Design of monoblock crossing for heavy operating conditions

Introduction. The authors analyse the influence of the design features of crossings with a solid core unit with wing rails and welded rail ends (monoblock crossing) on the occurrence of hazardous failures associated with design flaws. Stress distribution to ensure uniform stiffness and avoid dangerous failures while ensuring product manufacturability is an important issue in cross design. This is achieved by rationalising the casting's longitudinal force element.

Materials and methods. A computer simulation using ANSYS finite element analysis is used to determine the influence of the location of the force element in a monoblock crossing design on the fatigue safety factor. Operational tests of the prototype crossings were carried out on the second main track of the Experimental Loop of Railway Research Institute and at the Isilkul station of the West Siberian Railway.

Results. The influence of the geometry of the longitudinal rib of the crossing and its location on the failure-free operation of the structure is studied. Based on the calculation results and confirmed tests, the final geometric dimensions of the one- piece core unit with wing rails are proposed, taking into account product manufacturability. Recommendations are given for the positioning of the longitudinal ribs of the monoblock crossings during the design phase. The proposed design of the monoblock crossings is adopted for series production.

Discussion and conclusion. The lowest equivalent stresses are found in one of the monoblock crossing designs with two longitudinal stiffening ribs presented in the article. This design allows the product to operate in a way that prevents dangerous failures. The implementation of the principles of mathematical modelling used in this work, taking into account the adopted calculation scheme, ensures a significant reduction in the time required for the design and manufacture of crossings with a solid core unit with wing rails and welded rail ends.

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