Wheel–rail contact simulation with lookup tables and KEC profiles: a comparative study

Abstract

This paper describes and compares the use and limitations of two constraint-based formulations for the wheel–rail contact simulation in multibody dynamics: (1) the use of contact lookup tables and (2) the Knife-edge Equivalent Contact constraint method (KEC-method). Both formulations are presented and an accurate procedure to interpolate within the data in the lookup table is also described. Since the wheel–rail constraint contact approach finds difficulties at simultaneous tread and flange contact scenarios, the lookup table method is implemented with a penetration-based elastic contact model for the flange, turning the method into a hybrid (constant in the tread and elastic in the flange) approach. To deal with the two-point contact scenario in the KEC-method, a regularisation of the tread–flange transition allows the use of the constraint approach in the tread and also in the flange. To show the applicability and limitations of both methods, they are studied and compared with special emphasis in the calculation of normal and tangential contact forces. Numerical results are based on the simulation of a two-wheeled bogie vehicle in different case studies that consider irregular tracks and two wheel–rail profiles combinations: profiles that do not show two-point wheel–rail contacts and profiles that do show two-point wheel–rail contacts. Although results show a good agreement between both approaches, the use of the KEC-method is more extensive since it allows to reproduce the wheel-climbing scenario that cannot be simulated with the lookup table method with the hybrid contact approach. It is concluded that simulations with this later method may not be on the safe side.