Analysis of the mechanism of corrugation based on the scale test model

In order to explore the formation mechanism of corrugation in railway systems, the corrugation phenomenon is analyzed in detail from points of view of micro contact and material wear using the self-designed scale twin discs test rig. The results show that the longitudinal creep force is not a sufficient condition for corrugation formation, and the transverse creep force is indeed an important condition. Considering the scale factor (1:4) of the test model, it can be obtained that the passing frequency of corrugation on the rail wheel surface of 1700.78 Hz corresponds to the passing frequency of corrugation in the actual system of 425.20 Hz. Due to the frequency-fixed characteristic of corrugation, the above frequency is consistent with the line measurement results in the relevant literatures. The stick-slip analysis shows that the transverse slip of 0.0084∼0.3437 mm is greater than the longitudinal one of 0.0003∼0.1205 mm in the contact area. Combining experimental tests with the numerical analysis, it can be concluded that the theoretical mechanism of corrugation formation is that under the condition of transverse creep force saturation, the unstable vibration at a specific frequency causes the wear to have the frequency-fixed characteristic and eventually form corrugation, and the transverse wear has a greater influence on the evolution of corrugation.