Welcome to the 55th Hatfield Memorial Lecture

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Welcome to the 55th Hatfield Memorial Lecture

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Welcome to the 55th Hatfield Memorial Lecture

• Sponsored by
• The University of Sheffield
• SMEA
• Institute of Materials, Minerals and Mining
• Special Metals Forum
• Worshipful Company of Armourers Brasiers
• TWI Technology Centre (Yorkshire) Ltd
• Worshipful Company of Ironmongers
• Corus

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Railways and Materials Synergetic Progress
55th Hatfield Memorial lecture 4th December 2007

• Roderick A Smith
• Royal Academy of Engineering Research Professor
• Future Rail Research Centre
• Imperial College London

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The iron way le chemins de fer die eisenbahn
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Direction of travel
Acceleration, a, is limited to µg
mg
µ mg
Approximate coefficient of friction, µ Steel on
steel 0.15 Steel on teflon 0.04
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The great advantage of rail
Tractive effort Load x g is about 3
Big load
Tiny pull
Because the rolling resistance is very low, 6 1/2
lbs can pull 1 ton.
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In 1804 Richard Trevithick demonstrated the first
working rail locomotive. In May 2004, Railfest in
York celebrated this notable bicentenary.
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Saturday 29 May 2004
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Versailles, Sunday 8 May 1842 The first rail
accident to cause major loss of life, 75
killed A sensation throughout Europe Catalyst of
much early work on what became known as fatigue
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3 June 1998 Disaster of ICE 884 Wilhelm Conrad
Rontgen 200 kph derailment at Eschede, between
Hannover Hamburg
The ICE (Intercity Express) is the pride of the
German railways 101 people were killed This was
the worst post-war German railway accident and
the first to a high-speed train
anywhere Germanys Titanic
What happened? Why did it happen?
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The ICE was introduced into service in
1991 Within 2 months, less than 100, 000 km,
some wheels had to be replaced because of
irregular wear causing noise and vibration
(Unification DB joins East German Reichsbahn) By
August 1992, Deutsche Bahn (DB) had approved
a plan to replace the original solid wheels with
a new type of resilient (rubber sprung)
wheel January 1993,the first delivery of the new
wheels, including one fitted to ICE 884 Summer
1994, new wheels start to be fitted to
trains noise problems found to be reduced, but
the new wheels wear rapidly
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Legal proceedings
Three engineers, 2 from DB 1 from Tyssen-Krupp,
were charged with gross negligence I was hired
by the DB defence team I spent more than 2
years, wading through mountains of
paper, attending meetings in Germany, witnessing
tests in Sweden, listening to many discussions.
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Some key points from Eschede

• Consequences could have been averted if the train
  had stopped
• Design codes for solid wheels were not
  appropriate
• No tests to failure, so critical location unknown
• Inspections did not cover the inside of the rim!
• Depth of rim reduced to counter wear, thus
  bending stresses increased machining allowance
  for solid wheels not appropriate for supported
  tyre wheels
• Dynamic loads were not measured
• Inadequate testing before use, meant that failure
  location was not identified

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I had an immense advantage over many
others dealing with the problem inasmuch as I had
no fixed ideas derived from long-established
practice to control and bias my mind, and did
not suffer from the general belief that whatever
is, is right.                           Sir
Henry Bessemer
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Engineering, 1868 in the short space of one
month, upwards of one hundred rails were broken
by the trains on one of the English railways..
the lives of passengers (are) sacrificed by
the use of such rubbish as these iron rails were
composed of.
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The complexity of a modern bogie
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A Load7.5t, Unsprung mass2.3t
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B Load5.7t, Unsprung mass1.7t
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The steam age has given way to
The MECHATRONIC train
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Energy typical values

• Heart beat 0.5 J
• AA battery 4.3 kJ
• climbing 20m 14 kJ
• slice bacon 210 kJ
• kg coal 30 MJ
• litre petrol 40 MJ
• railway collision 20 to 1000MJ

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The British Rail Crashworthiness Programme

• Major studies as a result of Clapham
• Structural design
• Energy absorption at coach ends (2MJ)
• Materials, geometry and joints
• Role of testing and modelling
• HSE contribution anti-overriding
• Prompted research overseas

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Derailment of High-Speed train at Hatfield, 17
Oct 2000 The most traumatic and expensive
accident in UK railway history?
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Position of contact in normal running
Movement to gauge corner produces higher contact
stresses
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Severely deformed surface layer
10 ?m
5 15 mm
Region plastically strained by contact stresses
Bulk stresses in the rail due to bending,
residuals from manufacture, CWR stresses
Elastic contact stress field
100 ?m
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Direction of motion
5 to 15 mm
25 mm
Whilst under the influence of the contact stress
field, the crack propagates at a shallow angle of
15 o
The crack turns down to an angle of 70 o when
controlled by the bulk stresses
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Thank you