Parametric Finite Element Analysis on the Design of Railway Crossings for Increased Reliability

Crossings allow trains to change tracks and hence are an essential railway component. However, they are also bottleneck points on the rail network under increased rolling stock traffic. Crossings are subject to high loading conditions and therefore, their structural integrity is of critical importance for the safety and reliability of railway operations. As the wheel switches from one track to another, a vertical impact on the crossing nose or wing rail occurs. Wheel impacts can lead to several forms of damage, such as impact damage, wear, rolling contact fatigue, plastic deformation, among others. The crossing geometry is of utmost importance as the wing rail angle or nose shape can act as stress concentrators, further propagating damage and reducing the asset’s lifetime. The UK railway network alone comprises around 6,000 crossings, which need to be assessed and maintained with a frequency that ranges from one to three years in busy routes [1]. Modelling techniques, such as finite element analysis, can provide a better understanding of the stress states involved in this complex dynamic problem, leading to the optimization of the crossing geometry for an extended lifetime. In this paper, we evaluate changes in the design of railway crossings in a dynamic environment via finite element analysis. The effects of changes in the crossing length and angle, train speed, as well as nose design, are evaluated regarding impact and deformation. This paper provides advice on best design practices allowing for more reliable and long-lasting railway crossings.