Optimization and validation of a thermal simulation model for tread braking using an innovative small-scale experimental rig

This study presents the development and calibration of a simulation model for analysing thermal behaviour during tread braking, using an innovative small-scale experimental rig called ‘4-contact machine.’ This small-scale rig replicates the simultaneous interaction between the wheel, brake blocks, and rails, offering a unique capability to simulate real-world braking conditions in a controlled environment. The model was calibrated with experimental data from a 300-s test, achieving close agreement between simulated and measured temperature distributions. Key thermal parameters, including thermal resistances and contact conductance between components, were optimized and validated using tests of different durations (150 s, 450 s, and 650 s). Heat partitioning between the wheel, brake block, and rail samples was consistent across tests of various durations, aligning with values reported in the literature. The model provides a reliable framework for simulating the thermal effects of tread braking, offering valuable insights for improving railway brake system design. Future work will explore the scalability of these results for full-scale applications.