Rail grinding has been widely applied in railway networks worldwide to remove or prevent rolling contact fatigue (RCF) cracks. However, some concerns have arisen regarding grinding, that it may introduce initial damage to the rail and largely shorten the RCF life. This work aims to better understand the effect of grinding on the long-term degradation of in-service rails, particularly concerning White Etching Layer (WEL) and RCF cracks. Seven rail samples were selected and taken from the Belgian and Swedish railway networks, with different grinding histories, accumulated loads, and steel grades. The mechanical and microstructural properties of these samples were examined through the hardness test and optical microscopy. WEL and microcracks were observed in both ground and non-ground rails, suggesting that rail grinding does not create additional defects nor negatively impact the rail surface after long-term service. Macrocracks were observed only in rail samples that had undergone zero or a single grinding cycle, confirming the beneficial role of rail grinding in mitigating RCF cracks. Ratcheting is the dominant crack initiation mechanism under the examined conditions, while WEL may also contribute to crack formation, given that macrocracks predominantly occur at the transition between the WEL and the pearlite.

Frictional heat is generated at the wheel-rail interface during train operations, particularly under high slip ratios during acceleration and braking. Thermal effects can accelerate wear, induce plastic deformation, and contribute to thermal fatigue. Reliable modelling of wheel-rail contact that considers friction-induced thermal effects is desirable for the accurate prediction of wheel-rail interface deterioration. Several analytical and numerical models have been proposed to simulate thermal or thermomechanical wheel-rail loads but have rarely been validated, especially in high slip ratio scenarios where flash temperatures exceed 200 °C. This study develops and experimentally validates a three-dimensional thermomechanical finite element (FE) wheel-rail contact model for high slip ratio conditions, with contact temperatures reaching 360 °C. The model incorporates key mechanical parameters, including wheel loads, coefficients of friction, and slip ratios. Simulated rail surface temperatures across various slip ratios (5 %, 10 %, and 15 %) are compared with the flash temperatures measured with an onboard infrared thermal camera, showing good agreement with a maximum deviation of 9.9 %. This confirms the reliability of the model for simulating wheel-rail contact under thermal effects.

This paper investigates the growth and treatment of a major type of rail rolling contact fatigue (RCF) known as head checks (HCs). The analysis is based on extensive field data of 212 curved tracks made of R260 steel across the entire Belgian railway network. The HC crack depth was mainly measured by eddy current testing. The growth rates of HCs are analysed in relation to the curve radius, annual traffic load, and rail wear. The key findings are as follows: 1) Tracks with radii between 750 and 1000 m exhibit the highest HC growth rate of about 1.5 mm per 100 million gross tons (MGT) and the largest occurrence probability of about 25 %. 2) A counterintuitive result is that the HC growth per MGT is higher on lines with lower annual traffic loads, consistent with the trend observed in rail wear rates. 3) The artificial wear methods to control RCF, such as preventive grinding, should consider annual traffic load and service time, rather than solely accumulated tonnage, as is the current practice. Based on these findings, a new method is proposed to estimate the magic wear rate for the Belgian railways, which can serve as input for optimising grinding operations to mitigate HCs.

The conventional vertical track quality index (TQI) based on the standard deviation of longitudinal levels yields standardized railway track condition assessment. Nevertheless, its capability to identify problems is limited, particularly in the ballast and substructure layers when abrupt changes affect train-track interaction. Previous research shows that dynamic responses from moving trains via axle box acceleration (ABA) measurements can quantify abrupt changes in the vertical dynamic responses. Thus, this paper proposes a framework to design an enhanced vertical TQI, called EnVTQI, by integrating track longitudinal levels and dynamic responses from ABA measurements. First, measured ABA signals are processed to mitigate the influence of variation in measurement speed. Then, substructure and ballast-related features are extracted, including scale average wavelet power (SAWP) in the ranges 0.04 m^-1 to 0.33 m^-1 (substructure) and 1.25 m^-1 to 2.50 m^-1 (ballast). This enables identifying track conditions at different track layers. Finally, EnVTQI is determined by weight averaging between the conventional vertical TQI and the ABA features from moving trains. The performance of EnVTQI is evaluated based on 48 segments of a 200-m track on a Dutch railway line. The results indicate that EnVTQI helps to distinguish track segments that cause poor train-track interaction, which the conventional TQI does not indicate. EnVTQI can supplement the conventional TQI, improving the effectiveness of track maintenance decision-making.

This article develops and tests a self-contained railway track monitoring system that fits in existing vehicles without the need for speed and load control. Combining a train-borne laser Doppler vibrometer and axle box accelerometers enables synchronized measurements of train-track response under operational conditions. Utilizing a GPS antenna and video camera, we propose the multisignal processing method to obtain train-track vibrations with train position and speed. Then, we fuse the multiple signals to extract an impact index and a resonance index and further propose an interpretable anomaly detection strategy. We test the system on an operational line at 20-60 km/h under different working conditions and verify the detection results using information from conventional technologies. The impact index peaks near joints and welds, and the resonance index yields a good correlation with the measured track geometry. The developed solution achieves the detection, localization, and quantification of surface and support anomalies in railway tracks.

Computer-aided simulations are routinely used to predict a prototype's performance. High-fidelity physics-based simulators might be computationally expensive for design and optimization, spurring the development of cheap deep-learning surrogates. The resulting surrogates often struggle to generalize and predict novel scenarios beyond their training domain. We propose a two-stage methodology addressing the challenge of generalization. It employs physics-based simulators, supplemented with ordinary differential equations integrated into the recurrent architecture, to learn the intrinsic dynamics. The proposed approach captures the inherent causality and generalizes the dynamics irrespective of a data source. The presented numerical experiments encompass five fundamental structural engineering scenarios, including beams on Winkler foundations based on Euler-Bernoulli and Timoshenko theories, beams under moving loads, and catenary-pantograph interactions in railways. The proposed methodology outperforms conventional recurrent methods and remains invariant to data sources, showcasing its efficacy. Numerical experiments highlight its prospects for design optimization, predictive maintenance, and enhancing safety measures.

Wheel-rail high-frequency interaction is closely related to the formation of railway short-wave defects. Finite element (FE) method has been widely used to simulate wheel-rail dynamic systems, but its validity in modelling high-frequency interaction has not been fully demonstrated in three dimensions (3D). This work aims at comprehensively validating the 3D FE modelling of wheel-rail high-frequency interaction using a downscale V-Track test rig. First, the FE model of the V-Track is developed that comprehensively includes the 3D track elasticity. The simulated track dynamic behaviours are validated against hammer tests, and the major vibration modes are analyzed employing modal analysis. Afterwards, the simulate wheel-rail dynamic responses are comprehensively compared with measurement results up to 10 kHz. Their characteristic frequencies are identified and correlated to the eigenmodes of the vehicle-track system. The results indicate that the proposed 3D FE model is capable of comprehensively and accurately simulating the 3D track dynamics and wheel-rail dynamic interaction of the V-Track up to 10 kHz. Rail vibrations dominate the wheel-rail dynamic contact within 10 kHz, while the wheel vibrations play an increasingly important role at higher frequencies and become decisive near the wheel eigenmode frequencies. The V-Track overall achieves dynamic similarity to the real vehicle-track system.

Polygonal wear is a type of damage commonly observed on the railway wheel tread. It induces wheel-rail impacts and consequent train/track components failure. This study presents a finite element (FE) thermomechanical wheel-rail contact model, which is able to cope with the three possible generation and development mechanisms of polygonal wear: initial defects, thermal effect, and structural dynamics. The polygonal wear-induced impact contact and further development of wear are simulated. The simulated elastic contact solutions are verified against the program CONTACT. Different material properties (elastic, elasto-plastic and elasto-plastic-thermo, i.e. with thermal softening) and initial polygonal profiles are then applied to the FE model to investigate the influence of wheel/rail material and wear amplitude on wheel-rail contact stress and wear development. The simulations indicate that the wheel-rail impact-induced temperature may reach up to 362 ℃ at the contact interface, and the high temperature at the contact area influences wheel-rail contact stress and wear depth.

This paper presents a new approach to simulate forward and inverse problems of moving loads using physics-informed machine learning (PIML). Physics-informed neural networks (PINNs) utilize the underlying physics of moving load problems and aim to predict the deflection of beams and the magnitude of the loads. The mathematical representation of the moving load considered involves a Dirac delta function, to capture the effect of the load moving across the structure. Approximating the Dirac delta function with PINNs is challenging because of its instantaneous change of output at a single point, causing difficulty in the convergence of the loss function. We propose to approximate the Dirac delta function with a Gaussian function. The incorporated Gaussian function physical equations are used in the physics-informed neural architecture to simulate beam deflections and to predict the magnitude of the load. Numerical results show that PIML is an effective method for simulating the forward and inverse problems for the considered model of a moving load.

This paper proposes a novel framework for simulating the dynamics of beams on elastic foundations. Specifically, partial differential equations modeling Euler–Bernoulli and Timoshenko beams on the Winkler foundation are simulated using a causal physics-informed neural network (PINN) coupled with transfer learning. Conventional PINNs encounter challenges in handling large space–time domains, even for problems with closed-form analytical solutions. A causality-respecting PINN loss function is employed to overcome this limitation, effectively capturing the underlying physics. However, it is observed that the causality-respecting PINN lacks generalizability. We propose using solutions to similar problems instead of training from scratch by employing transfer learning while adhering to causality to accelerate convergence and ensure accurate results across diverse scenarios. The primary contribution of this paper lies in introducing a causality-respecting PINN loss function in the context of structural engineering and coupling it with transfer learning to enhance the generalizability of PINNs in simulating the dynamics of beams on elastic foundations. Numerical experiments on the Euler–Bernoulli beam highlight the efficacy of the proposed approach for various initial conditions, including those with noise in the initial data. Furthermore, the potential of the proposed method is demonstrated for the Timoshenko beam in an extended spatial and temporal domain. Several comparisons suggest that the proposed method accurately captures the inherent dynamics, outperforming the state-of-the-art physics-informed methods under standard L²-norm metric and accelerating convergence.

A primary challenge of physics-informed machine learning (PIML) is its generalization beyond the training domain, especially when dealing with complex physical problems represented by partial differential equations (PDEs). This paper aims to enhance the generalization capabilities of PIML, facilitating practical, real-world applications where accurate predictions in unexplored regions are crucial. We leverage the inherent causality and temporal sequential characteristics of PDE solutions to fuse PIML models with recurrent neural architectures based on systems of ordinary differential equations, referred to as neural oscillators. Through effectively capturing long-time dependencies and mitigating the exploding and vanishing gradient problem, neural oscillators foster improved generalization in PIML tasks. Extensive experimentation involving time-dependent nonlinear PDEs and biharmonic beam equations demonstrates the efficacy of the proposed approach. Incorporating neural oscillators outperforms existing state-of-the-art methods on benchmark problems across various metrics. Consequently, the proposed method improves the generalization capabilities of PIML, providing accurate solutions for extrapolation and prediction beyond the training data.

Short pitch corrugation has been a problem for railways worldwide over one century. In this paper, a parametric investigation of fastenings is conducted to understand the corrugation formation mechanism and gain insights into corrugation mitigation. A three-dimensional finite element vehicle–track dynamic interaction model is employed, which considers the coupling between the structural dynamics and the contact mechanics, while the damage mechanism is assumed to be differential wear. Various fastening models with different configurations, boundary conditions, and parameters of stiffness and damping are built up and analysed. These models may represent different service stages of fastenings in the field. Besides, the effect of train speeds on corrugation features is studied. The results indicate: (1) Fastening parameters and modelling play an important role in corrugation formation. (2) The fastening longitudinal constraint to the rail is the major factor that determines the corrugation formation. The fastening vertical and lateral constraints influence corrugation features in terms of spatial distribution and wavelength components. (3) The strengthening of fastening constraints in the longitudinal dimension helps to mitigate corrugation. Meanwhile, the inner fastening constraint in the lateral direction is necessary for corrugation alleviation. (4) The increase in fastening longitudinal stiffness and damping can reduce the vibration amplitudes of longitudinal compression modes and thus reduce the track corrugation propensity. The simulation in this work can well explain the field corrugation in terms of the occurrence possibility and major wavelength components. It can also explain the field data with respect to the small variation between the corrugation wavelength and train speed, which is caused by frequency selection and jump between rail longitudinal compression modes.