Abstract
Coil springs are widely used in the suspension systems of railway vehicles to bear loads and isolate vibrations. Many vehicles in one metro line in China have suffered from spring fractures that exhibit typical fatigue characteristics. In this study, experiments and numerical simulation were conducted to investigate the root cause of the coil spring fracture. The results indicated that the wheel out-of-roundness (OOR) had low-order polygonisation in the early stage of metro operation and has high-order polygonisation at the current stage, which can excite the resonance of the coil spring in different speed ranges. The dynamic stress of the coil spring increases considerably under wheel OOR excitation, which significantly shortens the service life of the coil spring. Wheel maintenance strategies and limit values are proposed for controlling the wheel OOR according to field investigation results to prolong the service life of the coil spring.
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