No abstract

No abstract

No abstract

A computer model, which simulates the ratcheting wear of a ductile material subject to repeated loading, is presented and discussed in detail. Variation of material properties is a feature of the model, failure by ductility exhaustion occurring at isolated points or extending regions of failure. Such regions form crack‐like features. Mechanisms for removal of weakened material from the surface as wear debris are described. The wear process causes a degree of surface roughness. The simplicity of the model enables simulation of millions of load cycles in only a few hours' computer time. The computer model is used to study the effect of partial slip on wear rate. When creepage is relatively low, the wear rate increases sharply with creepage. When creepage is relatively high, the wear rate is largely insensitive to the creepage.

A model of plastic strain accumulation, wear, and rolling contact fatigue (RCF) crack initiation in rail steel has been developed. Local to the contact zone, material is subject to severe cyclic stresses taking it beyond yield and leading to incremental accumulation of plastic deformation (ratcheting). This model is based on a ratcheting law derived from twin-disc, rolling-sliding contact experiments and can simulate thousands of ratcheting cycles with corresponding strain hardening. The model is being further refined to account for detailed microstructural changes. Sections of worn and fatigued rail, removed from service, have been metallurgically analysed. To obtain further data on rail-steel deformation and RCF crack initiation, twin-disc tests have been performed using discs cut from across a railhead and wheel rim. Two heat treatments were applied to some rail discs to investigate the effect of pro-eutectoid ferrite phase distributions and volume fractions. Tests were run to failure (defined by an eddy current crack-detection system) and to percentages of fatigue lives. Micro- and nano-hardness tests, and microstructural observations, have been used to suggest a micromechanism of fatigue crack initiation for the model. Application of this model will contribute to reduced maintenance costs and an improved understanding of RCF development.