a b s t r a c tThe prediction of the wear at the wheel-rail interface is a fundamental problem in the railway field, mainly correlated to the planning of maintenance interventions, vehicle stability and the possibility of researching specific strategies for the wheel and rail profile optimization. In this work the Authors present a model specifically developed for the evaluation of the wheel and rail profile evolution due to wear, whose layout is made up of two mutually interactive but separate units: a vehicle model for the dynamic analysis and a model for the wear estimation. The first one is made up of two parts that interact online during the dynamic simulations: a 3D multibody model of the railway vehicle implemented in Simpack Rail (a commercial software for the analysis of multibody systems) and an innovative 3D global contact model (developed by the Authors in previous works) for the detection of the contact points between wheel and rail and for the calculation of the forces in the contact patches (implemented in C/C++environment). The wear model, implemented in the Matlab environment, is mainly based on experimental relationships found in literature between the removed material and the energy dissipated by friction at the contact. It starts from the outputs of the dynamic simulations (position of contact points, contact forces and global creepages) and calculates the pressures inside the contact patches through a local contact model (FASTSIM algorithm); then the material removed due to wear is evaluated and the worn profiles of wheel and rail are obtained. This approach allows the evaluation of both the quantity of removed material and its distribution along the wheel and rail profiles in order to analyze the development of the profiles shape during their lifetime.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 fundamental in terms of precision and computational load. Moreover the different time scales characterizing the wheel and rail wear evolution require the development of a suitable strategy for the profile update: the strategy proposed by the Authors is based both on the total distance traveled by the considered vehicle and on the total tonnage burden on the track. The entire model has been developed and validated in collaboration with Trenitalia S.p.A. and Rete Ferroviaria Italiana (RFI), which have provided the technical documentation and the experimental results relating to some tests performed with the vehicle DMU Aln 501 Minuetto on the Aosta-Pre Saint Didier line.

The numerical wheel wear prediction in railway applications is of great importance for different aspects, such as the safety against vehicle instability and derailment, the planning of wheelset maintenance interventions and the design of an optimal wheel profile from the wear point of view. For these reasons, this paper presents a complete model aimed at the evaluation of the wheel wear and the wheel profile evolution by means of dynamic simulations, organised in two parts which interact with each other mutually: a vehicle's dynamic model and a model for the wear estimation. The first is a 3D multibody model of a railway vehicle implemented in SIMPACK™, a commercial software for the analysis of mechanical systems, where the wheel–rail interaction is entrusted to a C/C++user routine external to SIMPACK, in which the global contact model is implemented. In this regard, the research on the contact points between the wheel and the rail is based on an innovative algorithm developed by the authors in previous works, while normal and tangential forces in the contact patches are calculated according to Hertz's theory and Kalker's global theory, respectively. Due to the numerical efficiency of the global contact model, the multibody vehicle and the contact model interact directly online during the dynamic simulations.\ud \ud The second is the wear model, written in the MATLAB® environment, mainly based on an experimental relationship between the frictional power developed at the wheel–rail interface and the amount of material removed by wear. Starting from a few outputs of the multibody simulations (position of contact points, contact forces and rigid creepages), it evaluates the local variables, such as the contact pressures and local creepages, using a local contact model (Kalker's FASTSIM algorithm). These data are then passed to another subsystem which evaluates, by means of the considered experimental relationship, both the material to be removed and its distribution along the wheel profile, obtaining the correspondent worn wheel geometry.\ud \ud The wheel wear evolution is reproduced by dividing the overall chosen mileage to be simulated in discrete spatial steps: at each step, the dynamic simulations are performed by means of the 3D multibody model keeping the wheel profile constant, while the wheel geometry is updated through the wear model only at the end of the discrete step. Thus, the two parts of the whole model work alternately until the completion of the whole established mileage. Clearly, the choice of an appropriate step length is one of the most important aspects of the procedure and it directly affects the result accuracy and the required computational time to complete the analysis.\ud \ud The whole model has been validated using experimental data relative to tests performed with the ALn 501 ‘Minuetto’ vehicle in service on the Aosta–Pre Saint Didier track; this work has been carried out thanks to a collaboration with Trenitalia S.p.A and Rete Ferroviaria Italiana, which have provided the necessary techn...

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a b s t r a c tThe modelling and the reduction of wear due to wheel-rail interaction is a fundamental aspect in the railway field, mainly correlated to running stability and 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 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 wheel 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 in order to guarantee the same kinematic characteristics of the matching formed by ORE S1002 wheel profile and UIC60 rail profile with laying angle a p equal to 1/40 rad, widely common in European railways and characterized by good performances in both wear and kinematic behaviour.Wheel profiles evolution has been calculated through a wear model developed and validated by the authors in previous works with experimental data relative to the Italian Aosta-Pre Saint Didier railway line. This 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 non-linear 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 and UIC60 rail profile canted at 1/20 rad 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 (RFI). Both the innovative wheel profiles developed in this research activity for the UIC60 rail with cant 1/20 rad have proven to work fine in terms of resistance to wear if compared with the old ORE S1002 wheel profile.

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