To explore rail corrugation’s influence on high-speed train gearbox housing dynamic characteristics, this paper investigates the correlation between gearbox housing vibration acceleration energy and rail corrugation, proposing corresponding safety limits. Using vehicle-track coupling dynamics and multibody dynamics theories, a rigid-flexible coupling model for CRH3 vehicle-track systems was established. With rail corrugation and Wuhan-Guangzhou track spectrum as excitation, three gearbox housing vibration sensors analyzed effects of varying corrugation wavelengths/depths at different speeds on vibration energy. The vibration energy-rail corrugation correlation was explored, with vibration energy limits and maintenance safety limits proposed. Results show rail corrugation significantly increases gearbox housing vibration energy: points A and C exhibit stronger regularity (A’s maximum is 86.3% higher than C’s), with B most affected. For point A, mixed-wavelength high-frequency responses include single-wavelength components and harmonics, exciting gearbox housing high-frequency resonance. A power model (R2 = 0.9437) characterizes the correlation. A vibration energy threshold of 1.44 × 104 m2/s4 and corresponding rail corrugation maintenance limits are proposed. Practically, maintenance strategies should integrate operational conditions, track structure, and gearbox housing status, with timely maintenance when corrugation depth exceeds safety limits.
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