Keywords: railway crossings, finite element analysis, experimentation, methoding, simulation.

Cast austenitic manganese steel crossings are safety-critical components and expensive track components both in terms of unit cost and installation. There can be consequences when crossings fail such as serious accidents, train delays, additional maintenance requirements and costly removal and replacement. This research initially proposed and trialled a 5-stage crossing testing methodology using a pilot study incorporating experimental trials and finite element analysis. From this a series of extensive and successful main trials were conducted to test its suitability and reliability. This research further pushed the boundaries on crossing design and analysis by addressing a significant gap within the existing crossing literature. To date whole crossing analysis has never been demonstrated before in this way. In the past, the focus on crossings has always been on wheel/rail interaction using models with no methods features (required to aid manufacture) that focus on the crossing entirely above its neutral axis. This novel crossing testing methodology demonstrates it is possible to analyse a whole crossing in a structured fashion, embed it within a formal design process and provide new insights into crossing behaviour when under load.

This paper will demonstrate the results of the main static loading trials focussing on the repeatability of the methodology and how it can be used to assess design alterations and highlight potential improvements. The impact of manufacturing additions such as methods features and manufacturing allowances, both to aid casting, are also investigated.

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