Parallel EU projects – Parallella EU-projekt – Parallele EU-Projekte – Projets parallèles avec l’UEEU8. ERSProject leaderProfessor Roger Lundén,Applied MechanicsCo-workersMr Martin Helgen, MSc, andDocent Jan Henrik Sällström,both of Epsilon HighTechMr Tore Vernersson,Applied MechanicsPeriod 2002-09-01 – <strong>2003</strong>-06-30(– 2005-08-31)Budget EU keuro 206Budget <strong>CHARMEC</strong> Stage 3: keuro 200Stage 4: keuro 1000For photos of project leader and co-workers, see pages49 and 74The ers (Euro Rolling Silently) project of the FifthFramework Programme comprises a total of 317 manmonthswith a budgeted project cost of keuro 5880and a budgeted eu funding of keuro 2470. Chalmers/charmec’s commitment to ers is 20 man-months. Partnersin the project are Chalmers Applied Mechanics/charmec (Sweden), db (Germany), sbb (Switzerland),sncf (France) and Trenitalia (formerly part of fs, Italy)together with the six brake block manufacturers Becorit(Germany), Bremskerl Reibbelagwerke (Germany),Federal-Mogul Friction Products (formerly Ferodo, uk),Honeywell Bremsbelag (formerly Jurid, Germany),icer (Spain), and rütgers Rail (formerly rütgersAutomotive, Italy). The duration of the ers project is36 months and it is co-ordinated by sncf.The aim of the ers project is to develop new so-called“ll” type brake blocks for tread braked freight wagons(there are presently ca 650,000 of them in Europe).The blocks should be such that, without modificationto the wagons, they can replace the existing cast ironblocks of grade p10 (i e, a retrofit solution is sought).The new blocks (i) should produce lower rolling noisethan existing blocks (by causing only small irregularitieson the tread of the wheels) and possibly (ii) result inlower life-cycle costs. Further, they should (iii) havethe same dimensions as today’s cast iron blocks and(iv) behave in the same way as these in all operatingsituations (as regards block/wheel friction, wheel/railadhesion, temperature distribution etc). In particular,the new brake blocks (v) should not absorb metal particlesfrom the wheel. The blocks (vi) should be environmentallyfriendly and, finally, (vii) the remains of wornblocks should be recyclable.charmec’s investment in the project consists partlyof a description of state-of-the-art and partly of thermomechanicalsimulations. Our work is being carried outin collaboration with the consultancy Epsilon HighTech.Volvo Technology will probably be engaged as subcontractorin a “brake block technology” investigation.Our state-of-the-art report was first presented at atechnical meeting in Paris on 27 November 2002 withRoger Lundén and Jan Henrik Sällström participating.The report was approved by the eu partners in September<strong>2003</strong>. On 20 May <strong>2003</strong> Roger Lundén and MartinHelgen attended a technical meeting with representativesfrom sncf and db to discuss the thermomechanicalsimulations. It was decided that the tread braking testsperformed on the inertia dynamometer at sncf shouldbe simulated. Three kinds of block materials, i e, castiron, organic composite and sinter material, should bestudied for two wheel designs. Heat transfer to the railhas been studied separately for a tread braked wheel,the work being co-ordinated with that in project sd4.Jan Henrik Sällström, Martin Helgen, Tore Vernersson andRoger Lundén: ERS state-of-the-art report, Version 3,Chalmers Applied Mechanics, Gothenburg September <strong>2003</strong>,43 pp + Appendix 71 ppAjay Kapoor, Jonas Ringsberg, Lennart Josefson and FrancisFranklin: Shakedown limits in three-dimensional wheel-railrolling-sliding contacts, Proceedings 8th International FatigueCongress FATIGUE ’2002, Stockholm (Sweden) June 2002,vol 2, pp 1365-1372Martin Hiensch, Francis Franklin, Jens Nielsen, Jonas Ringsberg,Geert-Jaap Weeda, Ajay Kapoor and Lennart Josefson:Prevention of RCF damage in curved track through developmentof the INFRA-STAR two-material rail, Fatigue & Fractureof Engineering Materials & Structures, vol 26, no 10, <strong>2003</strong>,pp 1007-1017Martin Hiensch, Per-Olof Larsson, Olof Nilsson, Didier Levy,Ajay Kapoor, Francis Franklin, Jens Nielsen, Jonas Ringsbergand Lennart Josefson: Two-material rail development: fieldtest results regarding rolling contact fatigue and squeal noisebehaviour, Proceedings 6th International Conference on ContactMechanics and Wear of Rail/Wheel Systems (CM<strong>2003</strong>),Gothenburg June <strong>2003</strong>, vol I, pp 39-47Martin Hiensch: Two-material rail combats rolling contactfatigue, Railway Gazette International, September <strong>2003</strong>,pp 587-590Martin Hiensch, Per-Olof Larsson, Olof Nilsson, Didier Levy,Ajay Kapoor, Francis Franklin, Jens Nielsen, Jonas Ringsbergand Lennart Josefson: Development of a two-material railfor RCF and noise control, Proceedings 6th World Congresson Railway Research (WCRR <strong>2003</strong>), Edinburgh (UK) October<strong>2003</strong>, 12 pp57
Parallel special projects – Parallella specialprojekt (SP) – Parallele Sonderprojekte – Projets spéciaux parallèlesSP1. LUCCHINI SWEDEN AB (bilateral agreement)Bilateral agreements have run since 1987 betweenLucchini Sweden (formerly Sura Traction, abb SuraTraction 1990-96, Adtranz Wheelset 1996-2000) andChalmers Applied Mechanics (formerly Chalmers SolidMechanics). Our personnel have assisted the companyin the design, testing and marketing of wheelsets. Onerecent activity is reported in the paper (where the secondauthor listed is an employee of Lucchini’s)Roger Lundén, Jürgen Schneider and Tore Vernersson: Newwheelsets for 25 and 30 tonne axle loads, Presented at 6. InternationaleSchienenfahrzeugtagung, Dresden (Germany) October<strong>2003</strong>, 6 ppParallel special projects – Parallella specialprojekt (SP) – Parallele Sonderprojekte – Projets spéciaux parallèlesSP2. NOISE FROM SWEDISH RAILWAYScharmec has been engaged in Banverket’s overall effortsto reduce the noise emitted from Swedish railways.Results from the projects vb4, eu2 and eu3 are beingexploited. The first meeting with charmec was held inGothenburg on 24 January 2002 with participants fromBanverket’s Head Office and Western Track Region.Parallel special projects – Parallella specialprojekt (SP) – Parallele Sonderprojekte – Projets spéciaux parallèlesSP3. TRACK FORCE MEASUREMENTS ON X2Instrumentation of non-powered X2 bogieas used during the track force measurementsin October 2002 (courtesy TrainTechEngineering Sweden)A new extensive test campaign with in-field measurementsof the track forces caused by the Swedish highspeedtrain x2 was commenced by TrainTech Engineeringand charmec. Meetings to discuss and plan the campaignwere held at TrainTech Engineering’s premises inStockholm on 13 December 2001 and on 21 February,21 March and 10 October 2002. Collaborating organizationsin the planning have been Banverket, BombardierTransportation, charmec, Ingemansson Technology,kth Railway Technology, Lucchini Sweden, TrainTechEngineering and TrainTech Test Centre. The cash andin-kind financing (about msek 3.0) came from Banverket,Lucchini Sweden, sj ab and charmec.The measurements were performed on 21-25 October2002 with a train of type x2 in which a bogie had beenequipped by TrainTech Test Centre with accelerometersand measuring wheels and with a data collection system.The train ran three times Stockholm – Göteborg – Stockholm,twice Stockholm – Malmö – Stockholm, and onceStockholm – Sundsvall – Stockholm. The aim was tocover the high-frequency range of the load spectrum(up to, say, 2000 Hz) where large contributions to peakloads may originate. charmec contributed with backgroundanalysis and calculations. Preliminary results ofthe measurements have been used to identify stretchesof track where maintenance is needed. The full data arepresently being evaluated by TrainTech Engineeringand Ingemansson Technology. A dynamic finite elementanalysis of a trailing x2 wheel and a parallel dynamicmeasurement have been performed by the latter company.58