Research on the strain gauge mounting scheme of track wheel force measurement system based on high-speed wheel/rail relationship test rig

PurposeThis paper aims to analyze the stress and strain distribution on the track wheel web surface and study the optimal strain gauge location for force measurement system of the track wheel.Design/methodology/approachFinite element method was employed to analyze the stress and strain distribution on the track wheel web surface under varying wheel-rail forces. Locations with minimal coupling interference between vertical and lateral forces were identified as suitable for strain gauge installation.FindingsThe results show that due to the track wheel web’s unique curved shape and wheel-rail force loading mechanism, both tensile and compressive states exit on the surface of the web. When vertical force is applied, Mises stress and strain are relatively high near the inner radius of 710 mm and the outer radius of 1110 mm of the web. Under lateral force, high Mises stress and strain are observed near the radius of 670 mm on the inner and outer sides of the web. As the wheel-rail force application point shifts laterally toward the outer side, the Mises stress and strain near the inner radius of 710 mm of the web gradually decrease under vertical force while gradually increasing near the outer radius of 1110 mm of the web. Under lateral force, the Mises stress and strain on the surface of the web remain relatively unchanged regardless of the wheel-rail force application point. Based on the analysis of stress and strain on the surface of the web under different wheel-rail forces, the inner radius of 870 mm is recommended as the optimal mounting location of strain gauges for measuring vertical force, while the inner radius of 1143 mm is suitable for measuring lateral force.Originality/valueThe research findings provide valuable insights for determining optimal strain gauge locations and designing an effective track wheel force measurement system.