Abstract
In a rail vehicle, fatigue fracture causes a significant number of failures in the coil spring of the suspension system. In this work, the origin of these failures is examined by studying the rail wheel–track interaction, the modal analysis of the coil springs and the stresses induced during operation. The spring is tested experimentally, and a mathematical model is developed to show its force vs. displacement characteristics. A vertical 10-degree-of-freedom (DOF) mathematical model of a full-scale railway vehicle is developed, showing the motions of the car body, bogies and wheelsets, which are then combined with a track. The springs show internal resonances at nearly 50–60 Hz, where significant stresses are induced in them. From the stress result, the weakest position in the innerspring is identified and a few guidelines are proposed for the reduction of vibration and stress in rail vehicles.
Highlights
High-speed railways in India have achieved higher speeds, which help in the saving of energy and the protection of the environment
This work proposes equivalent dynamic and flexible spring models to consider the dynamic characteristics of coil springs in multibody dynamics analysis
A coupled vehicle track mathematical model was developed to analyze the influence on the stresses in the springs
Summary
High-speed railways in India have achieved higher speeds, which help in the saving of energy and the protection of the environment. As one of the longest railway networks in the world, vehicle safety and passenger comfort are key components of the service. The high speed of the railway has aided in the achievement of extensive and profound development in India. The coil spring and hydraulic damper are commonly used as vibration control elements in the rail vehicle. These are essential parts for ensuring safety and improving ride quality. Significant numbers of coil spring breakages have recently been found in the primary suspension during rail vehicle operations [1]
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