Development and Verification of a FEM Model of Wheel–Rail Contact, Suitable for Large Parametric Analysis of Independent Guided Wheels

• Published in: Vehicles Vol. 7; no. 3; p. 104
• Main Authors: García-Troya, Manuel, Sánchez-Lozano, Miguel, Abellán-López, David
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.09.2025
• Subjects: Accuracy; Boundary conditions; Boundary element method; Camber; Contact pressure; Contact stresses; Convergence; Deformation; Dynamic loads; Elastoplasticity; Finite element method; Friction; Half spaces; independent guided wheels; Load; Microslip; Parameterization; Parametric analysis; Preconditioning; Robustness (mathematics); rolling contact; Root-mean-square errors; Shear stress; Simulation; Software; wear optimization; Wheels; wheel–rail contact
• ISSN: 2624-8921; 2624-8921
• DOI: 10.3390/vehicles7030104

A quasi-static FEM framework for wheel–rail contact is presented, aimed at large parametric analyses including independently rotating wheel (IRW) configurations. Unlike half-space formulations such as CONTACT, the FEM approach resolves global deformations and strongly non-Hertzian geometries while remaining computationally tractable through three key features: (i) a tailored mesh transition around the contact patch, (ii) solver settings optimized for frictional contact convergence, and (iii) an integrated post-processing pipeline for creep forces, micro-slip, and wear. The model is verified against CONTACT, an established surface-discretization reference based on the Boundary Element Method (BEM), demonstrating close agreement in contact pressure, shear stress, and stick–slip patterns across the Manchester Contact Benchmark cases. Accuracy is quantified using error metrics (MAE, RMSE), with discrepancies analyzed in high-yaw, near-flange conditions. Compared with prior FEM-based contact models, the main contributions are: (i) a rigid–flexible domain partition, which reduces 3D computational cost without compromising local contact accuracy; (ii) a frictionless preconditioning step followed by friction restoration, eliminating artificial shear-induced deformation at first contact and accelerating convergence; (iii) an automated selection of the elastic slip tolerance (slto) based on frictional-energy consistency, ensuring numerical robustness; and (iv) an IRW-oriented parametrization of toe angle, camber, and wheel spacing. The proposed framework provides a robust basis for large-scale studies and can be extended to transient or elastoplastic analyses relevant to dynamic loading, curved tracks, and wheel defects.