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Biodegradable Lubricants for Railway Applications
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Content Wheel Flange Lubrication
1 Introduction 2 Wheel/Rail contact 3 Requiremen
ts 4 Solutions
5 Application 6 Results 7 Future
Aspects 8 Summary
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Lubricant consumption
Worlds lubricant consumption 37.000.000
tons Consumption in Germany 1.200.000 tons
Total loss lubricants 40.000 tons Railway
Systems 3.000 tons

• Total loss lubricants
• Concrete release agents
• Two-stroke engine oils
• Chain saw oils
• Chain- and Wire rope lubricants
• ...
• Switch lubricants
• Wheel flange lubricants
• Rail lubricants

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Wheel / Rail contact

• Wheel/Rail contact area fulfills several demands
• transmission of traction and braking forces
  between rail head and wheel surface
• absorption of steering forces between wheel
  flange and
• rail flange
• transmission of electric signals

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Wheel / Rail contact
Influence of Lubrication on Wheel flange wear
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Wear Effects on Rails and Wheel Flanges
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Wear Effects on Rails
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Requirements

• Generally
• Environmentally harmless
• Low water pollution
• High biodegradability
• No toxic components
• Should be solvent-free
• etc.
• These requirements are not yet homogeneously
  regulated. Regarding biodegradability, the test
  method according to CEC L-33-A-93 standard is
  commonly used. Additionally different
  OECD-guidelines are used.

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Requirements

• Wheel flange lubrication
• primary
• Reduction of friction between wheel and rail
  flange to reduce the risk of derailment and to
  minimise rolling noises generated in these
  contact zones.
• Reduction of wear of wheel and rail to minimise
  maintenance work and life cycle costs and to
  increase the availability of the rolling stock.
• secondary
• High adhesion (gets more and more important for
  high speed trains)
• Lubricity and sprayability should be independent
  from temperature
• Independence from the lubricating system used
• Good resistance against ageing
• Long storage time

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Solution

• Basics of lubricant formulation
• In these applications normally soft free-flowing
  greases are used, which can contain special solid
  lubricants.
• It is important, that all single components are
  checked with regard to their environmental
  potential, even though the base oil is by far the
  biggest portion of the lubricant.
• Base oils
• Regarding biodegradability we can choose
• from the following fluids
• Native esters
• Synthetic esters
• Low-viscous Polyglycols
• Low-viscous synthetic hydrocarbons

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Solution

• Beside the biodegradability the following
  properties have to be considered with the base
  oils
• Lubricity
• Flow behaviour at low temperatures
• Thermal resistance
• Solubility / Miscibility of additives
• Compatibility with materials
• Following the thickeners, which can be used in
  biodegradable lubricants
• Lithium soap
• Calcium soap
• Li-/Ca-Mix soap
• Inorganic thickeners, e.g. Bentonite

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Solution
Additives and Solid lubricants EP additives
play an important role, because wheel flange
lubrication, as well as switch lubrication is
working under boundary or extreme mixed friction
conditions.
Static friction
Boundary friction
Mixed friction
Fluid friction(hydrodynamic friction)
Coefficient of friction µ
Mixed Friction
Hydrodyn. Frict.
Speed (n)
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Solution
Additives and Solid lubricants Selection of
additives must be done also with regard to the
strong requirements of environmental aspects and
must fulfil all the tribological demands as
well. Long-term experience in practical
applications has shown, that special solid
lubricants can be extremely helpful in these
applications. Mostly special graphite types as
well as combinations of the so-called white solid
lubricants are used.
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Solution
Synergetic combination of the mentioned
components to ready formulations
AC Anti-corrosion, AW Anti-wear, AO
Anti-oxydant, EP Extreme Pressure FSS solid
lubricants
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Application

• to make sure that you have the right quantity of
  lubricant right in time at the right place
• Application to the wheel flange with
  On-Board-Systems
• Application to the rail flanks with
  Track-Side-Systems

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Application

• with automatic lubricators, which spray extremely
  small quantities of lubricant onto the wheel
  flanges
• normally only the first wheel set is lubricated,
  all the following axles are lubricated indirectly

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Rail and Wheel Flange Lubrication Systems
On-Board-Systems
Airless
Air-operated
sep. compressor
On-board comp.
Vogel SP 8 Vogel SP 9 DeLimon RE DeLimon
Railjet ÖBB Sepuls Secheron Woerner Beka
Fluilub Rebs
Saxonia SSL-3 Rebs Beka Fluilub
Mannesmann Rexroth Vogel-Brush Rebs
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Controlling of Lubricating Systems

• On-Board-Systems
• path-controlled
• time-controlled
• curve-controlled
• GPS-controlled
• combined

• Track-Side-Systems
• mechanically
• time-controlled
• vibration-controlled
• noise-controlled

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Application
Wheel flange lubrication, example
Type Vogel SP 9
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Application
Wheel flange lubrication, example
Type DeLimon RE
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Wheel flange lubricating systems, nozzles
mainly used nozzles at DB AG
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Wheel Flange Lubrication, Fitting Position of
Spray Nozzles
Best position L with brake shoe L2
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Application
Wheel flange lubrication, calculation
example Width of the spray jet on the wheel
flange 20 mm Wheel diameter 900
mm Lubricant quantity per spray cycle 30
mg Thickness of lube film on the first wheel
set ca. 0,5 µm
Spray pattern from test rig trial
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Application
Wheel flange lubrication, calculation
example Lubricant quantity per cycle 30
mg Travelling distance per cycle 500 m Total
distance 1000 km Lubricant consumption at
each side 60 g
Spray pattern from test rig trial
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Wear Effects on Rails
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Results Field test
Result Remarkably lower wear rates with the
biodegradable lubricant
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Results Field test
1991 Changing over from a conventional, mineral
oil based grease to a high performance,
biodegradable lubricant.
Causes for Wheel Flange Wear on Locomotive
Wheels (source Austrian Railway)
Flange wear
Flange/surface wear
Flat surfaces
Surface wear
Cracks
Others
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Rail and Wheel Flange Lubrication
Until 1991 conventional lubricant based on
mineral oil
Since 1993 TRAMLUB F 234 MOD 1
Wear Rate on Wheel Flanges (source Austrian
Railway)
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Summary

• Biodegradable lubricants for wheel flange
  lubrication
• have overrun their conventional ancestors and
  completely removed in many applications
• perform much better and at the same time help our
  environment by
• Reduction of driving power (up to 15)
• Reduction of wear, noise and friction
• Increase of the maintenance intervals
• Reduction of maintenance works
• Reduction of lubricant consumption
• Reduction of the risk of derailment
• Increase of Reliability, Availability,
  Maintainability, Safety (RAMS)
• Decrease of Life Cycle Costs (LCC)
• ...

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Rail and Wheel Flange Lubrication Systems
Track-Side-Systems
Hi-Rail
Portec PL SRS Clicomatic Schreck-Mieves/Moklansa
Schörling Portec etc.
Portec PL on duty
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Rail flank lubrication
Portec lubricator
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Rail flank lubrication
Delimon track-side lubricator
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Rail flank lubrication
Schreck-Mieves track-side lubricator
Delimon track-side lubricator
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Hi-rail systems
Schoerling 2-way vehicle for cleaning and
lubricating of rails and switches
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