Minimization of railhead edge stresses through shape optimization

The railhead is severely stressed under the localized wheel contact patch close to the gaps in insulated rail joints. A modified railhead profile in the vicinity of the gapped joint, through a shape optimization model based on a coupled genetic algorithm and finite element method, effectively alters the contact zone and reduces the railhead edge stress concentration significantly. Two optimization methods, a grid search method and a genetic algorithm, were employed for this optimization problem. The optimal results from these two methods are discussed and, in particular, their suitability for the rail end stress minimization problem is studied. Through several numerical examples, the optimal profile is shown to be unaffected by either the magnitude or the contact position of the loaded wheel. The numerical results are validated through a large-scale experimental study.