SIMPACK TRAINING Wheel/Rail Basics

SIMPACK: Wheel/Rail Basic Training

Analysis and Design of General Mechanical Systems

方向华

Beijng Engineering Solution Provider Ltd.

INTEC GmbH, Argelsrieder Feld 13, 82234 Wessling, Tel: 08153/92 88-0, Fax 08153/92 88-11, E-Mail: [email protected]
 SIMPACK TRAINING Wheel/Rail Basics

Contents

Î Overview: SIMPACK Wheel/Rail Functionality

Î The Track Joint, Degrees of Freedom
Î The SIMPACK Default Wheelset
Î EXAMPLE: Setting Up a Default Wheelset
Î Standard Track Models, Basic Contact Models
Î Some Tips for Completing the Vehicle
Î EXAMPLE: Building the Bogie Substructure
Î EXAMPLE: Completing the Vehicle
Î EXAMPLE: Linearised Wheel/Rail Contact
Î EXAMPLE: Eigenmode Analysis
Î EXAMPLE: Time Integration and General Wheel/Rail Specific Plots
Î EXAMPLE: Basic Track Irregularities
Î EXAMPLE: Ride Comfort
Analysis and Design
of General Î Profile Generation
Mechanical Systems
Î EXAMPLE: Root Loci
Î EXAMPLE: Critical Speed
Î Independent Wheels
(2)
 SIMPACK TRAINING Wheel/Rail Basics

Overview: SIMPACK Wheel/Rail Functionality

How to follow a given track How to get wheel and rail into contact
Track
Trackdefinition
definition Profile
ProfilePreprocessor
Preprocessor
standard,
standard,cartographic,
cartographic,measured for
measured formeasured
measuredprofiles
profiles

Track
TrackJoint
Joint Wheel/Rail
Wheel/RailElements
Elements
==wheels
wheels++rails
railswith
withprofiles
profiles
How to calculate the tangential forces
3D
3DProfile
ProfileContact
Contact
Contact
ContactForce
ForceElements
Elements by
byconstraints
constraintsor
orone-sided
one-sidedsprings
springs

Contact
ContactPreprocessor
Preprocessor Contact
ContactPreprocessor
Preprocessor
for for
forpre-calculating
pre-calculatingcontact
contactpoints
forpre-calculating
pre-calculatingtangential
tangentialforces
forces points

Special

Profile
ProfileLinearisation
Linearisation

(3)
 SIMPACK TRAINING Wheel/Rail Basics

The Track Joint Type 07

6 Degrees of Freedom:
s - along the track centre
Imaginary track center line y - lateral
z - vertical
ϕ - roll angle (around s)
Defined from Isys to body
ψ - yaw angle (around z)
Joint follows
γ - pitch or rolling angle
the track center (around y)
07
Alternatively:
x - 5 DOF (without γ)
- 1 DOF (only s)
y Joint type 09: like type 07, but
v = const. (5, 4 or 0 DOF)

z Attention!
Attention! zz axis
axis is
is downwards
downwards positive
positive
for
for wheel/rail models (according to
wheel/rail models (according to UIC)
UIC)

(4)
 SIMPACK TRAINING Wheel/Rail Basics

The SIMPACK Default Wheelset (1)

$M_Wheel_ProfRef $M_Rail_ProfRef
$M_Wheel_Contact $M_Rail_Contact
$M_Rail_Track_Frame
$M_Rail_Track_Camera
$L_RailWheel

$F_RW_Friction

$S_Rail_ProfRef
$S_Wheel_ProfRef
$S_Rail_Contact
$S_Rail_Track_Frame
$S_Rail_Track_Camera
3D Elements of
Wheels and Rails Note 1: Every _Rail_ and _Wheel_ element exists for the left and the right wheel.
Note 2: Replace _Wheel_ by the name of the wheelset body.
Î e.g. „$M_Wheelset1_ProfRef_Left“, „$L_RailWheel_Right_of_Wheelset1“, ...

(5)
 SIMPACK TRAINING Wheel/Rail Basics

The SIMPACK Default Wheelset (2)

Markers
Wheel profile definition
plane (e.g. taper line)

Wheelset body-fixed
Semi-wheelbase e0 reference frame
(BFRF)

Nominal wheel
radius r0
$M_Wheel_ProfRef

$M_Wheel_Contact
$M_Rail_ProfRef
(here canted with rail) $M_Rail_Contact
(both moving with the
current contact point)

Rail profile definition plane

(e.g. middle of rail head)

(6)
 SIMPACK TRAINING Wheel/Rail Basics

The SIMPACK Default Wheelset (3)

Track-Related Markers
(moving with the wheelset along the track)

$M_Rail_Track_Frame

Superelevation u

$M_Rail_Track_Camera

(7)
 SIMPACK TRAINING Wheel/Rail Basics

The SIMPACK Default Wheelset (4)

Constraints and Force Elements

$F_RW_Friction
for tangential forces

$L_RailWheel
Both acting at same
09 89 markers: 89 09
FROM $M_Rail_Contact
TO $M_Wheel_Contact

(8)
 SIMPACK TRAINING Wheel/Rail Basics

The SIMPACK Default Wheelset (5)

Sensors

$S_Rail_ProfRef
$S_Wheel_ProfRef
$S_Rail_Contact
$S_Rail_Track_Frame
$S_Rail_Track_Camera

Each FROM Isys TO according marker.

(9)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (1)

Pre-Processing Processing Post-Processing

Body Definition
Joints Definition

(10)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (2)

Some Important Steps to Be Done First

Create a new folder for training models and

in a new model:
• Change gravity to positive
z direction (+9,81 m/s²)

• Adjust view to standard view:

Wheel/Rail perspective view

(11)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (3)

Characteristics

Mass = 1000 kg
Ixx = 1000 kgm²
Iyy = 100 kgm²
Izz = 1000 kgm²

Track joint with 6 degrees of freedom

(12)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (4)

• Rename $B_body1 to $B_WS1 (Wheelset 1)

• Add body data
• Change 3D geometry of wheelset axle

(13)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (5)

• Set up the joint

• Generate wheel/rail elements
• Assemble system

(14)
 SIMPACK TRAINING Wheel/Rail Basics

Constraints and Dependent/Independent States

6 joint states - 2 constraints

Independent: freely adjustable by user and model dynamics
= 4 degrees of freedom (description by differential equation of motion)
Dependent: state results from kinematics
Wheelset
(description by algebraic kinematical equation)

09 07 09

Constraint 6 DOF, with Constraint

L W/R-Elements R

Default:
s - independent
y - independent
z - dependent
ϕ - dependent
ψ - independent
γ - independent

Imagine
Imagine laying
laying the
the wheelset
wheelset
down
down onto the track with
onto the track with aa
crane Æ only
crane Æ only s, y, ψ
s, y, ψ,, γγ adjustable
adjustable

(15)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (6)

Pre-Processing Processing Post-Processing

Body Definition
Joints Definition
Track Definition

(16)
 SIMPACK TRAINING Wheel/Rail Basics

Standard Track Models (1)

Straight Track
• Track length

Curved Track with Constant Horizontal Curvature

• Radius
• Superelevation, with reference length
• Track length

Curved Track with Variable Horizontal Curvature

Curve entry - curve passing - sign change of curvature (s-curve) - cross-over
• Radius
• Superelevation, with reference length
• Track length
• Further special parameters

Extension: Elastic Foundation (Ballast Mass)

(17)
 SIMPACK TRAINING Wheel/Rail Basics

Standard Track Models (2)

Superelevation

Centerline is elevated

Superelevation u Rotation about

inner rail
Reference length
= railbase

Superelevation u

Rotation about
centerline

(18)
 SIMPACK TRAINING Wheel/Rail Basics

Standard Track Models (3)

Curve Entry and Superelevation Ramp

Radius
Radius and
and superelevation
superelevation
Curve entry: R=∞ R = ∞ Æ RCurve have
have to
to be
be negative
negative for
for left-
left-
hand curves
hand curves
R = RCurve

Superelevation ramp (length identical with curve entry):

e u = uCurve ve u = uCurve
u Curv u Cur
0Æ 0Æ
u= u=
u=0 u=0
Smoothed over
distance 2h

Straight ramp S-shaped ramp

For
For standard
standard tracks,
tracks, also
also
the form (s-shaped, linear)
the form (s-shaped, linear)
of
of the
the curve
curve entry
entry corre-
corre-
sponds to the ramp.
sponds to the ramp.
(19)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (7)

• Set up an entry to a narrow curve

in the track definition window

(20)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting Up a Default Wheelset (8)

Pre-Processing Processing Post-Processing

Body Definition
Joints Definition
Track Definition
Vehicle Globals

(21)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Contact in SIMPACK (1)

1. Find the contact point

2. Determine normal
force

3. Calculate tangential
forces

(22)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Contact in SIMPACK (2)

Step 1: Finding the contact point

Default method: quasi-elastic

• Takes a „virtual“ material elasticity into account
• The resulting „virtual“ contact area is regularised (smoothed) and
converted into a single contact point
• Contact point moves steadily along the profiles

Old method: rigid

• Contact point location is the minimum distance between profiles
• Contact point can jump, e.g. on tread of S1002/UIC60 1:40

(Switch between methods in parameter set *.pp)

You
You should
should not
not use
use the
the rigid
rigid
method. It can cause numerical
method. It can cause numerical
problems
problems and
and is
is outdated.
outdated.
(23)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Contact in SIMPACK (3)

Step 2: Determining the normal force

Default method: constraint

• Uses the constraint type 09 between rail and wheel contact markers
• Normal force equals constraint force (negated)
• Avoids high-frequency oscillations: fast
• Only „pseudo wheel lift“ possible

Alternative method: elastic (one-sided spring/damper)

• Uses the force element 18 between rail and wheel contact markers
• Normal force equals spring/damper force
• High-frequency oscillations can slow down the calculation
• Real wheel lift possible

(Switch between methods in Vehicle Globals window: „constraint“/„elastic“)

(24)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Contact in SIMPACK (4)

Step 3: Calculating the tangential forces

Default method: Simplified non-linear theory (J. J. Kalker)

• Standard FASTSIM algorithm
• Uses Hertzian contact ellipse, derived from profile curvatures
and normal force
• Tangential forces T depend nonlinearly on creepage situation
• Ratio |T| / |N| is limited by the friction coefficient µ

Several alternative methods

(Switch between methods in Vehicle Globals window: „Contact Force“)

(25)
 SIMPACK TRAINING Wheel/Rail Basics

Some Tips for Completing the Vehicle

Topology of a Railway Vehicle

Car body
Secondary
Suspension

Bogie frame
Primary

no W/R-Func.
Suspension

07, 6 DOF,
no W/R-Func.
Wheelset

07, 6 DOF,
6 DOF, with

W/R-Func.
Constraint

Constraint
07

R
L

(26)
 SIMPACK TRAINING Wheel/Rail Basics

Substructures in Wheel/Rail Models (1)

The Idea
• Bogies are complicated devices, and built in at least twice
in most wheel/rail models Æ preferrably model as a substructure

The Problem
• In substructures, no changing or deleting of their
components is possible (only parameter settings)
• The switching between constraint and elastic contact is
not allowed if the wheelsets are within the substructure Car body

Substructure
„Bogie“ Bogie frame
(2x) and related
parts

2 Wheelsets

(27)
 SIMPACK TRAINING Wheel/Rail Basics

Substructures in Wheel/Rail Models (2)

Two Workarounds
• Include wheelsets into substructure if no change of contact
model (constraint/elastic) is intended
• Include wheelsets into substructure and resolve substructure
dependency before changing the contact model

The Solution
• Exclude wheel-rail elements of wheelsets from substructures and
define them in main model using dummy bodies
Car body

Substructure „Bogie“ (2x)

9
Bogie frame
2 x 2 Wheelsets and related
parts
0 DOF

2 x 2 WS_Dummy
Dummy
Dummy bodies
bodies have
have neglectable
neglectable
masses ( «
masses (« 0.001kg) and inertia
0.001kg) and inertia
moments. Their most important
moments. Their most important
elements
elements are
are their
their markers.
markers.

(28)
 SIMPACK TRAINING Wheel/Rail Basics

Substructures in Wheel/Rail Models (3)

The Solution
• The wheelsets within the substructure contain all the mass and inertia
properties along with the relevant markers, i.e. for primary suspension

• For correct positioning of the wheelsets within the substructure create

new markers in Isys for the O DOF joints.

Main Model with Substructure Bogie

Dummy Wheelsets

(29)
 SIMPACK TRAINING Wheel/Rail Basics

Substructures in Wheel/Rail Models (3)

Using Dummy Bodies for Connnecting Substructures

• Many connections: primary/secondary springs, dampers, . . .
• Simplify by introducing one or more dummy bodies per substructure

Car
Car body
body

0 DOF
Dummy
Dummy body
body

Secondary springs,
dampers, anti-roll bar,
07, 6 DOF
... Bogie
Bogie frame
frame and
and
Bogie
Bogie frame,
frame, related
related parts
parts
related
related parts
parts 0 DOF
and
and wheelsets
wheelsets Wheelsets
Wheelsets

2 Wheelsets Dummy_Wheelsets
Dummy_Wheelsets

07, 6 DOF
07, 6 DOF

(several)

(2x)
(30)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration

Track Definition
Body Definition
Joints Definition

(31)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (2)

Preliminary Steps, Wheelset

• Set up a new body “$B_WS_Training”.
DO NOT generate Wheel/Rail Elements.
Type of joint irrelevant. Refer to example:
“Setting Up a Default Wheelset”
• Add markers for axlebox/primary suspension
y = ± 1,0 m

• Save wheelset to data base

(32)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (3)

Create a New Body for the Bogie Frame

Centre of mass

Plane of 3D
primitive reference

Track plane

BFRF marker
• Name $B_BF
• m = 3000 kg
• Centre of mass z = -0.6 m
• Ixx = 1500 kgm², Iyy = 2500 kgm², Izz = 2800 kgm²
• I-Tensor relative to centre of mass

(33)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (4)

3D Primitives: Wheel Rail Bogie and traverses

Distance right left
L1

H2

H1

L2
B1

(34)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (5)

Markers for Primary and Secondary Suspension

• Primary: x = ± 1.25 m, y = ± 1 m, z = -0.5 m
• Secondary: x = 0 m, y = ± 1 m, z = -0.8 m

BFRF

Use
Use common
common abbreviations
abbreviations to
to keep
keep names
names
short.
short. Otherwise
Otherwise you
you could
could get
get into
into trouble
trouble
when
when working
working with
with substructures.
substructures.

• Save Body to Database

(35)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (6)

Create a New Model “Bogie Substructure”

BFRF, Bogie_frame

• Create two markers on Isys for wheelsets (x = ±1.25, z = -0.5)

• Two new bodies, “WS1” and “WS2”. Import wheelsets from database.
0 DOF Joints to respective markers on Isys.
• New Body “Bogie_Frame” from Database, Joint type 07 (general
wheel/rail joint) with 6 DOF, but without wheel/rail elements.
Remember! Only joints from Isys may be re-connected in main model

(36)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (6)

Create a New Model “Bogie Substructure”

BFRF, Bogie_frame
and Wagon_dummy

• New body “Wagon_dummy”. Mass and inertias 1.0e-6.

• Create marker “Wagon_dummy_Connect” for connection to wagon, z = -1
• Create identical marker “Isys_Connect” and replace joint markers
accordingly
• Generate appropriate primitive. Use new marker as reference marker.
• Add markers for SS. Use identity function to markers on frame.

(37)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (7)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration

Track Definition
Body Definition
Joints Definition
Force Elements
Database

(38)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (8)

Primary Suspension
• Type 05: spring/damper
parallel compact
• FROM marker on bogie frame

Why?
Why?
•• Stiffness/damping
Stiffness/damping definitions
definitions are
are given
given in
in
body
body reference
reference system
system of of FROM
FROM body
body ––
they
they would
would rotate
rotate ifif wheelset
wheelset were
were FROM
FROM
body
body
•• rr xx FF torques
torques are
are applied
applied on
on FROM
FROM body
body

• Use “Identity to...” feature

• Check with “Info - Force Elements”
that rabs is near zero (precondition
for calculation of nominal forces
with compact force elements)
• Generate 3D scaled springs PtP

(39)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (9)

Secondary Suspension
• Type 05: spring/damper
parallel compact
• FROM marker on Wagon_dummy

Why?
Why?
•• rr xx FF torques
torques are
are applied
applied on
on FROM
FROM body
body

• Use “Identity to...” feature

• Check with “Info - Force Elements”
that rabs is near zero (precondition
for calculation of nominal forces
with compact force elements)
• Generate 3D scaled springs, PtP

(40)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Building the Bogie Substructure (10)

Creating a Database
• Within the current directory create a database folder along
with the necessary standard subfolders

• Transfer the Wheelsets and Bogie (sys and ani files) from
the user specific database to the new database
• Transfer the substructure (sys and ani files) to the
database
• Copy body “Wagon” from training database to new database
• Remember to set the model specific database path before
using database components. Also necessary for opening
substructures within the database

(41)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (1)

Vehicle Data
s= 0 1.25 2.5 10.75 19 20.25 21.5 m

WS4 WS3 WS2 WS1

2.5 m Bogie_II Bogie_I
19 m

Car body:
• m = 32000 kg Primary suspension:
• Ixx = 56000 kgm², Iyy = 2.e06 kgm², Izz = 2.e06 kgm² w.r.t. cg
• cx = 3.e07 N/m, cy = 4.e6 N/m, cz = 1.2e06 N/m
• zcg = -1.8 m
• dx = 15000 Ns/m, dy = 2000 Ns/m, dz = 4000
Ns/m

Secondary suspension:
• cx = 150000 N/m, cy = 150000 N/m, cz = 450000 N/m
• dx = dy = 32000 Ns/m, dz = 20000 Ns/m

(42)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (2)

Creating the main model

• New model “Vehicle” (not in Database)

• Set gravity and standard wheel/rail view
• Define a straight track
• Create four dummy wheelsets (1.0e-6 mass and inertias) with appropriate
joints and wheel/rail elements
• Assign the corresponding “s” co-ordinates
• Save backup model as “Vehicle_START”

(43)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (3)

Creating the main model

• Create new body “Wagon” and import body from database

• Assign joint type 07, 6 DOF with corresponding “s” co-ordinate
Do not generate W/R elements
• Import bogie substructures from database.
• Assign corresponding “s” co-ordinates to the bogie frames
• Re-connect the wheelsets and wagon-dummies to the appropriate markers

(44)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (4)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration

Track Definition
Body Definition
Joints Definition
Force Elements
Database
Nominal Forces

(45)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (5)

Nominal Forces

• Nominal forces guarantee the static

equilibrium of the system for a
given state
• Railway vehicles are mostly modelled
according to a drawing (given state).
This means that nominal forces in
z direction have to be set
(pre-stress forces of the suspension)

• Nominal forces can be calculated manually (e.g. from

the weight forces of the bodies) or automatically

(46)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (6)

Calculation of Nominal Forces: Preliminary Steps

• Set global velocity of 1 m/s (Vehicle Globals window)

• Save the bogie model
• Perform a Test Call (Assembly Test) and make sure that there
are no unrealistic high accelerations:

================================================================================
================================================================================
Joint
Joint Accelerations
Accelerations ZGPP(1:nzj,joint_name)
ZGPP(1:nzj,joint_name)
================================================================================
================================================================================

zgpp($J_S_Bogie_II__J_Bogie_Frame)
zgpp($J_S_Bogie_II__J_Bogie_Frame) == -1.2106986D-10
-1.2106986D-10 8.3560125D-09
8.3560125D-09 1.0649356D+01
1.0649356D+01 -1.3927304D-08
-1.3927304D-08 -4.9563528D-13
-4.9563528D-13 -2.0178309D-10
-2.0178309D-10
zgpp($J_S_Bogie_I__J_Bogie_Frame
zgpp($J_S_Bogie_I__J_Bogie_Frame )) == -1.9118044D-10
-1.9118044D-10 8.2853727D-09
8.2853727D-09 1.0649356D+01
1.0649356D+01 -1.3808954D-08
-1.3808954D-08 0.0000000D+00
0.0000000D+00 -3.1863406D-10
-3.1863406D-10
zgpp($J_Wagon
zgpp($J_Wagon )) == 0.0000000D+00
0.0000000D+00 0.0000000D+00
0.0000000D+00 9.8100004D+00
9.8100004D+00 0.0000000D+00
0.0000000D+00 0.0000000D+00
0.0000000D+00 0.0000000D+00
0.0000000D+00
zgpp($J_WS4_dummy
zgpp($J_WS4_dummy )) == -2.3209192D-04
-2.3209192D-04 -1.1988399D-10
-1.1988399D-10 1.2342693D-22
1.2342693D-22 6.0863385D-12
6.0863385D-12 -7.9274563D-10
-7.9274563D-10 -1.1604212D-03
-1.1604212D-03

Most accelerations are

near zero: o.k. z acceleration of bogie frames and
carbody: Not unrealistic, because
IfIf there
there are
are unrealistic
unrealistic accelerations
accelerations (e.g.
(e.g. from gravity, but have to be
greater
greater than than 100
100 m/s²)
m/s²) there
there could
could bebe an
an error
error in
in eliminated in order to bring the
the model Æ double-check joints, forces
the model Æ double-check joints, forces etc. etc. system into equilibrium

(47)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (7)

Calculation of Nominal Forces

• Choose “Linear System” method (faster)

• Select all force directions that have
an associated stiffness (here all forces:
click “Init. with all Possible Forces”)
• Perform calculation

(48)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Setting up the complete vehicle (8)

Calculation of Nominal Forces

• Check the results:

- very similar values for symmetric
forces
- small residual accelerations

• Save results, force selection and

settings
• Reload the model in the 3D window

• Another Test Call shows that the

remaining accelerations have disappeared:

================================================================================
================================================================================
Joint
Joint Accelerations
Accelerations ZGPP(1:nzj,joint_name)
ZGPP(1:nzj,joint_name)
================================================================================
================================================================================

zgpp($J_S_Bogie_II__J_Bogie_Frame)
zgpp($J_S_Bogie_II__J_Bogie_Frame) == -6.4947233D-07
-6.4947233D-07 -1.7113615D-09
-1.7113615D-09 7.2216306D-07
7.2216306D-07 -9.3747062D-10
-9.3747062D-10 1.6621004D-10
1.6621004D-10 3.9063063D-07
3.9063063D-07
zgpp($J_S_Bogie_I__J_Bogie_Frame
zgpp($J_S_Bogie_I__J_Bogie_Frame )) == -6.4978020D-07
-6.4978020D-07 1.8447694D-09
1.8447694D-09 -4.3026497D-10
-4.3026497D-10 8.2260129D-10
8.2260129D-10 1.6709679D-10
1.6709679D-10 3.9011178D-07
3.9011178D-07
zgpp($J_Wagon
zgpp($J_Wagon )) == -7.3374536D-06
-7.3374536D-06 1.1689246D-10
1.1689246D-10 3.8505569D-06
3.8505569D-06 -9.3885937D-11
-9.3885937D-11 1.1722622D-07
1.1722622D-07 3.8159908D-05
3.8159908D-05
zgpp($J_WS4_dummy
zgpp($J_WS4_dummy )) == -2.1663677D-07
-2.1663677D-07 -6.5032494D-10
-6.5032494D-10 7.2816717D-22
7.2816717D-22 3.3011020D-11
3.3011020D-11 -1.3536010D-10
-1.3536010D-10 -6.0977707D-03
-6.0977707D-03

(49)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Linearisation, Eigenmode Analysis (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration

Track Definition Eigenmode Analysis
Body Definition
Joints Definition
Force Elements
Database
Nominal Forces
Linearisation

(50)
 SIMPACK TRAINING Wheel/Rail Basics

Linearisation, Eigenmode Analysis (2)

Linear Calculation Methods: Overview

Eigenmodes Frequency analysis Spectral analysis

4Root loci 4Guiding forces 4Guiding forces and
4critical parameters 4Accelerations accelerations:
statistical reaction to
4coupling mechanism statistically defined
excitations

Advantages Advantages Advantages

4very small computing 4small computing time 4small computing time
time 4analysis of the transfer 4realistic excitations
4view to the complete function performance
vehicle performance

Disadvantages Disadvantages Disadvantages

4no non-linear 4no non-linear 4no non-linear
dependencies dependencies dependencies

(51)
 SIMPACK TRAINING Wheel/Rail Basics

Linearisation, Eigenmode Analysis (3)

Equivalent Conicity λ

Plot of the wheelset‘s equivalent

conicities depending on the
linearization amplitude.
The equivalent conicity is related to
the cone angle βe of a double cone:
λ = tan(βe).

The „Klingel equation“:

re
L = 2π
2 tan β e Attention:
Attention: With
With wheel
wheel radii
radii
greater
greater than
than ~~ 550
550 mm,
mm, there
there is
is
indicates the wavelength of the no stable solution for
no stable solution for thethe
linearisation.
linearisation. This
This can
can lead
lead to
to
sinusoidal movement of a double
unsymmetrical
unsymmetrical plots,
plots, but
but the
the
cone on an ideal track. calculation will be correct!
calculation will be correct!

βe

(52)
 SIMPACK TRAINING Wheel/Rail Basics

Linearisation, Eigenmode Analysis (4)

Linearisation Methods in SIMPACK
Before
Before using
using linear
linear calculation
calculation
methods,
methods, the
the wheel/rail
wheel/rail contact
contact
Calculation of should be linearised.
should be linearised.
• equivalent conicity λ = tan(βe),
• roll angle parameter σ = ϕ/y ·e0,
• contact angle parameter ε = e0 ·Δβ/y

by means of
• Harmonic Linearisation (default method):
Minimisation of the mean square difference of the non-linear local
wheel radius function and the linear function λ·y to be approximated

• Equivalent Linearisation (according to Deutsche Bahn):

Determination of the wave period L of the wheelset with non-linear profiles,
leading to equivalent conicity λ. Calculation of σ and ε by Harmonic Linearisation.

• User-defined coefficients

(53)
 SIMPACK TRAINING Wheel/Rail Basics

Linearisation, Eigenmode Analysis (5)

Linearisation in SIMPACK
• Set a straight track
• Switch to linear contact geometry
• Choose harmonic linearisation
• Choose linearisation amplitude,
usually 3 mm

• Profiles are linearised; parameters

appear in echo area.

(54)
 SIMPACK TRAINING Wheel/Rail Basics

Linearisation, Eigenmode Analysis (6)

Calculation
• Copy all states to linearisation state
• Save the model and start eigenvalue
calculation
• Visualise eigenforms in model setup
(3D animation and State Plots)

Make
Make sure
sure that
that the
the residual
residual
accelerations
accelerations inin the
the model
model are
are
near zero!
near zero!

(55)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Time Integration and Plots (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration General Plots

Track Definition Eigenmode Analysis
Body Definition
Joints Definition
Force Elements
Database
Nominal Forces
Linearisation

(56)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Time Integration and Plots (2)

Offline Time Integration

• Configure time
integration
If necessary: stepsize
reduction for harsh
curve entries

Should be standard
for Wheel/Rail

• Start simulation
and measurements

(57)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Time Integration and Plots (3)

Useful Wheel/Rail Related Data

Wheelset lateral position in track y coordinate of track joint (07/09)

Wheelset yaw angle ψ coordinate of track joint
Output values of W/R friction force elements (type 89)

Creepage (longitudinal, lateral, spin) In contact coordinate system

Normal force N, traction forces Tx , Ty In contact coordinate system; towards wheel
Traction coefficients fx , fy = Tx/N, Ty/N
Wheel forces Y, Q In wheelset reference system; towards rail
Frictional power P For local contact point, wheel, wheelset, or vehicle
Contact point coordinates on wheel/on rail In wheel or rail profile reference system, along y
Longitudinal contact point shift axis
Semi-axes a, b of the Hertzian ellipse In wheel profile reference system, along x axis
Area of the Hertzian ellipse
Ratio of the semi-axes a/b
Current Kalker coefficients C11, C22, C23
...

(58)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Time Integration and Plots (4)

General Plot

• Open general 2D plot

• Define curves:
wheelsets’ and bogie’s lateral position,
wheelsets’ yaw angle,
wheel forces Y and Q for all four wheels,
contact point coordinates on wheels
and rail for the front wheelset,
frictional power for both front wheels

(59)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Basic Track Irregularities (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration General Plots

Track Definition Eigenmode Analysis
Body Definition
Joints Definition
Force Elements
Database
Nominal Forces
Linearisation
Track Irregularities

(60)
 SIMPACK TRAINING Wheel/Rail Basics

Basic Track Irregularities (2)

Types of Definitions

Stochastic User-defined Measured data

Generated from predefined
power spectrum Sinus excitation etc. Input from file
(ORE/ERRI)

Generated from user-

Input functions
defined power spectrum

Application to Track and Rails

Track-related Rail-related
uG

(61)
 SIMPACK TRAINING Wheel/Rail Basics

Basic Track Irregularities (3)

From PSD to excitations

• PSD = Power Spectral Density

• Power spectra describe the power distribution of a stochastic signal,
phase information is not included

• Transformation to distance domain by superposing many sine excitations

with amplitudes given by PSD
• Phases are set by a random generator

(62)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Basic Track Irregularities (4)

Create a PSD by Predefined Polynomial

Click on „Spectral Analysis“ and
• Defined in ORE B176 „Plot“ in order to visualise the
• Widely applicable for standard cases PSD

• PSD is approximated with a polynomial

Gauge
Gauge excitations
excitations are
are not
not pre-
pre-
defined. You may use the
defined. You may use the cross cross
level
level polynom
polynom for
for these,
these, too.
too.

Reference velocity is set

automatically by Vehicle Globals
(63)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Basic Track Irregularities (5)

Use the PSD for Excitation definition

• Select “Track-related” in the

track definition window

• Set a smoothing length for the

start

• Choose type 08 for vertical

excitation

(64)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Basic Track Irregularities (6)

Set Parameters

• ID 1..5 must be unique for each excitation

direction (random start value)
• If nfreq = fmax / fmin, the PSD is correctly
modelled, but the signal is periodic with a
rather small period.
If nfreq ≠ fmax / fmin, the signal is quasi-periodic,
but the PSD is not correct for low frequencies.
• Frequency dimension must be [1/m]
• Frequency grid should be aequidistant, otherwise
the PSD is not modelled correctly.

(65)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Ride Comfort (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration General Plots

Track Definition Eigenmode Analysis Ride Comfort
Body Definition
Joints Definition
Force Elements
Database
Nominal Forces
Linearisation
Track Irregularities

(66)
 SIMPACK TRAINING Wheel/Rail Basics

EXAMPLE: Ride Comfort (2)

• Start a new calculation with the defined
track irregularities
• Output vertical bogie
acceleration in
General 2D plot

• Apply Ride Index filter

“ISO vertical”

Be
Be careful
careful when
when handling
handling with with
PSDs,
PSDs, FFT
FFT etc.
etc. in
in frequency
frequency
domain.
domain. Double-check
Double-check all all results.
results.

(67)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration General Plots

Track Definition Eigenmode Analysis Ride Comfort
Body Definition
Joints Definition
Force Elements
Database
Nominal Forces
Linearisation
Track Irregularities
Profile Generation

(68)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (2)

Besides standard W/R profile

combinations like S1002/UIC60,
SIMPACK offers the possibility
Measured Profiles: to insert user defined profiles.
Wheel or Rail

For this reason the shown defi-

Preprocessor 1: nition cycle is used.
Profile Approximation

SIMPACK Profile: See also „How to Create Wheel-

Tab. Spline-Function
Rail Profiles for SIMPACK“.

r0,R0 Preprocessor 2:
Contact + Friction

SIMPACK Evalution Tables: SIMPACK

MBS Set Up Contact + Friction Calculation Modules

SIMPACK
r0,R0
MBS Data Base

(69)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (3)

The SIMPACK W/R profile generation can be divided into two major stages. First
the approximation of the W/R profile is carried out.

The SIMPACK Profile Approximation Preprocessor is located at

> SIMPACK PreProcess.
W/R Profile Approximation .
Profile type

Profile selection

Axis orientation of data

Scaling of data

Distance of knots

Profile extension

Tolerance of approximation

Plot selection

Save profile Perform profile approximation

(70)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (4)

The SIMPACK W/R Preprocessor expects the measured data of the wheel or rail profile being
defined in the shown data format. The data file with the measured profile data has to be saved
within the directory
SIMPACK_USER/SIMPACK.8xxx/run/dat/wheel_rail_profiles_measured/ .

two lines for comments

Number of lines with

measured data value pairs

Note: The maximum number of value pairs is limited to 600 !

The Y coordinate has to be increasing. Normally the
Y coordinate of measured data is given in the unit [mm]. For data in the
measured profile data unit [m] the scaling parameter within the W/R Preprocessor
has to be adapted.
Z coordinate of
measured profile data
(71)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (5)

Within the SIMPACK W/R Preprocessor it is assumed that the wheel and the rail profile is a
rightside profile (see picture below). The Y axis is always orientated to the right side of the profile.
In the default case SIMPACK set the Z axis upwards, but the switch of the axis orientation within
the SIMPACK W/R Preprocessor allows to offer measured data with downwards orientation of the
Z axis.
Wheel profile Rail profile
+Z

+Z

2 +Y +Y

1 2

( In opposite to the shown situation the Z axis can be orientated downwards.)

The range of the Y coordinate of the measured data depends on the selected contact model.
Normally, if no contact at the back of the wheel is expected, the shown area between the dotted
lines 1 and 2 will be suitable for the SIMPACK profile approximation. The vertical areas e. g. of the rail
profile are defined by the profile extensions within the SIMPACK W/R Preprocessor.

Note: Please avoid to define vertical profile areas within your measured data. These areas are often
responsible for problems of the profile approximation.

(72)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (6)

After every profile approximation check the profile‘s run, gradient and curvature within the
SIMPACK W/R Preprocessor!

If the profile approximation is carried out correctly, the generated SIMPACK profile should be saved in the directory
> SIMPACK_USER/SIMPACK.8xxx/run/dat/wheel_rail_profiles .

(73)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (7)

At the second stage of W/R profile generation the contact and friction tables suitable for the
selected contact model are created. This is done after selecting the favoured W/R profile
combination within the SIMPACK Vehicle Globals window and hitting the button „Apply as defaults“.

After generating the contact and friction tables please check these tables by the offered diagrams.
(74)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (8)

According to the chosen wheel/rail profile combination the so called *.pp file has to be adapted. The
*.pp file (OnePointContact.pp, MultiContact.pp, etc.) represents a list of parameters used for generating
the contact tables of the wheel/rail contact (see picture below).

All contact parameter files are located within the directory

> SIMPACK_user/SIMPACK.85xx./run/dat/wheel_rail_profiles/ .

** RIGID CONSTRAINT MESH PARAMETER

4 'SDEG'
0 0.0D0 0.0D0 'IROT, AROT, X1JUMP; IROT = 0 : COMPUTE ROTATION ANGLE'
-0.035D0 'SJUMP'
25 4 10 'NBAS1, NADD1, NBAS2' Essential parameters
0.1000 'WEIGHT-FLANGE'
for adaption of the
-0.030D0 0.0150D0 0.001D0 'YMIN, YMAX, DELY'
-3.000D0 3.000D0 0.200D0 'PHIMIN, PHIMAX, DELPHI' *.pp file are:
SJUMP
** GEOMETRICAL & FRICTIONAL MESH PARAMETER
Ymin, Ymax
2 'SDEG' SBOUND
0 0.0D0 0.0D0 'IROT, AROT, X1JUMP; IROT = 0 : COMPUTE ROTATION ANGLE'
-0.035D0 'SJUMP'
25 0 10 'NBAS1, NADD1, NBAS2'
1.0D0 'WEIGHT-FLANGE'
-0.030D0 0.0150D0 0.001D0 'YMIN, YMAX, DELY'
-3.000D0 3.000D0 0.200D0 'PHIMIN, PHIMAX, DELPHI'

** METHOD USED TO COMPUTE DATA FOR TABULATING

1 ' METHOD OF COMPUTING THE INPUT DATA FOR WHEEL_RAIL GEOMETRICAL FUNCTIONS'
' ( CONSTRAINT / CONTACT POINT / FRICTION PARAMETER )'
-0.0250D0 ' SBOUND : SEPARATION: FINE / COARESE GRID FOR WGEEL COORDINATE'
0.0002D0 ' DELS1 : INCREMENT OF FINE DISCRETIZATION IN VICINITY OF FLANGE'

(75)
 SIMPACK TRAINING Wheel/Rail Basics

Wheel/Rail Profile Generation (9)

SBound
SJump

The diagram Constraint Z shows the range The diagram Wheel Contact Coordinate
of the area between Ymin and Ymax. These helps to find suitable values for the para-
two parameters descibe the range of the meters Sjump and Sbound. Sjump describes
area around the change from the tread the point where the change between tread
to the flange. and flange takes place (Y coordinate does
not change very much, S coordinate chan-
In the shown case Ymin can be chosen with ges a lot). Sbound represents the begin of
a value of Ymin = -0.02 m, Ymax with a a fine discretization of the wheel profile within
value of Ymax = 0,02 m. the change from the tread to the flange.

In the shown case Sjump can be chosen with

a value of Sjump = -0.035 m, Sbound with a
value of Sbound = 0,025 m. (76)
 SIMPACK TRAINING Wheel/Rail Basics

Example: Root Loci (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration General Plots

Track Definition Eigenmode Analysis Ride Comfort
Body Definition Root Loci
Joints Definition
Force Elements
Database
Nominal Forces
Linearisation
Track Irregularities
Profile Generation

(77)
 SIMPACK TRAINING Wheel/Rail Basics

Root Loci (1)

• Real / imaginary plot

of the eigenvalues
damping > 0: instable!
• parameterised by
vehicle velocity
• shows if any
eigenvalues become
instable with increa-
sing velocity

y eh g
cit v in

e
icl
lo ith mp
• plus signs grow

v e s w da
with increasing

,
se de
eigenvalues independent

ea o
velocity

cr m
upon velocity

de y aw
• yaw mode shows
characteristic
behaviour

(78)
 SIMPACK TRAINING Wheel/Rail Basics

Root Loci (2)

Parameter Variation of Eigenmodes

• Open Parameter Variation

configuration window
• Select ParVar case “Root_loci”
• Set start and end velocity [km/h]

• No results need to be defined

• Perform Parameter Variation /
Eigenfrequency

(79)
 SIMPACK TRAINING Wheel/Rail Basics

Root Loci (3)

Parameter Variation of Eigenmodes

• Open Parameter Variation Plot

“Eigenfrequency”
• Adjust settings
• Click on “Plot”

(80)
 SIMPACK TRAINING Wheel/Rail Basics

Root Loci (4)

Parameter Variation of Eigenmodes

• Switch to “Min-Damping” representation

• Curve connects the
minimum damped
eigenvalues
• Curve crosses the
zero axis at
critical speed

Damping > 0: critical

speed at ca. 280 km/h

(81)
 SIMPACK TRAINING Wheel/Rail Basics

Example: Critical Speed (1)

Pre-Processing Processing Post-Processing

Body Database Offline Time Integration General Plots

Track Definition Eigenmode Analysis Ride Comfort
Body Definition Root Loci
Joints Definition Critical Speed
Force Elements
Database
Nominal Forces
Linearisation
Track Irregularities
Profile Generation

(82)
 SIMPACK TRAINING Wheel/Rail Basics

Critical Speed (2)

• Plot of critical speed

against conicity (or
other parameter)
• Determined with special
method: fast and accurate
• Automatic iteration of
critical speed
v

λ
(83)
 SIMPACK TRAINING Wheel/Rail Basics

Example: Critical Speed (3)

• Open ParVar configuration window

• Select ParVar case “Critical_Speed”
• Start and end velocity [km/h] need not
to be set here, only the type

• Second (middle) loop variates e.g.

equivalent conicity, σ and ε

(84)
 SIMPACK TRAINING Wheel/Rail Basics

Example: Critical Speed (4)

Parameter Variation of Critical Speed

• No results need to be defined

• Select “Generate Quasilinear Wheel-
Rail Profiles” in pre-calculations level 2

Every
Every time
time you
you select
select thethe linear
linear wheel-
wheel-
rail
rail profiles to be variated in any form
profiles to be variated in any form
(wheel
(wheel radius,
radius, linear
linear parameters
parameters
λ,
λ, σ,
σ, ε,
ε, ...):
...):
Use
Use the
the pre-calculation!
pre-calculation!
Otherwise
Otherwise the
the variation
variation does
does not
not work.
work.

(85)
 SIMPACK TRAINING Wheel/Rail Basics

Example: Critical Speed (5)

Parameter Variation of Critical Speed

• Set parameters of iteration method:

Initial value, increment, maximum and
precision in [km/h] (as selected in inner
loop configuration)

e iterates to critical speed

v with given precision
(inner loop - automatic iteration)

f next value of middle

loop: same procedure

and so on

If necessary, set „Linear method“

frequency range to is faster. Disable
d raises with increment until critical damping
be searched for if results seem
or maximum is reached
c initial value critical eigenvalue strange

λ (middle loop)
(86)
 SIMPACK TRAINING Wheel/Rail Basics

Example: Critical Speed (6)

Parameter Variation of Critical Speed

• Open Parameter Variation Plot

“Critical Parameter”
• Click on “Plot”
• Other representations
are only available if
there are a middle and
also an outer loop

(87)
 SIMPACK TRAINING Wheel/Rail Basics

Extra: Independent Wheels

• Three bodies: Axle bridge,

left wheel, right wheel
• Axle bridge: joint type 07
• Wheels: joint type 02 (essential)
• Wheel/Rail Elements located
on wheel bodies
• Wheel bodies’ reference
frames situated in the
track middle, like the

Right wheel
02 02

Left wheel
reference frame of the
Axle bridge
axle bridge

W/R Elements
07, 6 DOF,
Primary
Suspension
Attention:
Attention: Make
Make sure
sure to
to
•• set
set the
the wheels‘
wheels‘ centers
centers of
of
gravity to the true position
gravity to the true y position
y Bogie frame
of
of the
the wheel
wheel bodies,
bodies, and
and
07, 6 DOF

Constraint
Constraint

•• relate
relate the
the inertia
inertia tensors
tensors to
to the
the
centers
centers of
of gravity!
gravity!

R
L

(88)