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Solving the wheel-turnout contact geometry is complex because the rail section is varying along its longitudinal position. Besides, a large yaw angle will occur, especially when the vehicle passes the switch panel in a diverging route. However, previous researches seldom considered the aforementioned factors simultaneously in performing wheel–rail local contact analysis. This paper therefore proposes a novel three-dimensional (3D) contact geometry method considering the combined effects of varying rail profiles and the yaw angle. This study uses S1002CN wheels and the switch panel of a 1:12 turnout as research objects to study the contact geometry, normal and tangential contact solution. The results indicate that the combined influences of rail profiles varying within the contact patch and the yaw angle on the contact solution are significant. The variable rail profiles obviously affect the position of the contact point. With a yaw angle, the normal gap, contact patch shape and stress distribution calculated by the novel 3D contact geometry method are asymmetric along the lateral and longitudinal directions, especially when the wheel flange contacts with a rail gauge corner. The proposed method can improve the accuracy of the wheel–rail contact solution and help predict rail damage in switch panels.

A novel three-dimensional wheel–rail contact geometry method in the switch panel considering variable cross-sections and yaw angle