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Seizure and wear rate testing of wheel–rail contacts under lubricated conditions using pin-on-disc methodology
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.ORCID iD: 0000-0003-2489-0688
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
2008 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, 1425-1430 p.Article in journal (Refereed) Published
Abstract [en]

An increased wear rate and a shift of wear mechanism in the wheel-rail contact has been observed in tight curves, mainly due to the change from an almost pure rolling contact to more of a sliding contact. The wheel flange-rail gauge contact is commonly known to experience the toughest conditions of the overall wheel-rail contact in terms of contact pressure and sliding velocity. The wheel flange-rail gauge contact is preferably lubricated to reduce the wear rate and to minimise the risk of transition to severe wear or seizure. The amount and type of lubrication are therefore important parameters if one is to control the wear rate. In this study, a flange contact is experimentally simulated using pin-on-disc testing, to determine the difference in wear rate among a selection of lubricants under different contact conditions. The selection of lubricants consisted of environmentally adapted oils, mineral oils, and greases containing different amounts of EP and AW additives.The results of the pin-on-disc testing indicate that both the amount and type of lubrication applied is decisive for the wear rate and active wear mechanism. Tests have also been performed to simulate either on-board or wayside lubrication, by applying the lubricant at different intervals. A general observation is that under starved lubrication conditions a transition to severe wear is initiated and the wear rate increases rapidly, i.e., all tests indicate that the contact between wheel and rail must be lubricated to avoid high wear rates.

Place, publisher, year, edition, pages
2008. 1425-1430 p.
Keyword [en]
rail; wheel; wear rate; environmentally adapted; lubrication
National Category
Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:kth:diva-11581DOI: 10.1016/j.wear.2008.03.025ISI: 000258891700035Scopus ID: 2-s2.0-48049117761OAI: oai:DiVA.org:kth-11581DiVA: diva2:277822
Note
QC 20100721Available from: 2009-11-20 Created: 2009-11-20 Last updated: 2017-12-12Bibliographically approved
In thesis
1. On wear transitions in the wheel-rail contact
Open this publication in new window or tab >>On wear transitions in the wheel-rail contact
2009 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Wear transitions in the wheel–rail contact are of increasing interest since the general trend in railway traffic is toward increased velocities and axle loads. Curving increases the risk of flanging, causing the contact to change from an almost pure rolling wheel tread–rail head contact to more of a sliding wheel flange–rail gauge contact on the high rail in curves.

Under wheel flange–rail gauge contact conditions, wear transitions to severe or catastrophic wear will occur if the contact is improperly lubricated. Such a transition is the most undesirable transition in the wheel–rail contact, as it represents a very expensive operating condition for railway companies. The contact conditions responsible for this transition are very severe as regards sliding velocity and contact pressure, and thus place high demands on both the lubricant and the wheel and rail materials.

The focus of this thesis is on the transitions between different wear regimes in a wheel–rail contact. Wear is discussed both in traditional tribological terms and in terms of the categories used in the railway business, namely mild, severe and catastrophic wear. Most of the work was experimental and was performed at the Royal Institute of Technology (KTH), Department of Machine Design.

The effects of contact pressure, sliding velocity, and type of lubricant have been investigated, producing results that resemble those of other studies presented in the literature. The absence of research relating to the wheel flange–rail gauge contact is addressed, and it is concluded that a lubricant film must be present on rails in curves to prevent severe or catastrophic wear. The formulation of this lubricant can further increase its wear- and seizure-preventing properties. To obtain a deeper understanding of wear transitions, methods such as airborne particle measurement and electron microscopy have been used.

Paper A presents the test methodology used to detect seizure and discusses the wear-reducing influence of free carbon in highly loaded contacts.

Paper B presents the testing of seizure-initiating conditions for a range of environmentally adapted lubricants applied to wheel and rail materials; a transient pin-on-disc test methodology was used for the testing.

Paper C presents the use of pin-on-disc methodology to study the wear-reducing effects of a wide range of lubricants. The best performing lubricant was a mineral oil containing EP and AW additives.

Paper D relates wear rates and transitions to airborne particles generated by an experimentally simulated wheel–rail contact. The airborne particles generated varied in size distribution and amount with wear rate and mechanism.

Paper E relates additional analysis techniques, such as FIB sectioning, ESCA analysis, airborne particle measurements, and SEM imaging of airborne wear particles, to the contact temperature.

 

Place, publisher, year, edition, pages
Stockholm: KTH, 2009. 31 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2009:23
Keyword
Wear transitions; Wheel; Rail; Wear regime; Wear mechanism
Identifiers
urn:nbn:se:kth:diva-11563 (URN)978-91-7415-511-2 (ISBN)
Public defence
2009-12-11, M3, Brinellvägen 64, KTH, Stockholm, 10:15 (Swedish)
Opponent
Supervisors
Projects
Samba 6
Note
QC 20100721Available from: 2009-11-20 Created: 2009-11-20 Last updated: 2012-01-27Bibliographically approved
2. An experimental study on wear transitons in the wheel-rail contact
Open this publication in new window or tab >>An experimental study on wear transitons in the wheel-rail contact
2007 (English)Licentiate thesis, comprehensive summary (Other scientific)
Place, publisher, year, edition, pages
Stockholm: KTH, 2007. 25 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2007:02
National Category
Other Materials Engineering
Identifiers
urn:nbn:se:kth:diva-4389 (URN)
Presentation
2007-04-23, Rum M37, KTH, Brinellvägen 64, Stockholm, 13:15
Opponent
Supervisors
Note
QC 20101118Available from: 2007-05-22 Created: 2007-05-22 Last updated: 2012-01-27Bibliographically approved

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Olofsson, Ulf

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