Simulation analysis of effect of wheel out-of-roundness on dynamic stress of coil springs in metro vehicles

Abstract

Many Chinese metros experienced numerous fatigue failures of the coil springs in the suspension of vehicles. The field test results presented in our previous work showed that wheel out-of-roundness (OOR) was responsible for the failure of the coil springs. It is believed that the most effective countermeasure to eliminate wheel OOR is to reprofile wheel. The fatigue life of coil springs is an important reference for determining the reprofiling parameters. A sophisticated vibration model for train and track with flexible coil springs and flexible track was established and validated with field test results. The effects of wheel OOR and P2 resonance on the coil spring can be evaluated with this model. The relationship between wheel OOR and coil spring dynamic stresses was determined using multibody simulation (MBS). The fatigue life of the coil springs was evaluated using the parameters of the amplitude of the wheel OOR and the mileage. Under the premise of finding a balance between improving the service life of the coil springs and reducing the cost of reprofiling the wheel, viable proposals were made to solve the problem of coil spring fracture.