Rack railways are increasingly adopted in mountainous transportation networks due to their ability to operate on steep gradients. The gear-rack meshing mechanism introduces additional complexity to the train-track dynamic response. During downhill braking, the combined action of longitudinal braking forces and gravity may destabilize ballast and deform the track structure. This study investigates the dynamic characteristics of ballasted track in rack railways under downhill braking using full-scale field tests and a Multi-Body Dynamics-Discrete Element Method (MBD-DEM) simulation. First, full-scale field tests were carried out on a 120 ‰ gradient rack test line. Using conventional track condition monitoring sensors together with SmartRock sensors, we measured the wheel-rail forces, the accelerations of the rack and rail, the dynamic responses of the sleepers, and the mesoscopic dynamic behavior of ballast particles during emergency braking with different initial train speeds. Subsequently, in order to evaluate the system responses under different gradient levels and a wider range of operating conditions, and to examine in more detail the mesoscopic mechanical behavior within the ballast bed, an MBD-DEM coupled simulation model consistent with the test line was developed. Based on this model, response surface methodology was adopted to analyze the effects of gradient, train speed and braking deceleration on the track system. Results show that downhill braking induces significant axle load redistribution and longitudinal force imbalance. Higher gradients and braking loads exacerbate ballast instability. Response surface analysis indicates that gradient is the dominant factor governing longitudinal sleeper displacement. When gradients exceed 240 ‰, localized ballast instability occurs. Although sleeper displacements remain within the 2 mm safety threshold under the tested conditions, higher gradients or speeds are likely to increase track deformation and structural instability risks.
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