Numerical simulation and experimental study of wheelset press-fitting in rail heavy-duty maintenance machinery

To address the galling wear on the wheel seat surface induced during the wheelset press-fitting process in rail heavy-duty maintenance machinery, a numerical model for the oil-injection press-fitting of the wheelset is developed, considering factors such as interference fit, oil-injection holes, and press-fit load. The press-fit characteristics are then obtained from the model. Subsequently, wheelset press-fit tests are conducted to validate the accuracy of the numerical simulation model. Based on these findings, the effects of oil injection holes, press-fit load, and interference values on the contact state of the wheelset interface are further investigated. The results indicate that during the oil-injection press-fit process, the press-fit force increases and then decreases with displacement. A significant stress concentration occurs at the edges of the wheelset interface and around the oil groove. As the interference fit increases, the required maximum press-fit force also increases in a nearly linear manner. Adjusting the position of the oil injection hole can reduce the press-fit force. The maximum press-fit force required for oil-injection press-fitting is 64.2% lower than that required for cold press-fitting. These findings provide a theoretical basis for quality control in the wheelset press-fit process in rail heavy-duty maintenance machinery.