Search Results (57)

High-speed trains have revolutionized modern transportation with their exceptional speeds, yet the essence of this technological breakthrough resides in the train’s wheels. These components are engineered to endure extreme mechanical stresses while ensuring high safety and reliability. In this paper, we selected the rim and web as representative components of the wheel and conducted a comprehensive and systematic study on their microstructure and mechanical properties. The wheels are typically produced through integral forging. To improve the mechanical performance of the wheel/rail contact surface (i.e., the tread), the rim is subjected to surface quenching or other heat treatments. This endows the rim with strength and hardness second only to the tread and lowers its ductility. This results in a more isotropic structure with improved fatigue resistance in low-cycle and high-cycle regimes under rotating bending. The web connects the wheel axle to the rim and retains the microstructure formed during the forging process. Its strength is lower than that of the rim, while its ductility is slightly better. The web satisfies current property standards, although the microstructure suggests further optimization may be achievable through heat treatment refinement. Full article

To investigate how severe wear at No. 12 turnout frogs in an urban rail transit line operating at speeds over 120 km/h on the dynamic performance of the vehicle, a vehicle–frog coupled dynamic model was established by employing the 2021 version of SIMPACK software. Profiles of No. 12 alloy steel frogs and metro wheel rims were measured to simulate wheel–rail interactions as the vehicle traverses the turnout, using both brand-new and worn frog conditions. The experimental results indicate that increased service life deepens frog wear, raises equivalent conicity, and intensifies wheel–rail forces. When a vehicle passes through the frog serviced for over 17 months at the speed of 120 km/h, the maximum derailment coefficient, lateral acceleration of the car body, and lateral and vertical wheel–rail forces increased by 0.14, 0.17 m/s², 9.52 kN, and 105.76 kN, respectively. The maximum contact patch area grew by 35.73%, while peak contact pressure rose by 236 MPa. To prevent dynamic indicators from exceeding safety thresholds and ensure train operational safety, it is recommended that the frog maintenance cycle be limited to 12 to 16 months. Full article

Light alloy wheel rims, despite their widespread use, remain vulnerable to fatigue-related defects and mechanical damage. This study presents a method for assessing their technical condition based on acoustic parameter analysis and classification using a deep neural network. Diagnostic data were collected using a custom-developed ADF (Acoustic Diagnostic Features) system, incorporating the reverberation time (T₆₀), sound absorption coefficient (α), and acoustic energy (E). These parameters were measured during laboratory fatigue testing on a Wheel Resistance Test Rig (WRTR) and from used rims obtained under real-world operating conditions. The neural network was trained on WRTR data and subsequently employed to classify field samples as either “serviceable” or “unserviceable”. Results confirmed the high effectiveness of the proposed method, including its robustness in detecting borderline cases, as demonstrated in a case study involving a mechanically damaged rim. The developed approach offers potential support for diagnostic decision-making in workshop settings and may, in the future, serve as a foundation for sensor-based real-time rim condition monitoring. Full article

This article presents the influence of lubricant on selected tribological properties of the rolling–sliding association, i.e., the wheel–rail system. Three solid lubricants were tested: soybean grease, molybdenum disulfide and graphite grease. Under specific operating conditions, a beneficial influence of lubrication of the above-mentioned friction node was observed. This is valuable information for rolling stock owners, track operation or maintenance workers when making decisions about lubrication or its absence on a given section of railway track. In this way, tangible financial benefits (savings) are obtained by extending the durability of the wheel rim and rail, and, through extended periods of wheel set reprofiling, we significantly reduce operating costs. Solid lubricants (lubricating sticks) intended for the lubrication of railway wheel flanges must meet the requirements specified in the PN-EN 15427-2-1:2022 standard. Annex H. The wear patterns were observed and analyzed using both optical microscopy and scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectroscopy (EDS). The test results indicate that graphite is characterized by the lowest and most stable coefficient of friction over time, which makes it the most effective lubricant in terms of friction reduction. Soybean grease also shows stability and a low level of friction, but with a slight increase in value over a longer period of time. However, grease containing molybdenum disulfide, despite its initial effectiveness, loses its lubricating properties over time, resulting in a significant increase in friction. Full article

A plasma-assisted electrochemical deposition (PAECD) technology was introduced to coat a cast iron brake disc for the possible reduction of brake wear and brake wear particle (BWP) emission. The majority of the coating consisted of alumina (Al₂O₃), determined by energy dispersive X-ray (EDX) analysis and X-ray diffraction (XRD) analysis. To validate the above strategy of the coating technology for automotive brake corners, one brake stock rotor was replaced by a PAECD-coated rotor for a vehicle road test. After the road test, weight loss of the brake components (rotors and pads) was measured, showing that the alumina coating can reduce the brake wear by more than 70%. BWPs were also collected from wheel barrels, spokes, and brake friction rings of the coated and uncoated rotors during the road test. A morphology and chemical composition analysis of the collected BWPs indicated that the coating could reduce BWP generation from the original sources and avoid a metal pick-up (MPU) issue, leading to less metallic content in BWPs. This alumina coating may provide the auto sector with a sustainable approach to overcome the brake dust emission problem, evidenced by less wear of the brake pads, minimal wear of the coated brake rotor, less MPUs, and a clean wheel rim on the coated brake corner. Full article

In recent years, non-pneumatic tires have been gaining popularity, which can be seen in the increase in research results and proposals from world-class tire manufacturers (mainly as technology demonstrators). The possibility of eliminating the need to maintain compressed air is a major factor in the development of non-pneumatic tires and their usage in vehicles. Articles and patents were reviewed in relation to the load transfer mechanism, the design of non-pneumatic tire components, and recommendations for materials. Non-pneumatic tire top loaders are a desirable type of this type of wheel compared to bottom loaders, because they transfer loads over a larger part of the wheel, which increases their load capacity. Most non-pneumatic tires consist of a rim, an elastic structure, and a shear beam/band with a tread. The rim is used to secure the elastic structure and can be fitted with vibration dampers in the form of circumferential rubber rings. The gradient elastic structure, in comparison with the homogeneous structure (same thickness or dimensions of the elements), allows the range of axle displacements to be adjusted to the desired level without the need to increase the size of the wheel, and also influences the change in the location of the maximum stresses. The shear beam/ band mimics the properties of compressed air used in pneumatic tires. The shear beam/ band made as a webbing geometry ensures uniform pressure in the contact patch. The reinforced composite shear beam/ band ensures adequate bending strength with low energy losses and a small thickness of the beam/ band. Materials commonly used in the tire industry are used as reinforcement for the shear beam/ band, which was illustrated by the results of our own research. Full article

In the context of wheelchair racing, research primarily focuses on studying wheelchair ergonomics and determining kinematic, kinetic, and rolling resistance variables. One factor identified as influencing athletes’ performance is wheel skidding on the ground, a parameter complementary to rolling resistance. The objective of this study, therefore, is to identify, within a laboratory setting, the parameters that influence the risk of skidding in racing wheelchairs by measuring skidding torque. The ultimate goal is to enhance athletes’ performance by optimizing the interaction between the athlete and their wheelchair, and the wheelchair and the environment. In this perspective, four parameters were examined: the type of tubular, the camber angle, the tire pressure, and the load applied to the wheel using a skidometer. This tool characterizes a tire’s grip on a surface by measuring torques. The aim is to develop a system for classifying tire grip on dry athletics track at ambient temperature. The findings revealed that only the effects of load and tubular type had a significant impact on the torque values obtained. The tire that minimized the risk of skidding, among all tested combinations, is the Vittoria Pista Speed 23–28″. Furthermore, as the mass applied to the wheel increases, so do the resulting torques. This implies that a heavier athlete would require a greater force to be applied to the hand rim for the tire to skid. However, it was also demonstrated that the risk of skidding in a racing wheelchair is unlikely, as the torques obtained were over a range of 90 to 190 Nm. These values far exceed those typically exerted by para-athletes, which are a maximum of 60 Nm. The long-term goal would be to adjust the mode of torque application on the wheel using the skidometer for a more realistic field approach. Full article

The drive system of an electric car must meet road requirements related to overcoming obstacles and driving dynamics depending on the class and purpose of the vehicle. The driving dynamics of modern cars as well as size and weight limitations mean that wheel hub motors operate with relatively high current density and high power supply frequency, which may generate significant power losses in the windings and permanent magnets and increase their operating temperature. Designers of this type of motor often face the need to minimize the motor’s weight, as it constitutes the unsprung mass of the vehicle. Another limitation for motor designers is the motor dimensions, which are limited by the dimensions of the rim, the arrangement of suspension elements and the braking system. The article presents two directions in the design of wheel hub motors. The first one involves minimizing the length of the stator magnetic core, which allows for shortening of the axial dimension and mass of the motor but involves increasing the thermal load and the need for deeper de-excitation. The second one involves increasing the number of pairs of magnetic poles, which reduces the mass, increases the internal diameter of the motor and shortens the construction of the fronts, but is associated with an increase in the motor operating frequency and increased power losses. Additionally, increasing the number of pairs of magnetic poles is often associated with reducing the number of slots per pole and the phase for technological reasons, which in turn leads to a greater share of spatial harmonics of the magnetomotive force in the air gap and may lead to the generation of higher power losses and higher operating temperatures of permanent magnets. The analysis is based on a simulation of the motor operation, modeled on the basis of laboratory tests of the prototype, while the car is driving in various driving cycles. Full article

The research presented in this paper takes another step towards developing methods for automatic condition verification to detect structural damage to vehicle wheel rims. This study presents the utilisation of vibration spectra via Fast Fourier Transform (FFT) and a neural network’s learning capabilities for evaluating structural damage. Amplitude and time cycles of acceleration were analyzed as the structural response. These cycles underwent FFT analysis, leading to the identification of four diagnostic symptoms described by 20 features of the diagnostic signal, which in turn defined a condition vector. In the subsequent stage, the amplitude and frequency cycles served as input data for the neural network, and based on them, self-organizing maps (SOM) were generated. From these maps, a condition vector was defined for each of the four positions of the rim. Therefore, the technical condition of the wheel rim was determined based on the variance in condition parameter features, using reference frequencies of vibration spectra and SOM visualisations. The outcome of this work is a unique synergetic diagnostic system with innovative features, identifying the condition of a wheel rim through vibration and acoustic analysis along with neural network techniques in the form of Kohonen maps. Full article

This paper presents the results of the study of the kinematics and dynamics of an elastic steered wheel depending on its state, the kingpin unit design parameters, and the tire characteristics in order to obtain dependencies for calculating the tire steering resistance torque in static state and during movement. It was established that when steering in static state, the locked steered wheel is taken as a complex mechanism, and the tire contact patch is rotated about the kingpin axis–support surface intersection point. When turning the unlocked steered wheel, it was determined that the tire contact patch participates in transport and relative motions. The transport motion center is the projection onto the support surface of the center of rotation of the wheel about the kingpin axis. The relative motion center is within the contact patch and is determined experimentally. For both states of the steered wheel, analytical dependencies were obtained for determining the tire steering resistance torque. The results of the analytical studies were experimentally verified on a bench equipped by components and aggregates of a truck, and included an additional rigid false wheel and a special rim. The false wheel made it possible to experimentally determine the tire contact patch transport motion center, and the special rim—to change the knuckle length in the range of 0.22–0.82 m. Full article

The accurate prediction of tire and brake thermomechanical behavior is crucial for various applications in the automotive industry, including vehicle dynamics analysis, racing performance optimization, and driver assistance system development. The temperature of the brakes plays a crucial role in determining the performance of rubber by altering its temperature. This change impacts the rim and the air within the tire, leading to variations in temperature and tire pressure, which consequently affect the vehicle’s overall performance. Traditionally, these components have been modeled separately, neglecting the crucial thermal interaction between them, thereby losing a lot of important information from the outside that influences the tire. This paper presents a novel method that overcomes this limitation by coupling the thermomechanical models of the tire and brake, enabling a more comprehensive understanding of their combined behavior. Therefore, the present work could be an interesting starting point to understand how a control system can be influenced by the thermodynamic of the wheel–brake system. Full article

In this study, finite element (FE) simulation by the software Abaqus was relied on to investigate the roll forming process of a wheel rim made of an innovative dual-phase steel, i.e., DP590, after flash butt welding (FBW). In the simulation, an FE model was generated, including the design of the dies for flaring, three-roll forming, and expansion, and detailed key processing parameters based on practical production of the selected DP590. Combined with the microstructures and properties of the weld zone (WZ) and heat-affected zones (HAZs) after FBW, the distribution of stress/strain and the change in thickness of the base metal (BM), WZ and HAZs were analyzed, and compared in the important stages of roll forming. Theoretically, the variation in the microstructure and the corresponding stress–strain behaviors of the BM, WZ, and HAZs after FBW have led to the thickness reduction of DP590 that originated from softening behaviors occurring at the region of subcritical HAZs (SCHAZs), and a small amount of tempered martensite has evidently reduced the hardness and strength of the SCHAZ. Meanwhile, the distribution of stress/strain has been influenced to some extent. Further, the study includes the influence of the friction coefficient on the forming quality of the wheel rim to guarantee the simulation accuracy in practical applications. In sum, the dual-phase steel has to be carefully applied to the wheel rim, which needs to experience the processes of FBW and roll forming, focusing on the performance of SCHAZs. Full article

This paper designs a kind of air suspension mechanical-vibration-reduction wheel for mining engineering vehicles; the research work on topology analysis and the structural optimization of the inner and outer rims are carried out with this wheel as the research object. Using Workbench finite-element analysis software, taking the results of static analysis and modal analysis of the two as constraints, a variety of structural improvement styles are obtained through a topology analysis method and compared and verified, and a more reasonable improvement result is selected and assembled into a whole wheel for final analysis and verification. The results show that the optimization results of the wheel still meet the design’s load-bearing requirements, and the weight is lighter; the topology analysis results are ideal. Full article

This paper summarizes the results of numerous studies aimed at improving the operating characteristics of electric motors used in light electric vehicles (LEVs). This review focuses on four types of electric motors that can be installed in the drive wheel rims of LEVs. Due to the availability of new magnetic materials and the use of advanced techniques for optimizing the design of electric motors, new motor topologies have emerged. The latest generation motors have been shown to be more efficient, have higher torque density, and generate less torque ripple. This paper indicates and discusses current trends in the topology of electric motors designed for LEV drives. In this context, the effectiveness of the proposed design modifications in terms of selected motor operational characteristics was assessed. The proposed new topologies were compared with commercial solutions, also in terms of the possibility of improving their operational parameters. Full article

Vehicles often experience low tire pressures and high torques in off-road operations, making tire–rim slip likely. Tire–rim slip is undesirable relative rotation between the tire and rim, which, in this study, is measured by the relative tire–rim slip rate. There is little research on the effect of different terrains on tire–rim slip despite its significance for off-road driving; therefore, this topic was explored through Finite Element Analysis (FEA) simulations. An upland sandy loam soil was modelled and calibrated using Smoothed-Particle Hydrodynamics (SPH), and then a Regional Haul Drive (RHD) truck tire was simulated driving over this terrain, with a drawbar load added to increase drive torque. To examine their effects, five parameters were changed: tire–rim friction coefficient, longitudinal wheel speed, drawbar load, vertical load, and inflation pressure. The simulations showed that increasing the tire–rim friction coefficient and the inflation pressure decreased the tire–rim slip while increasing the vertical and drawbar loads increased the tire–rim slip. Varying the longitudinal wheel speed had no significant effect. Tire–rim slip was more likely to occur on the soil because it happened at lower drawbar loads on the soil than on the hard surface. These research results increased knowledge of tire–rim slip mechanics and provided a foundation for exploring tire–rim slip on other terrains, such as clays or sands. Full article