1. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 1 Noise Reduction in the Wheel/Rail-System by Application of Rail Head Treatment Products Updated version of the paper presented on behalf of the 4th Rail Vehicle Conference, Dresden, Germany, 18.-20. October 2000 Dipl.-Ing. Harald Willrich FUCHS LUBRITECH GmbH, D-67685 Weilerbach Tramway-Seminar Tours, France, 18.-19. November 2002

2. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 2 Noise Reduction in the Wheel/Rail-System by Application of Rail Head Treatment Products Content:  Problem  Reasons  Solution  Products  Application  Consumption quantities  Results  Conclusions

3. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 3 Problem:  „Wheel Squeal“ when travelling through curves  Disturbing noises with high frequencies  Molestion of people living near the track  high costs for noise preventing measures  additionally: wear on wheels and rails  Keyword: corrugation  costs for maintenance of vehicles and track

4. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 4 Reason:  different distances for inner and outer wheel when travelling through narrow curves, which cannot be egalized by the different rolling radii  distorsion of the axles  differential longitudinal creep forces  Stick-slip-Effects, normally on the low rail  also lateral creep forces

5. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 5 Solution:  steered wheel sets: better adaptation of the bogie axles to the curve radius  disadvantage: high costs, reduces only wheel flange wear  Single wheel suspension: nearly no longitudinal creep forces, but higher lateral creep forces

6. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 6 Solution:  Noises are produced in the Wheel/rail contact area  Countermeasures have to be set exactly there  Rail Head Treatment with appropriate products  Braking and Traction forces have to be maintained  Transmission of electric signals must not be influenced

7. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 7 Products: TRAM-SILENCETRAM-SILENCE 00 Base oil:nativesynthetic Thickener:Ca-soapinorganic Solids: Metal powder, Graphite Properties: - biodegradable - very adhesive - extremly pressure resistant - wide temperature range - easy to apply - constant friction coefficient - wear reducing - good corrosion protection - water resistant

8. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 8 Sprayability of TRAM-SILENCE 00:

9. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 9 Sprayability of TRAM-SILENCE 00: +20°C 0°C -10°C -20°C -15°C System: Beka Fluilub System: Rebs

10. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 10 Friction coefficients: Tannert-test: no Stick-slip, constant level of friction after running-in friction value 0,085 resp. 0,143 Almen-Wieland-test: Scuffing load > 18 kN friction value 0,144 resp. 0,140 SRV-test: constant friction level friction level 0,124 resp. 0,138

11. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 11 Friction coefficients: Tannert-test TRAM-SILENCE TRAM-SILENCE 00

12. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 12 Consumption quantities:  As much as necessary, as few as possible  manual application: „depending on local conditions“, Spots of lubricant in a distance of 1-2 m, beginning 10-20 m before the curve starts

13. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 13 Consumption quantities:  Track-side systems: Qunatity is normally determined by the lubricator, appr. 1 g per cycle, split on several outlets, controlling by activation of the lubricator  On-board systems: depending on local conditions quantities between 10 and 100 mg per meter of track

14. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 14 Consumption quantities  Depending on local conditions, for examples curve radius, condition of wheel and rail, weather etc.  Braking behaviour, traction and train detection must not be influenced  No risk for individual traffic crossing the track

15. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 15 Results When applied properly, all requirements are fulfilled:  Braking distance is not increased  Traction is maintained  Signalling is not affected  No influence on isolating joints  Wheel squeal is dramatically reduced  wear is reduced  Individual traffic is not endangered

16. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 16 Results Excerpt from an test report of Dutch Railway NS about TRAM-SILENCE: “In the quantities tested in this examination (0,04 g/m und 0,1 g/m) the product is safe. Braking behaviour is not worse than on wet rails and detection behaviour is ok. The noise reducing effect could be proved. With the used WOERNER- lubricator the product could be applied reproducable.” Amsterdam 1998

17. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 17 Results Excerpt from an test report of Hamburger Hochbahn AG (Metro Hamburg) about TRAM-SILENCE: “When using TRAM-SILENCE as a top-of-the-rail wetting agent and observing certain boundary conditions, the braking distances do not exceed the limit values according to BOStrab (German Tramway Guidelines).“ Hamburg, 2000

18. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 18 Results Remarkable reduction of squealing noise

19. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 19 Conclusion  Application will be done more and more by means of automatic lubricators.  In the meantime a number of appropriate lubricators are available.  Selection of the most suitable system depends on local conditions.  Optimum consumption rates have to be found by field tests.  Further investigation on the corrugation problem  Wheel-squeal should no longer be a problem!

20. FUCHS LUBRITECH GMBH Tram-Seminar, Tours, 18.-19.11.2002 / 20 Thank you very much for your attention www.fuchs-lubritech.de