manicka dhanasekar & nannan zong, qut - new generation insulated rail joints
DESCRIPTION
Manicka Dhanasekar & Nannan Zong, QUT delivered the presentation at the RISSB’s 2013 Rail Turnouts Workshop. The RISSB’s National Rail Turnouts Workshop 2013 gives all those involved an in-depth forum to consolidate and share the latest technical information for rail turnouts. Drawing on industry expertise, the workshop features technical and practical presentations that address key turnout functions in an every-day operational context. For more information about the event, please visit: http://www.informa.com.au/railturnoutsworkshop13TRANSCRIPT
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Manicka Dhanasekar & Nannan Zong (QUT)
Acknowledgements: Robert Taylor (ARTC)/ Ian Marks (QR)/ Chris West (Thermit)/ David Wexler (UoW)/ Paul Boyd (CQU)/ Vladimir Luzin (ANSTO)/ Dr Thusyanthan (Cambridge, UK)/
Andy Take (Queens University, Canada)/ Thaminda Bandula Heva (PhD student)/ Chandu Rathod (PhD Student) & Hossein
Askarinejad (PhD Student)
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THE CONTEXT IRJ is a gapped rail joint – the gap of which must be maintained over
its life: Similar to the Point Blades/ Switch IRJs are source of Impact: Similar to the Crossings in Turnouts IRJs suffer from Ratchetting: Similar to the Tips of Blades & Crossings High Yield Materials Trialed in Turnouts & IRJs; fundamental studies
are limited. THIS PRESENTATION WILL BRIDGE THIS GAP IN KNOWLEDGE
IRJs: Gapped Joints in Rail Assets
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Safety Critical Devices Train Identification – Signalling Track Circuitry for Broken Rail Detection
Designed as per AS1085.12 Fabricated in Industry – High QA Life 7% - 35% of CWR : THE Problem Very difficult to use Technology for monitoring IRJ
performance/ onset of failure: TOO LOCALISED
On the IRJs (GIJs)
16km
IRJ IRJ
SLEEPERS
ISOLATED BLOCK
SECTIONRAILS
SHUNT
DEVICE
SHUNT
CURRENT
SENSORS
CURRENT SOURCE
VOLTAGE
SENSOR
PROCESSOR
OUTPUT
VOLTAGE
SENSOR
CURRENT SOURCE
CONTROL UNIT
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Major Incidents: IRJ Failure
Union Pacific USA: 27 May 2000
3,500 people were evacuated
Total damages > $35 million
Canadian Pacific: 18 Jan 2002
300 people were injured; Total damages > $10M
PN Ore Car NSW: 01 Oct 2006
14 Wagons Written-Off
Track Damage
1 Week Traffic Disturbance
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Failure Modes of IRJs
Railhead Ratchetting
Endpost Battering
Insulation Delamination
Bolt Looseness
Jointbar Cracking
Maintenance
Railhead Grinding
Weld Repair
Ballast Tamping
Joint Straightening
JOINT REPLACED
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Repetitive Wheel Passage Cause Ratchetting & Gap
Closure Electrical signalling crew “chisel repair (mechanical damage)”
When damage is excessive, or joint bars break, new IRJs welded; No guideline to positioning of the gap: Suspended between sleepers? Or supported onto the sleeper?
Ballast depth?
Frequency of ballast tamping?
Rail Grinding near gap?
IRJs are positioned randomly when replaced
The ROOT CAUSE is the passage of loaded wheels: Let‟s re-visit the theory of wheel-rail contact
Field Practices: IRJ
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Wheels Passing Gaps Produce Impact and Railhead
Ratchetting
Is Impact Load itself THE Problem?
Is the Wheel-Railhead Contact at the Un-Supported Gapped Edge THE Problem?
Is the rail yield strength THE problem?
Fundamental Research Questions
Dr Zong will uncover the answer…………
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6 IRJs monitored Gap narrowing
Joint dipping
Time Based Observation: Over 19 Months
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Gap Narrowed
Joint Dipped
Time Based Observation: Over 19 Months
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Shakedown Theory
Assumes elliptic Hertzian Pressure: Not Applicable for IRJs
Theory 1.2
1.0
0.8
0.6
0.4
0.2
0.0
-0.22b
b0
-b-2b 3a
4a5a
6a7a
P/P0=1.02
x y
P/P
0
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
P/P
0
0.0
-0.20
0.5aa
1.5a2a -2b
-b0
-b-2b
y x
P/P0=1.49
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How does the railhead material respond?
Lattice Spacing Narrowed at Top in Severely Trafficked Railhead
0 5 10 15 20 25 30 35 40 45 50 55 60
-60
-55
-50
-45
-40
-35
-30
-25
-20
-15
-10
-5
0
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Experiments: Field Instrumented IRJ in the field
General view of data recording setup
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Modelling
Rapid Variation of Strain in the Plastic zone => Very Fine
Mesh
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Is Impact @ Gap THE problem?
10mm
5mm
174KN 163KN
Gap size was 8.5mm in 2003 – now it is 5mm
~9% impact load cannot cause 65% life reduction
Contact impact from field test Contact impact force from FEA
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Is low yield railhead steel THE problem?
Martensitic Stainless Steel (~1200MPa)
Maraging Steel (~2000MPa)
VAS (~1600MPa) – through hardened railhead?
INTERFACE with rail steel seems a problem
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Idea???
IF the stress concentration moves away from the corner into the railhead, with reduced magnitude, THEN the rail end should behave like a continuous rail (in theory).
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Is vertical cut of the rail THE problem?
Both 90° / 75° cuts are Just Vertical – leaving the top of railhead vulnerable
Would fillet shape do any good?
Rail curve length 40.05
1.42
x y
z
1852.86
1698.851544.831390.821236.811082.80928.78
774.77620.76466.74312.73
158.720.00
Stess (MPa)von Mises
Railhead Surface
RailendSurface
Rail Symmetric Surface
923.32
838.02762.81687.54612.23536.96461.66
386.32311.02235.77160.45
85.130.00
Stess (MPa)von Mises
x y
z
Rail Symmetric Surface
Railhead Surface
RailendSurface
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Looks Like we ‘Solved’ THE problem?
0
20
40
60
80
100
120
140
160
180
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018
Co
nta
ct fo
rce
(KN
)
t (s)
New shape IRJ
Conventional IRJ
Impact force – very similar (Current &
Optimal)
The maximum Mises stress is 989MPa; ~
40% lower than the current1664MPa
The stress concentration is always away
from rail end, functioning as the
continuous rail
Is 989MPa still too much?
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0
200
400
600
800
1000
1200
1400
1600
-0.01 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12
Str
ess
(N/m
m2)
Strain
A1 B1
A2 B2
A3 B3
A4 A5
A6 A7
How does the railhead material respond? Heat affected zone
0
100
200
300
400
500
600
700
800
900
1000
0 5 10 15 20 25 30 35 40
0.2
% Y
ield
Str
en
gth
(N
/mm
2)
Depth from rail top (mm)
RailA
Is 989MPa still too much?
The testing done was uniaxial; in real case
hydrostatic stress will enhance yield 10% - 20%
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Is THIS our New Generation IRJ?
This is good – we have a trouble-free „gap‟!
How to avoid broken joint bars?
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Is jointbar stiffness THE problem?
Force transmission into jointbar complex
Better „structural jointbars‟ still fails
MAY BE we get rid of them?
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New Generation IRJ - Prototyping
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New Generation IRJ – QUESTIONS?
THANK
YOU