Multidimensional Wear Evolution Characteristics of Rail Corrugation in Long Steep-grade Section

CUI Xiaolu; HUANG Jun; WANG Shiqi; ZHONG Yanming; LINGHU Jun; ZHONG Jianke; DONG Ruixi

doi:10.16490/j.cnki.issn.1001-3660.2026.13.014

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Surface Technology ›› 2026, Vol. 55 ›› Issue (13) : 160-172. DOI: 10.16490/j.cnki.issn.1001-3660.2026.13.014

Friction, Wear and Lubrication

Multidimensional Wear Evolution Characteristics of Rail Corrugation in Long Steep-grade Section

CUI Xiaolu^1,*, HUANG Jun¹, WANG Shiqi¹, ZHONG Yanming¹, LINGHU Jun², ZHONG Jianke², DONG Ruixi²

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Abstract

The long steep-grade section is a high-incidence area for rail corrugation in mountainous city metros, where the unique topographic conditions lead to more complex wheel-rail interaction and more severe rail wear issues that have long plagued the safe and stable operation of metro systems. With the typical corrugation-prone section of Chongqing Metro Line 10, a representative mountainous city metro line, as the research object, this study comprehensively explores the wear evolution characteristics of rail corrugation in long steep-grade sections through a combination of in-depth field investigations and numerical simulation methods. Firstly, a systematic and long-term field investigation is carried out on the target section; during the investigation, rail corrugation samples are collected at different operation periods to cover the entire wear process, and advanced high-precision measurement technologies are used to continuously detect key parameters including length, width, depth and phase. Based on the rigorous statistical analysis of a large volume of measured data, the basic rules of rail corrugation evolution in multiple dimensions are initially clarified, laying a solid data foundation for the subsequent numerical simulation and mechanism analysis. Then, fully considering the special dynamic characteristics of wheel-rail contact in steep-grade sections, a transient analysis finite element model of wheel-rail contact is established, which accurately integrates the actual line parameters and vehicle dynamic parameters of Chongqing Metro Line 10. Meanwhile, a rail wear calculation model is developed, which can realize the accurate quantitative calculation of wear amount under different operation conditions. Finally, based on the friction-coupled vibration theory, the dynamic vibration response of the wheel-rail system in the steep-grade section is thoroughly analyzed, and the distribution and transmission law of vibration energy in the rail structure are clearly revealed. Combined with the friction work theory, the intrinsic correlation between friction work and wear amount is deeply explored, and the multi-dimensional evolution characteristics of rail corrugation are comprehensively analyzed from both vibration response and wear characteristics perspectives. Results show that the wear evolution of rail corrugation in the long steep-grade section presents a multi-dimensional changing trend: within one month, the length exhibits a significant trend of extending toward both ends, with an extension amplitude of nearly twice, the width displays a gradual expansion trend with an expansion amplitude of 13.6%. The depth shows a significant increasing trend, with an increase amplitude of 100% and the phase exhibits a trend of slow offset, with a total offset of 1.95 mm. In conclusion, the extension of rail corrugation length is mainly caused by the propagation of wheel-rail vibration energy along the rail longitudinal direction; the expansion of corrugation width is mainly attributed to the increase of wheel-rail lateral slip amplitude under the combined influence of slope and curve. The deepening of corrugation depth is the direct result of the amplification of local vibration energy at the corrugation position. The phase offset is mainly induced by the uneven distribution of frictional shear stress between the front and rear of the corrugation peak. This study not only deeply reveals the intrinsic wear evolution mechanism of rail corrugation in long steep-grade sections, but also provides a scientific theoretical basis and reliable technical support for the formulation of targeted and efficient maintenance strategies for mountainous city metros, which is of great practical significance for improving operation safety, reducing maintenance costs and promoting the sustainable development of metro systems.

Key words

rail corrugation / multidimensional wear / wear evolution / evolution characteristics / friction-coupling vibration / long steep-grade

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CUI Xiaolu, HUANG Jun, WANG Shiqi, ZHONG Yanming, LINGHU Jun, ZHONG Jianke, DONG Ruixi. Multidimensional Wear Evolution Characteristics of Rail Corrugation in Long Steep-grade Section[J]. Surface Technology. 2026, 55(13): 160-172

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Funding

The National Natural Science Foundation of China General Program (52575202, 52275176); Chongqing Outstanding Youth Science Fund Project (CSTB2025NSCQ-JQX0026)