WIDEM - Wheelset Integrated Design and Effective Maintenance
Overview
Background & policy context:
The economic efficiency and competitiveness of the rail transportation mode depends on safety, availability and maintenance of its individual highly loaded structure components such as railway wheelsets. The WIDEM project aimed to improve efficiency and competitiveness through a fundamental re-examination of wheelset design, which in turn will facilitate improved maintenance practices. Combining inputs from reliable service measurement of wheel-rail forces carried out by means of an innovative instrumented wheelset and extensive assessment of actual material properties, an original endurance strength design concept was developed and validated through a comprehensive testing programme on full scale wheelset prototypes.
Objectives:
Combining inputs from reliable service measurement of wheel-rail forces carried out by means of an innovatively instrumented wheelset and an extensive assessment of actual material properties, an endurance strength design concept was developed and validated through a comprehensive testing programme on full-scale wheelset prototypes. A flexible numerical tool was also proposed as an upgrading of existing knowledge.
Additionally, the project developed and evaluated alternative NOT (non-destructive testing) techniques that allow a greatly increased detection probability and a size estimation of cracks to set up a schedule for NOT periodic inspection. The research work led to the definition of wheelset design procedures and maintenance methods to be implemented into existing standards for a quick and easy optimisation of the process.
Methodology:
Description of work :
- creation and validation of an innovative methodology to design and validate wheelsets. This methodology is based on load spectra and S-N curve for the material in the full-scale condition;
- definition of a rigorous methodology to test the fatigue resistance of full-scale axles and wheels;
- research on fretting fatigue phenomena, which takes place under axle seats, by taking into account seats and section transition geometry, press fit pressure and axle/hub slip;
- the WIDEM project has developed an innovative measuring wheelset using up-to-date wireless data processing and transmission technology.
A flexible numerical tool was also proposed as an upgrading of existing knowledge. Additionally, the project developed and evaluated alternative NOT (non-destructive testing) techniques that allow a greatly increased detection probability and a size estimation of cracks to set up a schedule for NOT periodicity inspection. The research work led to the definition of wheelset design procedures and maintenance methods to be implemented into existing standards for quick and easy optimisation of the process.
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