The effectiveness of different wear indicators in quantifying wear on railway wheels of freight wagons

Abstract

Railway infrastructure relies on the dynamic interaction between wheels and rails; thus, assessing wheel wear is a critical aspect of maintenance and safety. This paper focuses on the wheel–rail wear indicator T-gamma (Tγ). Amidst its use, it becomes apparent that Tγ, while valuable, fails to provide a comprehensive reflection of the actual material removal and actual contact format, which means that using only Tγ as a target for optimization of profiles is not ideal. In this work, three different freight wagons are evaluated: a meter-gauge and a broad-gauge heavy haul vehicles from South American railways, and a standard-gauge freight vehicle operated in Europe, with different axle loads and dissimilar new wheel/rail profiles. These vehicles are subjected to comprehensive multibody simulations on various tracks. The simulations aimed to elucidate the intricate relationship between different wear indicators: Tγ, wear index, material removal, and maximum wear depth, under diverse curves, non-compensated lateral accelerations (Anc), and speeds. Some findings showed a correlation of 0.96 between Tγ and wear depth and 0.82 between wear index and material removed for the outer wheel. From the results, the Tγ is better than the wear index to be used when analyzing wear depth while the wear index is more suited to foresee the material lost. The results also show the low influence of Anc on wear index and Tγ. By considering these factors together, the study aims to improve the understanding of wheel–rail wear by selecting the best wear analysis approaches based on the effectiveness of each parameter.