A new integrated model to predict wheel profile evolution due to wear

▶ A comprehensive and effective wheel profile wear model is developed. ▶ The coupling dynamics vehicle–track model can take track structure deformation into account. ▶ Kalker's non-Hertzian rolling contact theory solves the W/R contact problem more precisely. ▶ The developed model can simultaneously and effectively predict wear of 8 wheels of the whole vehicle. The important published papers on railway wheel profile wear in the past are reviewed and have been highlighted. A wheel profile wear prediction methodology is developed to improve an extant model and used to predict the wear of the wheels of railway vehicle operating on sharp curved tracks. The methodology includes the coupling dynamics of railway vehicle and track, the three-dimensional contact geometry analysis of wheel/rail, Kalker's non-Hertzian rolling contact theory, and Archard wear model. The normal loads, creepages and lateral displacements of the wheel/rail are first obtained through the coupling dynamics analysis of the vehicle/track. Then the wheel/rail contact geometry calculation is carried out to get the normal gap between the undeformed wheel/rail. Based on the attained parameters, the wheel–rail rolling contact is calculated using the modified Kalker's non-Hertzian theory, and the normal stress, slip and contact areas are obtained. Afterwards, the Archard wear model is used to calculate the wear depth on the wheel tread, and the two means, which are called the smoothing spline and the Super-smother, are used to smooth the wear distribution curve and the updated wheel profile due to the accumulated wear after a number of passages. A numerical example is presented to verify the present effective methodology. The obtained numerical results are reasonable, and indicate that the numerically reproduced wear phenomena of the wheels of the vehicle are consistent with those occurred at railway sites.