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The wheel-rail rolling contact finite element model has been generally considered to be a better choice for solving the high-frequency wheel-rail responses and local stress/strain states, compared to the traditional multi-body dynamics model. However, some thorny issues in the wheel-rail finite element analysis need to be solved or avoided, such as difficulties in geometry modelling especially for describing those multiple irregular wheel tread defects, possible computation termination by mesh distortion, and the balance between the computational efficiency and accuracy. Thus, an innovative computational method was proposed in this study, to transform the geometric irregularities induced by wheel out-of-roundness (wheel flat, tread spalling and wheel polygonization) to the randomly irregular displacement excitation of the wheel-rail contact, where the randomisation of the size, shape and distribution of wheel tread defects were considered. Based on geometrical relationships of the wheel-rail contact, the formulas of the wheel-rail contact displacement irregularity caused by various wheel tread defects, which was equivalent to the corresponding wheel-rail geometrical irregularity, were derived. And then the randomly irregular wheel-rail displacement satisfied to several various random distribution functions were generated by pseudo-random number sequence. Finally, the proposed method is demonstrated to facilitate applications of the explicit wheel-rail contact finite element model.

A mathematically-based study of the random wheel-rail contact irregularity by wheel out-of-roundness