Study on wear characteristics and authorized limits of switch rails of high-speed turnout

Purpose It is quite universal for high-speed turnouts to be exposed to the wear of the stock rail of the switch rail during the service process. The wear will cause the change of railhead profile and the relative positions of the switch rail and the stock rail, which will directly affect the wheel–rail contact state and wheel load transition when a train passes the turnout and will further impose serious impacts on the safety and stability of train operation. The purpose of this paper is to provide suggestions for wear management of high-speed turnout. Design/methodology/approach The actual wear characteristics of switch rails of high-speed turnouts in different guiding directions were studied based on the monitoring results on site; the authorized wear limits for the switch rails of high-speed turnout were studied through derailment risk analysis and switch rail strength analysis. Findings The results show that: the major factor for the service life of a curved switch rail is the lateral wear. The wear characteristics of the curved switch rail of a facing turnout are significantly different from those of a trailing turnout. To be specific, the lateral wear of the curved switch rail mainly occurs in the narrower section at its front end for a trailing turnout, but in the wider section at its rear end when for a facing turnout. The maximum lateral wear of a dismounted switch rail from a trailing turnout is found on the 15-mm wide section and is 3.9 mm, which does not reach the specified limit of 6 mm. For comparison, the lateral wear of a dismounted switch rail from a facing turnout is found from the 35-mm wide section to the full-width section and is greater than 7.5 mm, which exceeds the specified limit. Based on this, in addition to meeting the requirements of maintenance rules, the allowed wear of switch rails of high-speed turnout shall be so that the dangerous area with a tangent angle of wheel profile smaller than 43.6° will not contact the switch rail when the wheel is lifted by 2 mm. Accordingly, the lateral wear limit at the 5-mm wide section of the curved switch rail shall be reduced from 6 mm (as specified) to 3.5 mm. Originality/value The work in this paper is of reference significance to the research on the development law of rail wear in high-speed turnout area and the formulation of relevant standards.