Applied Sciences (May 2023)
Influence of Bogie Maintenance and Retrofitting on Wheel Wear: Analysis Using Integer Programming and Multibody Simulation
Abstract
Brazilian railroads are continuously looking to increase their asset performance. In this sense, wheel/rail interface studies have been conducted, which allowed benefits that were not previously considered. Improved wheel/rail contact can significantly reduce maintenance costs, increase energy efficiency, and increase operational safety. For rolling stock, wheel consumption usually has the highest maintenance cost and is among the highest total costs of a railroad. Therefore, the understanding of wheel wear behavior, which is carried out in an integrated manner with permanent track and operating conditions, must be investigated in depth. This study aims to analyze the influence of bogies on wheel wear. Two aspects were considered: maintenance conditions and bogie design. The maintenance conditions were evaluated through wayside and field measurements. The collected data were later statistically evaluated and modeled in integer programming to optimize and review the maintenance strategy, which could avoid premature wheel scrapping after 5 years, allowing for a regular wheel life of 9 years. This analysis has allowed for the development of a new bogie maintenance parameter, which is not defined in manual and rule standards. The bogie design modernization was analyzed using the VAMPIRE multibody simulation software. The retrofitted bogie was modeled to improve the dynamic behavior and analyzed using wheel/rail contact theory. The polymer suspension elements’ modelings were thoroughly detailed for each property to illustrate the retrofit’s design features. Therefore, to calculate the gains of the retrofitted bogie, a methodology was built to compare the results of wheel wear in a real railroad track section. This methodology can be used to show that the retrofit can provide a reduction in wheel wear of 40% for ride control for a broad gauge (1600 mm).
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