Curve Lubrication and Locomotive Adhesion Projects Presenter: Prof. Colin Cole

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2 Curve Lubrication and Locomotive Adhesion Projects Presenter: Prof. Colin Cole Research Program Leader: Engineering and Safety Program CRC for Rail Innovation

3 Curve Lubrication and Locomotive Adhesion Projects This Presentation covers two projects Although the issues can be related, these two research projects were completed separately: Curve Lubrication: Focused on Flange Lubrication and wear Locomotive Adhesion: Focused on rail stresses

4 Curve Lubrication

5 Aims: Curve Lubrication Research that leads to ranking applicators in order of effectiveness Comparison of Lubricants Investigate grease suitability for various lubricators Evaluating the economics

6 Curve Lubrication As the project progressed the experimental program was limited to wayside lubricators and trails were conducted on: 2 pump types 2 applicator types 5 grease types

7 Curve Lubrication 2 Pump types Mechanical/Hydraulic Electric Electric systems seem to offer improved overall results due to the ability to get condition monitoring information

8 Curve Lubrication Lubricator Placement Track Curvatures at Test Site Direction of Travel Curve Radius (m) Curvature (1/m) Track Kilometridge (km) Radius (m) Curvture (1/m)

9 Curve Lubrication The Testing Environment: Heavy haul environment ~ 50 GMT/year. April May June Maximum Temperatures (C) Minimum Temperatures (C) Rainfall (mm) Indicative sub-tropical weather conditions of the test program were: Temperatures: 15 to 26 degrees C. Rainfall : Fairly dry, 20mm of rain for the month.

10 Curve Lubrication Applicator types Long Bars Short Bars

11 The Grease?? Grease A Grease B Grease C Grease D Grease E NLGI Colour Black Black Dark Grey Black Black Solid Additives Graphite Graphite Thickener Lithium Lithium Lithium Microgel Lithium Drop Point, C >200 Kinematic Visc, mm 2 /s, 40 C C 15 Density kg/m Operating Temp, C Range -10 to to to to +80 Flash Point, C > >180 Auto Ignition, C >320 Molybdenum disulfide Yes 3.0% 3.0% EP additives Friction modifiers Special additives Graphite additives Special additives

12 Curve Lubrication Electronic Lubricator with major components

13 Key results included: Curve Lubrication The Long bars usually performed better than short bars A particular Grease type gave much better results that the other for greases tested with a carry distance of 4.6km

14 Curve Lubrication Key results included (Applicators): Grease A Trial Grease C Trial Hydraulic Electric Electric Hydraulic Hydraulic Electric Electric Supplier X Supplier X Supplier X Supplier Y Supplier Y Supplier X Supplier Y 2SB-HR 1 LB-ER 2 LB-ER 2 SB-HR, 2 SH-HR 2 LB-ER 2 LB - ER 0.34 km 1.39 km 0.33 km 0.72 km 2.87 km 4.62 km 1.55 km

15 Curve Lubrication Key results included (Greases): Distances Distance (km) Grease A Grease B Grease C Grease D Grease E Grease Type Carry Distance (km) From Lubricator Curve Distance (km) Covered Lubricators : Electric 2 LB - ER Grease A Grease B Grease C Grease D Grease E Carry Distance (km) Curves Distance (km)

16 Curve Lubrication Key results included (Greases): Improvement Factors Improvement Factor Grease B Grease C Grease D Grease E Grease Type Carry Distance Curve Distance Lubricators : Electric 2 LB - ER Grease A Grease B Grease C Grease D Grease E Carry Distance (km) Datum Curves Distance (km) Datum

17 Curve Lubrication Track Curvatures at Test Site Direction of Travel 4.6 km Carry Distance Curve Radius (m) Curvature (1/m) Track Kilometridge (km) Radius (m) Curvture (1/m)

18 Things we Learned: Curve Lubrication It is necessary to test lubricators and get adjustments right It is necessary to test rail surface friction conditions to establish the carry distance performance

19 Curve Lubrication Test Lubricators

20 Curve Lubrication Test rail surface friction

21 Conclusions: Be careful with these results: Curve Lubrication The experimental scope was limited to one heavy haul system tropical and sub-tropical temperatures In all lubrication Viscosity so Temperature and Climate are significant

22 Conclusions: Curve Lubrication Testing Lubricants may extend coverage by 100% Applicators also need to be properly placed and adjusted

23 Curve Lubrication Conclusions: The question of savings? Depends on current practice how much lubrication is already effective. How much track is already managed? How many sharp curves? (maybe 4% of track)

24 Conclusions: Curve Lubrication Correct installation and lubrication choice could save 50% or more capital and maintenance costs. [You might need < half as many] Fuel savings are limited as the number of sharp curves are limited. On Australia s heavy haul systems correct curve lubrication accounts for 0.6% energy savings [This might not be a small number]

25 Curve Lubrication Conclusions: Rail savings could be $1M/ year in rail steel alone. [Based on heavy haul usage] Opportunity savings (via reduced rail replacement) could be much more

26 Locomotive Adhesion

27 Locomotive Adhesion Aims: Understand the performance characteristics of high adhesion locomotives Give an assessment of high adhesion locomotives in regard to their potential to cause track damage and the various mechanisms involved

28 Locomotive Adhesion Traction was studied in the context of: Longitudinal train dynamics to derive realistic locomotive drawbar forces Locomotive vehicle dynamics in order to consider the part played by wheel unloading and bogie steer Traction system dynamics in order to consider the part played by very short force transients Wheel- rail contact Finite Element Analysis (FEA) to evaluate rail stresses

29 Locomotive Adhesion Longitudinal train dynamics

30 Locomotive Adhesion Locomotive vehicle dynamics

31 Locomotive Adhesion Wheel- rail contact Finite Element Analysis (FEA)

32 Locomotive Adhesion Three common Australian locomotive types were evaluated and compared, namely: Model C44ACi (AC): UGL manufactured GE locomotive GT46C Ace (AC): EDI manufactured EMD locomotive Cv40-9i (DC): UGL manufactured GE locomotive All simulation tests were on nominally 4,500 tonne trains with three locomotives head end.

33 Locomotive Adhesion Locomotive Specifications Locomotive Type C44ACi (AC) GT46C ACe (AC) Cv40-9i (DC) Locomotive Mass (t) Max TE (kn) Speed (km/h) Cont. TE (kn)

34 Locomotive Adhesion Slow high traction operation: 250m curves, 1 in 37 grade Locomotive Type Speed (km/h) Adhesion (%) C44ACi (AC) GT46C ACe (AC) Cv40-9i (DC)

35 The Rail Stress Results: Locomotive Adhesion

36 Locomotive Adhesion 600 Simulated Heat Results 3 rd Axle Temperature rise ( o C) Surface (z = 0 µm) z = 1 µm z = 5 µm z = 10 µm z = 20 µm z = 50 µm z = 75 µm z = 100 µm x/a

37 Locomotive Adhesion Conclusions from research: The differences in the traction performance between the AC and DC locomotives, of similar type as analysed in this project cannot be regarded as significant when adjustment is made for slightly different operating points, tractive effort and locomotive specifications

38 Locomotive Adhesion Conclusions from research: Limitations in Results: Only one type of traction scenario ( low speed, tight curvature, high TE) was assessed in detail We cannot say that the overall performance of AC and DC locomotives are identical there are many differences giving rise to different issues

39 Locomotive Adhesion Conclusions from research: Based on the shakedown map, ratchetting, and damage is anticipated to be initiated on the surface of the rail head, or subsurface of the rail gauge Clearly the lug down state for this train mass and track to near maximum tractive force (typically 20km/h) will induce rachetting, irrespective of locomotive type

40 Locomotive Adhesion Conclusions from research: In the scenario simulated rail temperature high enough to form white etching layer (WEL) are possible

41 Locomotive Adhesion Conclusions from research: Operation in the more extreme traction conditions as defined by the study will result in rail damage requiring: Rail grinding, or Changes to operations (adding more locomotives and operating at lower adhesion levels or operating with less train mass)

42 Curve Lubrication and Locomotive Adhesion Projects Questions and Discussion

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