The University of Sheffield and
LBFoster
Driving Innovation in Track Components
and Friction Management
Dr Roger Lewis
Department of Mechanical Engineering
Overhead
Line Wear
(Network
Rail)
40 kN
60 kN
80 kN
Some
Current
Railway
Engineering
Projects
0.9
1
0.8
3
0.7
0.6
0.5
0.4
0.3
0.2
0.1
2
0
-0.1
20
40
60
80
100
Traction Gels
(LBFoster)
Time (secs)
Top of Rail FMs &
Adhesion
Measurement
(LBFoster )
-440
1200
REPHIC
SEVE
STRO
CATA ITION
S
TRAN
RE
SEVE
TGamma vs
wear, Wear
Transitions
and Mapping
(RSSB, KTH)
0
Contact Pressure (MPa)
Voltage Across Discs (V)
Wheel/
Rail
Isolation
(LU,
LBFoster)
Rail Joint
Innovation
(LBFoster)
1000
800
600
400
0.00
CATASTROPHIC
MILD
437.5 -- 500.0
375.0 -- 437.5
312.5 -- 375.0
250.0 -- 312.5
187.5 -- 250.0
125.0 -- 187.5
62.50 -- 125.0
0 -- 62.50
-445
-450
Wheel Wear
Prediction (Alstom)
Z [mm]
20 kN
Contact Pressure (MPa)
Wheel/Rail
Contact
Measurement
Rail
Grinding
(Network
Rail)
-455
-460
-465
-470
-475
-820
0.05
0.10
0.15
Sliding Speed (m/s)
0.20
New Profile
Vehicle 1 - Left Wheel
Vehicle 2 - Left Wheel
-800
-780
-760
-740
Y [mm]
-720
-700
-680
Sheffield
LBFoster Rail Products
•
Bonded insulated joints
•
Friction management
•
Wayside data collection
•
Direct fixation fasteners
•
Railcar products
•
Power rail systems
•
Coverboards
•
Track components
13/04/2015 © The University of Sheffield
How we work together
Today’s
focus
Consultancy
Short term projects
Friction management – test
development and new
product benchmarking
Research
PhD
Wheel/rail contact – effect of
third-body materials
Knowledge
Transfer
Knowledge Transfer
Partnership (KTP)
(www.ktponline.org.uk)
IBJ innovation
Commercial
Testing
Short term projects
Track components
13/04/2015 © The University of Sheffield
Insulated joints: Areas of interest
Condition
Monitoring
Endpost lipping
problem
Fatigue performance
of whole joint
Effect of decarburisation
on fishplates
Shear strength of
epoxy glue layer
13/04/2015 © The University of Sheffield
Fishplate Decarburisation
• Decarburisation could affect
the fatigue properties and
weaken the fishplate
• Testing will cyclically load
steel fishplates with varying
amounts of surface
decarburisation
• Effects of decarburisation on
fishplates will be determined
and methods for enhancing
fatigue performance
13/04/2015 © The University of Sheffield
Decarb
layer in
steel
fishplates
Cyclic Load
Fishplate
Support Blocks
Test Base
Endpost Lipping
• Plastic deformation of the rail
over the endpost causes
electrical insulation failure
• Twin-disc testing has attempted
to model this behaviour
• Testing will lead to
understanding of this type of
failure and the creation of
techniques to reduce the
problem and premature failure
13/04/2015 © The University of Sheffield
Glued joint shear testing
• A test to establish the
difference in properties
between various glues and
insulating liner materials
• Glued insulated joints are
sectioned and the rail is
pushed through the joint
• Aim to introduce new and
improved insulating
materials to the market
with better shear properties
13/04/2015 © The University of Sheffield
Load Cell
Joint
Section
Test
Base
Sheared
Fishplate
Full-scale IBJ testing
•
Standard and bespoke fatigue test
apparatus currently used to conduct
standard tests to verify joint
performance (aim to not fail)
•
•
13/04/2015 © The University of Sheffield
Aim now is to develop full life cycle
testing (by changing the support
set-up and the loads applied to the
insulated joint)
This test can then be used to
assess impact on life of design and
material changes
Cyclic Loading
Condition
Monitoring
• Development of an
ultrasonic based
system to monitor
key interfaces
underway
• Technique proven
on simple bolted
interfaces
13/04/2015 © The University of Sheffield
Transducers
Mounted on
Under-side
Friction Management
• Extensive adhesion tests carried out with
and without contaminants (oil, water, leaves
etc.)
• Traction gels for adhesion enhancement
(leaf layers generated in twin disc tests and
gels applied)
• Top of rail FMs (noise and vibration
mitigation)
• Effect of stick lubricants on wheel/rail
isolation
0.9
1
• Third-body layers and oxides
• Adhesion measurement
Voltage Across Discs (V)
0.8
3
0.7
0.6
0.5
0.4
0.3
0.2
0.1
2
0
-0.1
0
13/04/2015 © The University of Sheffield
20
40
60
Time (secs)
80
100
Benefits of the collaboration
• Access to University expertise and test
facilities
• Gearing for R&D projects – either through
University or external sources
• Short term problem solving
• Long term approach possible
13/04/2015 © The University of Sheffield