Dynamic response of axle box bearing for high-speed train considering wheelset flexibility and polygonal wear

In this study, a flexible wheelset was added to a rigid-flexible coupled vehicle dynamics model, in which the axle box bearings are accurately modeled. The measured wheel's polygon wear profile and Wuhan-Guangzhou track spectrum are used in the model to define the wheel tread and track irregularity, respectively. We conducted a field test on the Wuhan-Guangzhou railway line to validate the model. Then, we investigate how the dynamic properties of the axle box bearing are impacted by the wheelset flexibility and polygonal wear of wheel. We found that the polygonal wheel with a rigid wheelset causes high-frequency vibration in wheelset and axle box, and increases the axle box bearing's internal contact force. Additionally, the flexible wheelset with a normal wheel tread can alleviate the wheel/rail impact and reduce the axle box's vertical vibration as well as the axle box bearing's internal contact force. When the vehicle is running at v = 300 km/h, the excitation frequency caused by the wheel's 20th-order polygon is 576.5 Hz, and the flexible wheelset's 20th-order modal frequency is 577 Hz. The two frequencies are similar, when considering the polygonal wheel and flexible wheelset simultaneously, the wheelset will resonate. And the resonate of wheelset will increase the local deformation of the axle end and deteriorate the bearing operating environment, causing a significant increase in the bearing contact force. Finally, the axle box bearing's dynamic characteristics are summarized when vehicle velocity varies from 50 to 350 km/h and wheel polygon wear amplitude ranges from 0.01 to 0.05 mm.