The development features of corrugation on the straight track metro line are studied to find the root cause of corrugation. Firstly, the measured corrugation characteristics on the line are investigated and a three-dimensional wheel-rail (WR) rolling contact finite element (FE) model is constructed. Then, the WR stick-slip (SS) characteristics, WR contact and rail wear are analyzed to understand the evolution process of corrugation from the micro transient point of view. Finally, combined with a system stability analysis, the development trend of corrugation is characterized from the macro perspective. The results show that the WR contact has a significant SS variation under the corrugation condition, which promotes the initial corrugation to develop further. For the fixed node in the contact area on the rail surface, the maximum stress and strain of the section where it is located will gradually transfer from the subsurface to the surface with the wheel running, so the damage prone position will also form first on the subsurface and gradually transfer to the surface. This shows from the micro viewpoint that the formation of wave crest/trough in the corrugation section is a bottom-up process of damage accumulation. The corresponding frequency of 648 Hz of the unstable vibration mode in the WR system is close to the passing frequency of 656 Hz of measured corrugation, demonstrating that the initial corrugation will tend to intensify with the wheel running.
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