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Aiming at the problems of low accuracy and easy to cause resonance in the work of the flat sand system, the topology optimization design of the cantilever beam structure of the flat sand system is carried out in this paper. Starting from the internal material layout of the cantilever beam, taking the distortion energy density of the material as the optimization goal, the alterable density method was used to optimize the topology of the cantilever beam in the ABAQUS software, and the most reasonable material distribution is obtained. The optimization results show that when the applied load is 400 N required by the working conditions, the displacement of the front end of the cantilever beam decreased from 4.205 to 1.447 mm, which meets the requirements of the working conditions after optimization. The maximum stress decreased from 20.04 to 6.824 MPa. When the mass of the cantilever beam decreases by 41.4%, the 1 st order natural frequencies of the cantilever beam increased by 2.481 Hz, which is far away from the external excitation frequencies, and the dynamic performance of the cantilever beam is improved. The maximum displacement of the model after topological optimization is verified to meet the requirements of the working condition through the angle change test, which effectively improves the overall utilization of materials and provides a theoretical basis for the design of the flat sand system.

The wheel-rail contact asymmetry on the left and right sides of the wheelset while navigating high-speed vehicles through turnouts can lead to lateral motion of the wheelset, ultimately resulting in substantial vibrations in the vehicle system. This study employs the trace method to examine the changing pattern of the wheel-rail equivalent conicity in the turnout area as the wheel profile evolves. A coupled system dynamics model containing flexible turnouts is established. Specifically, the model examines the lateral position of wheel-rail contact points, the lateral motion of the wheelset, and the lateral vibration acceleration of the vehicle system. The study indicates that the lateral motion characteristics of high-speed trains passing through turnouts are influenced by the degree of wheel wear. When the wheels are slightly worn (for mileage below or equal to 100,000 km), the lateral dynamic responses of the vehicle system are affected by the inherent structure of the turnout. When the wheels are severely worn (for mileage above or equal to 150,000 km), the lateral dynamic response of the vehicle system is no longer affected by the inherent structure of the turnout. [ABSTRACT FROM AUTHOR]

The dynamic effects involved in wheel-rail interactions can be increased by the traction force potentially causing rapid degradation of turnout rails. A precise stress/strain analysis is essential for wheel-rail frictional rolling contact and the related degradation. Therefore, an explicit finite element method is established considering dynamic effects related to the contact. Furthermore, the frictional rolling contact solutions and related degradation with different traction coefficient in turnout are investigated. The results indicate that the effect of asymmetric excitation caused by traction force and geometric irregularities will lead to yaw motion of wheelset. The width of running band on the switch rail is increased as the top surface width of the switch rail increases. In addition, the contact patch on the switch rail will gradually shift forward compared to that on the stock rail, leading to excessive shear stress and increase of microslip. Meanwhile, the adhesion-slip distribution, uneven wear and severe plastic deformation during transition are recognized. [ABSTRACT FROM AUTHOR]

This research elucidates the influence of the 60N rail profile on the dynamic interaction between wheel and rail, and the dynamic performance within the turnout. The influence of the 60N profile on the long-term service efficiency of turnouts was scrutinized. Subsequently, an optimization approach for the 60–60N rail combination profile was suggested. The main conclusions are as follows: (1) During the passage in the main direction, the 60N rail profile enhances driving stability and mitigates the progression of wear. However, it causes focalized wheel–rail contact on the rail head and escalates contact stress. (2) During the passage in the branch direction, the 60N rail profile amplifies the lateral dynamic force and rail wear rate in the closure panel, engendering two-point contact and increased contact stress. (3) In the early stage of field service of turnouts, a robust correlation exists between the contact band and the rail profile. In the fragile cross-section of the point rail, the contact band of the 60N rail profile turnout fully occupies the rail head, potentially causing stress concentration on the non-working edge position. By the stable service period, the wheel–rail contact band is mainly influenced by total weight. (4) An optimization method for the 60–60N combination profile was proposed with the corresponding machining tool profile designed. This strategy can avoid the profile transition before and after the turnout, reduce field maintenance workload, enhance running stability of straight passage through the turnout, and preclude fatigue damage in the weak cross-sections of the point rail. [ABSTRACT FROM AUTHOR]

The high-speed turnout is a key part of railway track infrastructure. A process of wheel-load transition and single-wheel/multi-track contact take place in the turnout area, causing significant wheel-rail interaction. Most high-speed turnouts include movable-point crossings. To investigate the wheel-rail transient rolling contact behaviour in movable-point crossings, a 3D finite element (FE) model of a wheelset rolling over a crossing was introduced. The actual geometrical profile of the wheel and the rails in turnouts, the nonlinear materials, the actual relative motion between the point/wing rail, and the moving postures of the wheelset were considered. The simulated mode shape was compared with the experimental mode shape to verify the wheel-rail coupling model. Precise frictional rolling contact solutions and dynamic response, including wheel-rail force, contact stress, equivalent stress, equivalent plastic strain, and stick-slip distribution of the contact patches, were all studied. After this, the parametric analysis of dynamic wheel-rail contact behaviour was carried out. The simulated results indicate that the proposed explicit finite element method can characterise wheel-rail coupled dynamic interaction and mesoscopic rolling contact behaviour well, and improve the understanding of wheel-rail contact behaviour in the movable-point crossing panel of the high-speed turnouts. [ABSTRACT FROM AUTHOR]

In this paper, to address the shortcomings of the crossing structure design based on the elastic bending center method and the lack of related research, an optimization method for high-speed turnout crossing structures was proposed based on the actual elastic deformations of point and splice rails. Based on the finite element theory, the actual loading characteristics and spatial variable section characteristics of point and splice rails were fully considered, and a refined simulation analysis model of the switching system of point and splice rails in crossing areas was established. Moreover, the elastic deformation lines of point and splice rails in the nonworking state were obtained for the first time, which were consistent with actual situations. On this basis, system optimization was performed for the connecting parts of the crossing with a movable point in a high-speed turnout. In the crossing structure simulation model, the length adjustment values of the first–sixth spacer blocks between the branch line–wing and point rails and between the mail line–wing splice rails were ≤1 mm. Moreover, the lengths of the seventh–ninth spacer blocks decreased by gradually increasing amounts, and the length of the ninth spacer block decreased the most (∼6 mm). The length of the second spacer block between the point and splice rails slightly increased, but the length of the third spacer block significantly decreased by 6 mm. The length adjustment value of the distance block between the point and splice rails was smallest (0.7 mm). The calculated optimal lengths of the connecting parts of the crossing were found to be close to the empirical values used in actual manufacturing processes, and the dimension optimization patterns were completely consistent with actual situation, which validates the proposed optimization method. Thus, the proposed method can effectively improve the coordination between rails and connecting parts in crossing areas, substantially reduce internal stresses in crossing systems, and improve their assembly performance and service life. Moreover, the proposed optimization parameters can provide valuable references for the research on next-generation high-speed turnouts (400 km/h) and for improving the designs of existing high-speed turnouts. [ABSTRACT FROM AUTHOR]

Improved averaging method was used to receive the vibration differential equation of the approximate solution, and the amplitude frequency response equation was obtained. By employing an averaging method, the transition boundary was calculated. The types of the amplitude-frequency responses were analyzed; secondly, the functions were also used for stability analysis by the linear system theory. Finally, the vibration isolation effect of different parameters on the system are analyzed. Increasing damping ratio weakened the vibration of the system, and strengthened the effect of vibration isolation.

Bonded insulated rail joints (Bonded IRJ) are essential to insulate rails and ensure normal operation of track-circuit signalling. Therefore, bonded IRJs cannot be replaced by the continuously welded joints and are widely existing in high-speed turnouts, by which the wheel-joint impact has been severely threatening the ride safety and comfort. Few researchers are concerned about how the damaged bonded IRJ deteriorates the wheel-rail contact behaviour in high-speed turnouts. To this end, this paper proposed a transient wheel-rail impact model based on the actual irregularities. Results show two different wheel-rail impact modes. The concave shape of the irregularities will induce the discrepancy of impact position when the running speed varies, thus the increase in speed causes the peak wheel-rail force to decrease in downward impact mode as opposed to upward impact. Besides, wheel-joint impact induces greater contact stress and area of contact patches in the vicinity of the end-post, contributing to wider light bands which are consistent with the on-situ conditions. Therefore, the proposed wheel-bonded IRJ impact model can provide guidance in the research of RCF and wear on bonded IRJ, explore the forming reason of the depression and provide a valuable reference for maintenance or damage detection of bonded IRJ. [ABSTRACT FROM AUTHOR]