Dynamics response analysis of bearings in heavy- haul freight vehicles under the effect of wheel damage

As heavy-haul railways in China continue to develop vigorously, bearing damage in heavy-haul freight wagons also has a significant impact on train operational safety. The dynamic response of bearings under wheel-rail damage conditions needs clarification. Firstly, a rigid-flexible coupling dynamic model and the double-row tapered roller bearing submodel for a C80 heavy-haul vehicle were established. Then, the wheel-rail dynamic response excitation induced by wheel flats (WF) and wheel diameter differences (WDD) was analyzed. Finally, the load responses of the lubricated bearing under WF damage scenarios were evaluated. The results show that the wheel-rail vertical force increases with both vehicle speed and WF length, and WDD has a comparable effect on the wheelset lateral force. Increased rotational speed leads to greater axial and radial bearing forces, while a longer WF aggravates this trend. WF also influences the non-load-bearing raceway area, where the response decays to equilibrium after peaking at 14.8 kN, while the outer ring’s maximum impact load shows a symmetric distribution. Bearing lubrication effectively mitigates these internal impacts, prolonging bearing life. This research offers theoretical insights for bearing design and maintenance in heavy-haul systems.