Search Results (57)

The disposal of agro-industrial waste is a pressing environmental issue. At the same time, due to the high silica content in specific agricultural residues, their processed products can be utilised in various industrial sectors as substitutes for commercial materials. This study investigates the key technological, physico-mechanical, and viscoelastic properties of industrial elastomeric compounds based on synthetic styrene–butadiene rubber, intended for the tread of summer passenger car tyres, when replacing the commercially used highly reinforcing silica filler (SF), Extrasil 150VD brand (white carbon black), with a carbon–silica filler (CSF). The CSF is produced by carbonising a finely ground mixture of rice production waste (rice husks and stems) in a pyrolysis furnace at 550–600 °C without oxygen. It was found that replacing 20 wt.pts. of silica filler with CSF in industrial tread formulations improves processing parameters (Mooney viscosity increases by up to 5.3%, optimal vulcanisation time by up to 9.2%), resistance to plastic deformation (by up to 7.7%), and tackiness of the rubber compounds (by 31.3–34.4%). Viscoelastic properties also improved: the loss modulus and mechanical loss tangent decreased by up to 24.0% and 14.3%, respectively; the rebound elasticity increased by up to 6.3% and fatigue resistance by up to 2.7 thousand cycles; and the internal temperature of samples decreased by 7 °C. However, a decrease in tensile strength (by 10.7–27.0%) and an increase in wear rate (up to 43.3% before and up to 22.5% after thermal ageing) were observed. Nevertheless, the overall results of this study indicate that the CSF derived from the carbonisation of rice production waste—containing both silica and carbon components—can effectively be used as a partial replacement for the commercially utilised reinforcing silica filler in the production of tread rubber for summer passenger car tyres. Full article

This study investigates the development of a tire wear model using finite element techniques. Experimental testing was conducted using the Hoosier R25B slick tire mounted onto a Mustang Dynamometer (MD-AWD-500) in the Automotive Center of Excellence, Oshawa, Ontario, Canada. A general acceleration/deceleration procedure was performed until the battery was completely exhausted. A high-fidelity finite element tire model using Virtual Performance Solution by ESI Group, a part of Keysight Technologies, was developed, incorporating highly detailed material testing and constitutive modeling to simulate the tire’s complex mechanical behavior. In conjunction with a finite element model, Archard’s wear theory is implemented algorithmically to determine the wear and volume loss rate of the tire during its acceleration and deceleration procedures. A novel application using a modified wear theory incorporates the temperature dependence of tread hardness to measure tire wear. Experimental tests show that the tire loses 3.10 g of mass within 45 min of testing. The results from the developed finite element model for tire wear suggest a high correlation to experimental values. This study demonstrates the simulated model’s capability to predict wear patterns, ability to quantify tire degradation under dynamic loading conditions and provides valuable insights for optimizing performance and wear estimation. Full article

Aiming at the problem that the aggravation of the wheel tread wear of high-speed trains leads to the deterioration of train operation performance and an increase in re-profiling times, a multi-objective data-driven optimization design method for the wheel profile is proposed. Firstly, the chaotic map is introduced into the population initialization process of the golden jackal algorithm. In the later stage of the algorithm iteration, random disturbance is introduced with optimization algebra as the switching condition to obtain an improved optimization algorithm, and the performance index of the optimization algorithm is verified to be superior to other algorithms. Secondly, the improved multi-objective optimization algorithm and data-driven model are used to optimize the tread coordinates and obtain an optimized profile. The vehicle dynamics performance of the optimized profile and the wheel wear evolution after long-term service are compared. The results show that the tread wear index of the left and right wheels in a straight line is reduced by 62.4% and 62.6%, respectively, and the wear index of the left and right wheels in a curved line is reduced by 26.5% and 5.5%, respectively. The stability and curve passing performance of the optimized profile are improved. Under the long-term service conditions of the train, the wear amount of the optimized profile is greatly reduced. After the wear prediction of 200,000 km, the wear amount of the optimized profile is reduced by 60.1%, and it has better curve-passing performance. Full article

The design of the suspension system affects handling and stability, vibrations of the steered wheels, vehicle ride comfort, and tyre tread wear. One of the most important vibration parameters is acceleration; high acceleration values can have an adverse effect on both the driver and passengers, as well as on the components of the vehicle’s suspension and handling. This paper presents the results of the effects of acceleration on the components of a front-independent MacPherson suspension system. Data on the accelerations were obtained from theoretical and experimental studies. A simulation study was conducted, taking into account the elastic and damping characteristics of the elastic components. The experimental study was conducted under laboratory conditions by using a suspension tester, BEISSBARTH, and a measuring system developed with LabVIEW 2021 SP1 and MATLAB R2022b software. The experiments were conducted with different tyre pressures and by using bushings made from different materials. The experimental tests were conducted with two rubber bushings within the mounting of the arm, as well as a rubber bushing and a polyurethane bushing. The experimental results were compared and analyzed. Two theoretical models were considered: one is a mathematical model, and the other is a simulation model which uses the finite element method. Numerical dynamic analysis of the suspension was performed using the SolidWorks 2023. Full article

Tread braking is still extensively used on freight wagons due to lower purchasing and maintenance costs compared to disk braking. Cast iron brake blocks were replaced by composite materials (organic or sintered) that result in a lower wheel roughness, reducing rolling noise. Unfortunately, composite brake blocks have a lower thermal conductivity, negatively affecting the wheel mechanical behavior as the braking energy is almost entirely dissipated by the wheels, which are therefore subjected to higher temperatures. Mechanical properties of the wheel material, such as yield stress and Rolling Contact Fatigue (RCF) behavior, markedly decrease with temperature, resulting in higher wear rates and wheel tread damage. Contacted to analyze defects not clearly defined in the current regulations used for maintenance and inspections, the authors surveyed the literature and the technical documentation about tread-braked wheels. The paper provides an updated view about the state-of-the-art of the research on thermomechanical behavior of railway wheels and discusses the implication of the increased thermal stresses generated by composite brake blocks. Full article

The contact characteristics of radial tires are crucial for optimizing stress distribution, deformation, and wear. The non-uniform contact stress behavior induced by complex tread patterns remains under-explored in existing tire mechanics research. Taking the 205/50R17 radial tire as a representative case, a reverse modeling approach was employed to develop an accurate finite element model for tires incorporating intricate tread pattern features. The fidelity of the proposed tire simulation model was confirmed utilizing high-precision contour profiling techniques. The impact of diverse usage conditions and design parameters on the tire outer profile and ground contact characteristics under static and free-rolling states was analyzed. Experimental observations demonstrate that the increased inflation pressure leads to a proportional decrease in contact area. Under incremental vertical loading, the contact patch develops progressively into a saddle-shaped geometry featuring elevated shoulder regions and a recessed central zone. Increasing the belt angle compromises its hoop-stiffening function, thereby inducing elliptical contact patch geometry. Larger design diameters compromise contact length symmetry in shoulder regions. Variation in shoulder thickness at 85% of the tread width results in a significant difference in contact length between the left and right tread blocks in the rolling state. This work enables refinement strategies for both tread configurations and tire dimensional designs in industrial applications. Full article

Accurately simulating the thermal behavior of wheel–brake shoe friction on long downhill ramps is challenging due to the complexity of modeling appropriate heat source models. This study investigates heat generation during the frictional braking process of freight train wheels and brake shoes under long-slope conditions. Four heat source models—constant, modified Gaussian, sinusoidal, and parabolic distributions—were developed based on energy conservation principles and validated through experimental data. A thermomechanical coupled finite element model was established, incorporating a moving heat source to analyze the effects of different models on wheel tread temperature distribution and its evolution over time. The results show that all four models effectively simulate frictional heat generation, with computed temperatures, deviating by only 6.0–8.2% from experimental measurements, confirming their accuracy and reliability. Among the models, the modified Gaussian distribution heat source, with its significantly higher peak local heat flux (2.82 times that of the constant model) and rapid attenuation, offers the most precise simulation of the non-uniform temperature distribution in the contact region. This leads to a 40% increase in the temperature gradient variation rate and effectively reproduces the “hot spot” effect. The new non-uniform heat source model accurately captures local temperature dynamics and predicts frictional heat transfer and thermal damage trends. The modified Gaussian distribution model outperforms others in simulating local temperature peaks, offering support for optimizing braking system models and improving thermal damage prediction. Future research will refine this model by incorporating factors like material wear, environmental conditions, and dynamic contact characteristics. Full article

The development of intelligent tire technology has attracted increasing attention from researchers to build different tire models to obtain the state parameters of the tire and to try to correlate these parameters with sensors. To address the challenge of characterizing the evolution of wear in traditional tire mechanics models, this study proposes a physical model that incorporates tire wear. The model is an improvement over the traditional flexible ring model, incorporating brush theory. By establishing the mechanical equilibrium equation of the tread unit, a tire dynamic equation incorporating wear state variables is constructed. The strain–displacement relationship is analyzed to determine the correlation between the strain field and the displacement field. The results show that the strain signals obtained from the physical model and the finite element model maintain a high degree of consistency, validating the reliability and effectiveness of the proposed model. In addition, the correlation between the tire wear and strain signal characteristics was successfully revealed by comparing the physical model and the finite element model. The proposed model provides a theoretical foundation for future research on intelligent tires, as well as a basis for related studies on tire wear, tire lifespan, and tire mechanical properties. Full article

Hollow wear on wheels is a common form of surface damage often observed in high-velocity vehicles. It is widely recognized that hollow wear of the wheel tread degrades the dynamic performance of rail vehicles, especially in the issue commonly referred to as “operational stability”, and leads to abnormal wheel–rail contact interactions. However, the evaluation criteria for vehicle stability are not uniform, which affects the assessment of wheel conditions and the timing of wheel re-profiling during maintenance. Therefore, numerical simulations were conducted by matching the measured worn wheel profiles with standard rails, and three different methods were employed to evaluate vehicle stability in this article. The numerical results revealed that the wheel equivalent conicity exhibits a nonlinear characteristic caused by hollow wear, which means that the nominal equivalent conicity is unable to accurately represent the geometric contact relationship between the wheel and rail. Under identical wheel wear conditions, a certain difference was observed in the critical speed of the vehicle determined by the velocity-reducing method and the bifurcation configuration method. Both methods were capable of reflecting the impact of wheel hollow wear on vehicle stability at the critical speed. Compared to the velocity-reducing method, the bifurcation configuration method can better reflect the transition process of a vehicle from stable running to hunting instability. Furthermore, the lateral vibration acceleration values measured above the bogie frame indicated that slight wheel wear is insensitive to increased speed. However, when the wear was severe, the lateral vibration acceleration of the bogie was found to increase sharply, exceeding the established stability criteria. This phenomenon was consistent with the safety alarms that occurred during actual vehicle operation, indicating that the vehicle had failed to meet stability requirements. Full article

This paper introduces a new concept of a smart and sustainable tire based on a removable tread band: ECOTIRE. Current tires, though crucial for road information and vehicle control, such as braking, traction, and turning, remain disconnected from Advanced Driver Assistance Systems (ADAS). Additionally, their production, use, and recycling pose significant environmental challenges, requiring sustainable materials and lifecycle improvements. The ECOTIRE concept makes it possible to separate the part of the tire subject to wear and apply new materials with reduced environmental impact. At the same time, the service life of the casing is extended, facilitating the introduction of sensors that improve vehicle safety. This study explores the purely mechanical connection between the casing and tread, demonstrating the feasibility of this innovative tire structure while eliminating the need for rubber matrix-based materials for a proper bond between the two components. Experimental tests using a rubber sample to simulate the tire–road contact patch validate the effectiveness of the mechanical link under varying normal loads. Grip test results, measuring longitudinal and lateral forces, show promising performance. This advancement in tire technology marks a first step toward sustainability, tire performance, and smart integration, ultimately reducing environmental impact. Full article

Tires are important for the transmission of forces, good traction of the vehicle, and safety of the passengers. Tires also influence vehicle fuel consumption and cause tire and road wear pollution to the environment in the form of microplastics. In the United States, the Uniform Tire Quality Grading (UTQG) for tread wear is reported on the tire sidewall and is used as an indicator of the expected service life of a tire. In Europe, a similar approach that applies tread depth reduction measurements and projection to the minimum tread depth is under discussion. Tread depth measurements will be carried out in parallel with abrasion measurements over the recently introduced abrasion rate test in the United Nations regulation 117. Testing is carried out with an on-road convoy method accompanied by a vehicle fitted with reference tires to minimize the influence of external parameters. In this brief review, we start with a short historical overview of the methods that have been applied so far for the measurement of tire service life. Based on the limited publicly available data, we calculate the average tread depth reduction per distance driven for summer and winter tires fitted both in the front and rear axles of passenger cars (1–1.2 mm for front wheels and 0.5–0.6 mm for rear wheels per 10,000 km). We theoretically estimate the tread mass loss per mm of tread depth reduction (250 g per 1 mm tread depth reduction, depending on the tire size) and we compare the values to experimental data obtained in recent campaigns. We give estimations of the tire service life as a function of the tread wear UTQG (100 times the indicated tread wear rating). We also discuss the projected service life using tread depth reduction and mass loss. Full article

The bogie gearbox bearing is one of the critical components in the running gear of trains, and its dynamic characteristics significantly influence the safety and stability of the entire system. In addition to internal excitations within the gearbox, during actual operation, the system is notably affected by wheel-rail disturbances, such as wheel tread wear and track irregularities. As train operating speeds increase, these impacts become more complex and pronounced. This study focuses on the cylindrical roller bearings at the input end of the bogie gearbox. A dynamic model accounting for the effects of centrifugal force and lubrication was proposed by analyzing the force characteristics of the rolling elements, inner and outer rings, and the cage, respectively. The model was verified through the velocity characteristics of the internal components. Furthermore, a method for obtaining wheel-rail excitation based on a coupled dynamic model of the bogie and wheel-rail system was proposed. Based on this, a comparative analysis was conducted on the internal contact load characteristics and the vibration characteristics of each component of the bogie gearbox bearings under different wheel polygonal excitation amplitudes and orders, as well as under the combined influence of track irregularities and wheel polygons. The results indicate that wheel polygonal excitation and track irregularity excitation have significant effects on bearing vibration and contact load. An increase in the polygonal order and amplitude intensifies the contact load between the rolling elements and the outer ring, thereby increasing bearing vibration. Additionally, a higher polygonal order leads to more frequent impacts between the rolling elements and the outer ring. The coupling effect of wheel-rail excitations further amplifies bearing vibration and contact load. Full article

This article investigates the safety potential of a freight transportation company, considering tire set selection as one of the most important aspects to ensure safe driving and a reliable transportation service. The revision of tire sets selection in large vehicle fleets is attributed to a new regulation from the United Nations to maintain non-deteriorating tire wet braking performance up to a minimum allowable wear limit, encouraging both safety and sector sustainability, as a significant part of tires are currently replaced before reaching a tread depth of 3 mm. In this research, an experimental test was conducted that involved four maneuvers with a truck using ten different sets of tires (including new and retreaded) to determine which set performs better in critical driving conditions. The results are then analyzed using the TOPSIS method where the most efficient set of tires and the best alternatives are selected. Finally, the safety of trucks on the road using the appropriate set of tires is evaluated by the estimated accident reduction potential. It should be mentioned that the optimal selection of the truck tire set is also important for sustainable transportation, as the pollution of worn tires remains a relevant environmental issue. Full article

The aim of the present study was to develop a concept for the inverse analysis of wear mechanisms in cast steel wheels of a pig iron wagon after long-term operation. Samples were taken from the flange and the tread edge area of fourteen wheels. The impact of wheel parameters and repair methods on their wear was assessed. An analysis was carried out to determine whether welds were made as part of casting correction or as repair welds. Changes in the microstructure of the weld area, the heat-affected zone, and the parent material resulting from operation were determined. The main wear mechanism in the area of the welds and the parent material is the plastic flow of the material resulting from high unit pressures. The hardness of the material is found to be contingent upon its chemical composition, the microstructural components, and the degree of plastic deformation resulting from wear (it has been established that increasing alloying results in increased hardness; a comparable effect is observed in the formation of non-equilibrium structures (bainite)). The increase in hardness is attributed to strain hardening, a consequence of exploitation. Research and analytical methods have been developed to differentiate the results of repair processes for wear effects in a highly loaded friction node with non-stationary lubrication conditions from repair processes applied to castings of large structural components. Full article

Since excessively worn tires pose a significant risk to vehicle safety, it is crucial to monitor tire wear regularly. This study aimed to verify the efficient tire wear prediction algorithm proposed in a previous modeling study, which minimizes the required input data, and use driving test data to validate the method. First, driving tests were conducted with tires at various wear levels to measure internal accelerations. The acceleration signals were then screened using empirical functions to exclude atypical data before proceeding with the machine learning process. Finally, a tire wear prediction algorithm based on a 1D−CNN with bottleneck features was developed and evaluated. The developed algorithm showed an RMSE of 5.2% (or 0.42 mm) using only the acceleration signals. When tire pressure and vertical load were included, the prediction error was reduced by 11.5%, resulting in an RMSE of 4.6%. These findings suggest that the 1D−CNN approach is an efficient method for predicting tire wear states, requiring minimal input data. Additionally, it supports the potential usefulness of the intelligent tire technology framework proposed in the modeling study. Full article