1. The University of Sheffield and LBFoster Driving Innovation in Track Components and Friction Management Dr Roger Lewis Department of Mechanical Engineering

2. Some Current Railway Engineering Projects Overhead Line Wear (Network Rail) Rail Joint Innovation (LBFoster) Traction Gels (LBFoster) Top of Rail FMs & Adhesion Measurement (LBFoster ) Wheel Wear Prediction (Alstom) TGamma vs wear, Wear Transitions and Mapping (RSSB, KTH) Wheel/Rail Contact Measurement Wheel/ Rail Isolation (LU, LBFoster) Rail Grinding (Network Rail)

3. 25/08/2014© The University of Sheffield LBFoster Rail Products Bonded insulated joints Friction management Wayside data collection Direct fixation fasteners Railcar products Power rail systems Coverboards Track components Sheffield

4. How we work together 25/08/2014© The University of Sheffield ConsultancyShort term projectsFriction management – test development and new product benchmarking ResearchPhDWheel/rail contact – effect of third-body materials Knowledge Transfer Knowledge Transfer Partnership (KTP) (www.ktponline.org.uk) IBJ innovation Commercial Testing Short term projectsTrack components Today’s focus

5. 25/08/2014© The University of Sheffield Insulated joints: Areas of interest Shear strength of epoxy glue layer Effect of decarburisation on fishplates Endpost lipping problem Fatigue performance of whole joint Condition Monitoring

6. 25/08/2014© The University of Sheffield Fishplate Decarburisation Decarburisation could affect the fatigue properties and weaken the fishplate Testing will cyclically load steel fishplates with varying amounts of surface decarburisation Effects of decarburisation on fishplates will be determined and methods for enhancing fatigue performance Test Base Fishplate Support Blocks Cyclic Load Decarb layer in steel fishplates

7. 25/08/2014© The University of Sheffield Endpost Lipping Plastic deformation of the rail over the endpost causes electrical insulation failure Twin-disc testing has attempted to model this behaviour Testing will lead to understanding of this type of failure and the creation of techniques to reduce the problem and premature failure

8. 25/08/2014© The University of Sheffield Glued joint shear testing A test to establish the difference in properties between various glues and insulating liner materials Glued insulated joints are sectioned and the rail is pushed through the joint Aim to introduce new and improved insulating materials to the market with better shear properties Test Base Joint Section Sheared Fishplate Load Cell

9. 25/08/2014© The University of Sheffield Full-scale IBJ testing Standard and bespoke fatigue test apparatus currently used to conduct standard tests to verify joint performance (aim to not fail) Aim now is to develop full life cycle testing (by changing the support set-up and the loads applied to the insulated joint) This test can then be used to assess impact on life of design and material changes

10. 25/08/2014© The University of Sheffield Condition Monitoring Development of an ultrasonic based system to monitor key interfaces underway Technique proven on simple bolted interfaces Transducers Mounted on Under-side Cyclic Loading

11. Friction Management Extensive adhesion tests carried out with and without contaminants (oil, water, leaves etc.) Traction gels for adhesion enhancement (leaf layers generated in twin disc tests and gels applied) Top of rail FMs (noise and vibration mitigation) Effect of stick lubricants on wheel/rail isolation Third-body layers and oxides Adhesion measurement 25/08/2014© The University of Sheffield

12. Benefits of the collaboration Access to University expertise and test facilities Gearing for R&D projects – either through University or external sources Short term problem solving Long term approach possible 25/08/2014© The University of Sheffield