence of the pos- influence of the position of the rail cooling effect (con-
ition of the rail cooling effect i.e. the effect of the stant offset wheel–rail contact from rolling circle or
assumed axial position of the rolling contact and oscillatory lateral movement of the contact) was stu-
second, the influence of banding during a stop brak- died for braking over longer time periods. Also, the
ing cycle. In order to the study the effect of the pos- influence from banding during a stop braking cycle
ition of the rail cooling effect, a drag braking cycle has been studied.
(30 kW for 30 min) was simulated which gave a slow In conclusion, when it comes to implications for
increase of the tread temperature. For a constant pos- wheel dimensioning, the present study indicates that
ition for the wheel–rail contact, it was found that the the global build-up of stress in the wheel rim does not
maximum tread temperature ranged from 220 to change when pressure (or temperature) disturbances
256 C (or that the part of the heat going to the rail are present. However, if the heat partitioning mech-
at the end of the brake cycle ranges from 21 to 27%). anisms (i.e. the sharing of power at the frictional inter-
The lowest temperature was found for a wheel–rail face within the third-body layer) changes as a result of
contact slightly towards the field side of a central a locally increased temperature, then global heat par-
brake block position, and the highest tread tempera- titioning will also change. The cooling effect of the rail
ture occurred for a wheel–rail contact towards the on the wheel has been shown to be of minor import-
flange side. The position giving the highest cooling ance for short stop braking cycles where the heat from
(i.e. lowest tread maximum temperature) coincided braking dominates over the cooling influence of the
with the position giving the maximum tread tempera- rail on the wheel. However, for prolonged braking
ture if no rail cooling effect was considered. It was actions, or when multiple braking actions are studied
found that the nominal position of the wheel–rail con- with intermediate cooling, the cooling effect of the rail
tact at the rolling circle (yt ¼ 65 mm from the field side does become important for the evolution of the bulk
of the rim) gave a maximum tread temperature of temperature in the wheel rim. In general, there is still a
241 C (the rail cooling effect then takes 25% of the strong demand to reduce train noise by introduction
brake power). These examples with a constant wheel of new brake block materials. However, the thermal
position show the limitations of the rail cooling effect, behaviour of these blocks is not been optimised they
but in reality the position of the wheel–rail contact is can cause wheel tread damage as a result of excess
dictated by the running behaviour of the train, i.e. heat entering the wheel. The method proposed in
how the wheelset moves laterally on the rail. For this paper can be used by engineers to shed light on
this reason, the wheel–rail contact was allowed to the local stress distribution and damage in the wheel
move on the tread for given time periods. For these tread, wheel deflections and thermal capacity of a
cases it was found that slow oscillations gave max- wheel design or braking system.
imum temperatures somewhat lower than for
moving on straight track (constant rolling at the roll-
ing circle). However, for faster implemented vari-
Acknowledgements
ations the maximum tread temperature decreased
towards the lowest value for a constant position This work was performed as part of the doctoral project
(giving 220 C) with a temperature of 226 C. Lastly, ‘Thermal capacity of railway wheels’ carried out at the
Department of Applied Mechanics at Chalmers University
the influence from simulated banding during a stop
of Technology, Gothenburg, Sweden. It forms part of the
braking cycle was studied. For this case, it was found
activities within the Swedish National Centre of Excellence
that rail cooling effect has a minor influence on the CHARMEC (CHAlmers Railway MEChanics, see
maximum temperatures which may be explained by www.chalmers.se/charmec). The support of the project
the high power levels sent to the wheel, generally steering committee constituted from representatives of
making the cooling heat fluxes from the rail cooling Bombardier Transportation, Faiveley Transport, Interfleet
effect or convection small or negligible. This was illu- Technology and SL Technology is gratefully acknowledged.
strated by comparing the maximum tread tempera- Professor Emeritus Bengt Åkesson assisted in improving the
tures when the rail cooling effect was not considered manuscript.
density (kg/m3)
’ angular coordinate
Superscript
brake braking
max, min maximum and minimum, respectively
red reduction
Subscripts
b, r, w block, rail and wheel, respectively
t tread