Triennial Report 2009
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triennial report 1 July 2006–30 June 2009 review 1 July 1995–30 June 2006 plans 1 July 2009 –30 June 2012 Chalmers Railway Mechanics – a NUtEK/VINNOVA Competence Centre Chalmers University of technology fOREWORD This is a reportCHARMEC on the organization, operation and Status as of February 2008 3(3) fi nancing of Stage 5 of the Swedish National Competence Upper names(s): Project leader(s) and supervisor(s) Centre charmecresearch, which originated 1995 from−2008 a nutek/vinnova Lower name(s): Doctoral candidate or other co-worker(s) government grant for the period 1995-2005. Summaries of the research conducted at the CentreSD are presented. A EU review of StagesSystem 1, 2, 3 and för 4 and övervakning a look forward at och Stage Drift 6 Parallella EU-projekt are also included. The fold-out on pages 100-102Programme contains an area overview 4 of Programme area 5 all charmecSystems projects (now for 85 monitoring) that are either andongoing operation or Parallel EU projects have been implemented since the Centre started. SD1 SD5 EU1 EU6 Professor Emeritus Bengt Åkesson has assisted with the Braking of freight trains Active and EuroSABOT 3 HIPERWHEEL 3 compilation and editing of this Triennial3 Report. – a systems approach semi-active systems Prof Roger Lundén Prof Roger Lundén Prof Göran Gerbert in railway vehicles Mr Tore Vernersson / Doc Jens Nielsen / Gothenburg inMr September Daniel Thuresson 2009 2 Prof Jonas Sjöberg Mr Martin Petersson Dr Anders Ekberg Ms Jessica Fagerlund roger lundén SD2 SD6 EU2 EU7 Director of charmec Sonar pulses for Adaptronics for bogies Silent Freight 3 INFRASTAR 3 braking control 3 and other Prof Lennart Josefson / Dr Jens Nielsen Prof Roger Lundén Prof Bengt Schmidtbauer railway components Mr Martin Petersson / Doc Jens Nielsen / Mr Hans Sandholt Prof Viktor Berbyuk Mr Markus Wallentin Dr Jonas Ringsberg / Mr Albin Johnsson Prof Birger Karlsson SD3 SD7 EU3 EU8 Computer control Thermal capacity of tread Silent Track3 ERS 3 of braking systems braked railway wheels 3 Doc Jens Nielsen Prof Roger Lundén for freight trains Prof Roger Lundén / Mr Clas Andersson Mr Martin Helgen / Mr Håkan Edler / Prof Jan Torin Dr Tore Vernersson Doc Jan Henrik Sällström / Mr Roger Johansson 2 – 5 Mr Tore Vernersson SD4 SD8 EU4 EU9 Control Wear of disc brakes ICON 3 EURNEX 3 of block braking and block brakes Prof Lennart Josefson Prof Roger Lundén Prof Roger Lundén Prof Roger Lundén / Mr Jonas Ringsberg Doc Anders Ekberg Mr Tore Vernersson 2 Dr Tore Vernersson Project SD4: EU5 EU10 Heat partitioning EuroBALT II 3 INNOTRACK between brake block, wheel rim and rail Prof Tore Dahlberg 4 Prof Roger Lundén Mr Johan Oscarsson Dr Mats Ander / Mr Jim Brouzoulis / Doc Anders Ekberg / Doc Magnus Ekh / Dr Göran Johansson / Dr Elena Kabo / Dr Elias Kassa / Laser beam Prof Jens Nielsen / Doc Jonas Ringsberg / Coating Laser beam Mr Johan Sandström / Mr Johan Tillberg William Chalmers (Project1748-1811 EU7:) from Gothenburg, Director Project EU10: Two-material CHARMEC/Chalmers of the Swedish Eastrail India development Company, bequeathed a large is one of 35 partners sum of money to the start in 1829 of an industrial school from 9 EU countries that later became the Chalmers University of Technology involved in this European Front cover: Photoelastic experiment illustrating stress fields Integrated Project arising during two-point contact between wheel and rail kaboTM February 2008 MU8. Butt-welding of rails 37 EU6. HIPERWHEEL – Development of an 62–63 MU9. Rolling contact fatigue of 38 innovative high-performance railway wheels railway wheelset MU10. Crack propagation in railway wheels 38–39 EU7. INFRASTAR – Improving railway 63 infrastructure productivity by MU11. Early crack growth in rails 39 sustainable two-material rail development MU12. Contact and crack mechanics for rails 40 EU8. ERS – Euro Rolling Silently 64 MU13. Wheel and rail materials at 40 EU9. EURNEX – European Rail Research 64–65 low temperatures Network of Excellence MU14. Damage in track switches 41 EU10. INNOTRACK – Innovative 65–67 MU15. Microstructural development 42 Track Systems during laser coating EU11. QCITY – Quiet City Transport 67 MU16. Alternative materials for 42–43 Programme area 6 wheels and rails Parallel special projects (SP) MU17. Elastoplastic crack propagation in rails 44–45 SP1. Lucchini Sweden ab (bilateral agreement) 68 MU18. Wheels and rails at high speeds 45–47 SP2. Noise from Swedish railways 68 and axle loads SP3. Track force measurements on x2 68 MU19. Material anisotropy and RCF 47 SP4. vae ag (bilateral agreement) 68 of rails and switches SP5. voestalpine Schienen GmbH 68 MU20. Wear impact on RCF of rails 48 (bilateral agreement) MU21. Thermal impact on RCF of wheels 49 SP6. Development of a quiet rail 69 MU22. Improved criterion for surface 50 SP7. Lateral track stability 69–70 initiated RCF SP8. Design of insulated joints 71 MU23. Material behaviour at rapid thermal 51 SP9. Sleeper design for 30 tonne axle load 71 processes SP10. Noise reduction measures and 71–73 MU24. High-strength steels for railways rails 52 eu project qcity MU25. Thermodynamically coupled contact 53 SP11. Vertical contact forces of 73–74 between wheel and rail high-speed trains Programme area 4 SP12. New sleeper specifications 75 Systems for monitoring and operation (SD) SP13. Alarm limits for wheel damage 75–76 SD1. Braking of freight trains 54 SP14. Particle emissions and noise 76–77 – a systems approach from railways SD2. Sonar pulses for braking control 55 SP15. Computer program for design of 77 SD3. Computer control of braking systems 55 block brakes for freight trains SP16. Identification of dynamic properties 78 in track of timber sleepers and concrete SD4. Control of block braking 56 replacement sleepers SD5. Active and semi-active systems 57 SP17. Switch sleeper specifications 78 in railway vehicles SP18. Ground vibrations from railway 79 SD6. Adaptronics for bogies and other 58 traffic – a prestudy on the influence railway components of vehicle parameters SD7. Thermal capacity of tread braked 59 Academic awards 80 railway wheels International conferences 81 SD8. Wear of disk brakes and block brakes 60 Partners in industry 82–83 Programme area 5 Results and effects in industry 84–85 Parallel EU Projects (EU) Björn Paulsson in the chair 1995—2008 86–87 EU1. EuroSABOT – Sound attenuation 60 by optimised tread brakes Special events and achievements 88–95 EU2. Silent Freight – Development of new 61 financial report technologies for low noise freight wagons Report per party 95–97 Report per programme area 97–98 EU3. Silent Track – Development of new tech- 61 nologies for low noise railway infrastructure Management and administration 98 EU4. ICON – Integrated study of 62 CHARMEC Stage 6 99 rolling contact fatigue Concluding remarks 99 EU5. EUROBALT II – European research 62 CHARMEC research 1995–2012 100–102 for an optimised ballasted track Chalmers facts 2009 103 4 CONtENtS foreword 2 Reflections from the Director 5 Executive summary 6 Introduction 7 Vision and goals 8 Board and Director 8–9 Quality assessment and knowledge transfer 10 Programme areas CHARMEC Stage 5 11 Summary of CHARMEC Stage 5 12–13 Projects and results 14 Programme area 1 Interaction of train and track (TS) TS1. Calculation models of track structures 14 TS2. Railhead corrugation formation 15 TS3. Sleeper and railpad dynamics 15 TS4. Lateral track dynamics 16 TS5. Out-of-round wheels 16–17 – causes and consequences TS6. Identification of dynamic forces in trains 17 TS7. Dynamics of track switches 18–19 TS8. Integrated track dynamics 19–20 TS9. Track dynamics and sleepers 20–21 TS10. Track response when using 21-22 Under Sleeper Pads (USP) TS11. Rail corrugation growth on curves 22–23 TS12. Identification of wheel/rail contact forces 24 TS13. Optimization of track switches 25 Programme area 2 Vibrations and noise (VB) VB1. Structural vibrations from railway traffic 26 VB2. Noise from tread braked railway vehicles 26 VB3. Test rig for railway noise 27 VB4. Vibrations and external noise from 27 train and track VB5. Wave propagation under high-speed trains 28 VB6. Interaction of train, soil and buildings 28 VB7. Vibration transmission in railway vehicles 29 VB8. Ground vibrations from railways 30 VB9. Dynamics of railway systems 31 VB10. External noise generation from trains 32–33 Programme area 3 Materials and maintenance (MU) MU1. Mechanical properties of ballast 33 MU2. New materials in wheels and rails 34 MU3. Martensite formation and damage 34 around railway wheel flats MU4. Prediction of lifetime of railway wheels 35 MU5. Mechanical properties of concrete sleepers 35 MU6. Rolling contact fatigue of rails 36 MU7. Laser treatment of wheels and rails 36–37 3 REFLECTIONS from the Director The demand for cutting-edge railway research has never A high-level research centre takes around ten years to been greater as the railway sector assumes more and establish. This is no secret to the scientific world. charmec more responsibility for efficient and sustainable transport. has passed this phase and developed an arsenal of knowl- Increasing traffic volumes are accompanied by higher train edge, tools and experience. The challenge now lies in speeds and greater axle loads, while time available for cop- maintaining scientific curiosity and striving forward, both ing with maintenance, repairs and operational disturbances of which come naturally to a young centre. We will stay shrinks. The trial-and-error period is over. We need to true to our motto of combined academic excellence and in- know the consequences before we act. dustrial relevance. A key ingredient is communication: with the scientific community, by having our research reviewed In response, the railway sector is travelling down the same and criticized; and with Banverket and our industrial route as many other industries - computer simulations partners, by having our relevance scrutinized and research become standard practise and advanced simulations are translated into world-class products and practices.