Wheel/rail contact testing

Article: Wheel/rail contact testing

Performance of wheels, axle shafts, rails, points, etc.

Using 1:1 test stands and operational testing routines, we will investigate the performance of wheels, axle shafts, rails, points and other rail track and vehicle components. The components are analysed in full scale and under operative loads. Areas of focus include material concepts, improving maintenance procedures, noise protection and diagnostic techniques.

DB Systemtechnik is QMS certified to the ISO 9001 standard.

Our tests:

Details
  • Analyses to determine general wear and the wear and rolling contact fatigue behaviour of different materials used for wheels, rails and points
  • Rollover attempts on rails, points of turnout and common crossings
  • Influence of friction coefficients in relation to lubricants and friction modifiers
  • Qualification of permanent way welding procedures/welding consumables
  • Quantification of the residual service life of axle shafts to determine inspection intervals
  • Rollover attempts on the components of adjustable wheelsets, conventional wheelsets
  • with resilient wheels, and much more
  • Testing of diagnostic systems for wheelsets and track components
  • Measuring of rolling noise and the influence of wheel noise absorbers and dampers (acoustic analyses)

Our stationary testing facilities:

Wheel-rail test bench A - roller test bench
Location

Kirchmöser, Bahntechnikerring 74

Operation

Rolling test stand for investigations of the wheel-rail contact (R/S)

Focus

Wheel-rail wear

  • Out of round wheels
  • Wheel tread damage due to rolling contact fatigue
  • Influence of wheel material
  • Influence wheel profile
  • Validation and parameterization of R/S simulation models


testing of wheel

  • materials wheel profiles
  • New developments for non-destructive testing or diagnostic systems
  • Rail head conditioners (friction modifier)

acoustic measurements

  • rolling noise
  • Creation of curve squeaks
  • Influence of wheel noise absorbers
Wheelset
  • Running and driving wheel sets
  • Wheel diameter: 400 to 1,250 mm
  • Material and profile: variable
Track roller
  • Arrangement underfloor
  • Diameter: 2.1m
  • Rail material: R260
  • Rail Profile/Inclination: 60 E2 1:40

Parameter

  • Axle load: up to 340 kN (34 t)
  • Lateral force: up to 30 kN
  • Speed: up to 300 km/h
  • Track curves: from 300 m radius to ∞
  • Lubrication or moistening possible

Equipment

  • concentricity measurement
  • cross profile measurement
  • NDT for crack detection

Dr. Stefan Hartmann

DB Systemtechnik GmbH
Werkstoff und Fügetechnik

Bahntechnikerring 74
14774 Brandenburg-Kirchmöser
Germany

Wheel-rail test stand A - linear test stand
Location

Kirchmöser, Bahntechnikerring 74

Operation

Linearprüfstand für Untersuchungen des Rad-Schiene-Kontakts

Focus

Wheel-rail wear

  • tread wear
  • Rolling Contact Fatigue (Head Checks)
  • Influence of rail material
  • Influence R/S profile
  • welded joints
  • crossing frogs
  • Validation and parameterization of R/S simulation models

Qualification of rails according to DBS 918 254 testing of

  • rail materials
  • rail profiles
  • New developments for non-destructive testing or diagnostic systems
  • Rail head conditioner (Friction modifier)

Rail

  • Wheel diameter: 800 - 920 mm
  • Material and profile: variable
  • Material and profile: variable
  • alsow switch rails, frogs
Parameter
  • 1,000 rolls/h
  • 20,000 load tons/h with 20 t wheelset load
  • Axle load: up to 40 t,
  • Lateral force: up to 20 kN
  • Track curves: from 300 m radius to ∞
  • Lubrication or moistening possible

Equipment

  • 3D geometry drawing
  • NDT for crack detection

Dr. Stefan Hartmann

DB Systemtechnik GmbH
Werkstoff und Fügetechnik

Bahntechnikerring 74
14774 Brandenburg-Kirchmöser
Germany

Wheel-rail test stand B - linear test stand
Location

Kirchmöser, Bahntechnikerring 74

Operation

Linear test bench for examining the wheel-rail contact with the introduction of longitudinal forces

Focus

wheel-rail wear tread wear

  • Rolling contact fatigue (head checks, squats)
  • Influence of R/S material, material pairing
  • Influence R/S profile, profile pairing welded joints
  • Validation and parameterization of R/S wear simulation models

testing of

  • New rail materials
  • Wheel and rail profiles, profile pairing
  • New developments for non-destructive testing or diagnostic systems
  • Rail head conditioner (Friction modifier)
Wheel
  • Wheel diameter: from 640 - 1250 mm
  • Material and profile: variable
Train
  • Length: 1.2 to 1.4 m
  • Material and profile: variable

Parameter

  • 5,000 load cycles/h
  • 100,000 load tons/h with 20 t wheelset load
  • Axle load: up to 40t
  • Longitudinal force: up to 34 kN
  • Lateral force: up to 60 kN
  • Track curves: from 120 m radius to ∞
  • Lubrication or moistening possible

Equipment

  • thermography
  • 3D geometry drawing
  • NDT for crack detection

Patrick Hoffmann

Werkstoff- und Fügetechnik

DB Systemtechnik GmbH

Bahntechnikerring 74
14774 Brandenburg-Kirchmöser
Germany

Wheel-rail test stand C - rolling test stand
Location

Kirchmöser, Bahntechnikerring 74

Operation

Roll test bench for wheel and wheel set constructions
Focus

Rollover tests under real loads

  • New wheel designs, also with rubber suspension
  • New wheelset designs gauge wheel sets
  • Crack propagation tests on axles
  • Testing of new developments for non-destructive testing or diagnostic systems

Wheelseat

  • Wheel sets (wheel diameter 600 - 1,200 mm)
Track roller
  • e.g. B. 10 million load changes (continuous load) in 12 days
  • Axle load up to 340 kN, lateral force up to 80 kN up to 160 km/h, programmable load spectrum

Parameter

  • Running and driving wheel sets
  • Wheel diameter: 600 to 1,200 mm
  • Profile: cylindrical
  • Material: variable
Equipment
  • Telemetry for strain gauge measurements
  • Thermography for rubber-sprung wheel constructions

Thorsten Geburtig

Werkstoff- und Fügetechnik

DB Systemtechnik GmbH

Bahntechnikerring 74
14774 Brandenburg-Kirchmöser
Germany