Long-term wear and rolling contact fatigue behaviour of a conformal wheel profile designed for large radius curves

ABSTRACT There are many reasons to optimise the wheel–rail interface through redesign or maintenance. Minimising wear and rolling contact fatigue (RCF) initiation on wheels and/or rails is often at the forefront of such considerations. This paper covers the design of a conformal wheel profile and its long-term wear and RCF performance to optimise the wheel–rail interface and subsequently reduce the occurrence of surface-initiated RCF on South Africa’s iron ore export line. A comparative study is performed using multibody dynamics simulation together with numerical wheel wear and RCF predictions. The advantages of a conformal wheel profile design are illustrated by evaluating the worn shape and resulting contact conditions of the conformal design. The conformal design has a steadier equivalent conicity progression and a smaller conicity range compared with the current wheel profile design over the wheel’s wear life. The combination of a conformal wheel profile design with 2 mm hollow wear and inadequate adherence to grinding tolerances often result in two-point contact, thereby increasing the probability of RCF initiation. The conformal wheel profile design proved to have wear and potential RCF benefits compared with the current wheel profile design. However, implementation of such a conformal wheel profile must be accompanied by improved rail grinding practices to ensure rail profile compliance.