A finite element model to simulate the physical mechanisms of wear and crack initiation in wheel/rail contact

Daves, Werner; Kubin, Wilhelm; Scheriau, Stephan; Pletz, Martin

doi:10.1016/j.wear.2016.05.027

Cited by 43 publications

(16 citation statements)

References 28 publications

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“…Numerical analysis allows to explain the mechanism of wear and determine local stresses values. The obtained results of operational investigations prove that cracks and spallings of the micro and macro scale appear in areas with maximum stress and deformation, there is proof in work [2]. On the basis of the conducted simulation tests, FEM was found to be the right tool used to identify the areas of special wear hazard.…”

Section: Discussionmentioning

confidence: 66%

“…As a result of mutual blocking of dislocating dislocations and the presence of atoms of dopants of alloying elements, gradual strain strengthening occurs. In work [2] authors presented a new twodimensional plain strain rough wheel/rail contact model is developed which includes stick-slip phenomena of the realistic contact situation and is related in a mechanically justified way to the three-dimensional situation. Appearing the small rough areas causes pick of the stresses in surface layer.…”

Section: Introductionmentioning

confidence: 99%

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An attempt to use the results of microtomographic studies of the surface after the period of operation in the numerical analysis of wheel-rail contacts

Bąkowski

Anderson

Brodny

2020

mech

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During the contact of two bodies, their interaction causes an increase in stress and thus an increase in surface energy. Therefore, this energy, depending on the type of material, can cause physicochemical changes in it, which in turn lead to the phenomenon of decohesion. In order for the phenomenon to occur, it must be exceeded the limit of strength of the material is usually the yield point. Depending on the material's properties (especially hardness) the time in which contact surfaces stay in contact is extremely important because the longer it is, the more energy will be transferred to the other body. In the case of materials with a high hardness, the energy is first converted into elastic and then plastic impacts, causing plastic deformation and dislocation motion, leading to the separation of material layers and its defect. However, much more plastic materials are faster than the yield point and the separation of material in the form of flaky wear debris. The paper presents the influence of selected exploitation factors on the condition of the surface layer through the use of simulation tests using the Finite Element Method (FEM). The surface layer was mapped using a computer microtomograph and the influence of operational parameters on its condition was presented using simulation tests by means of FEM.

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Section: Discussionmentioning

confidence: 66%

Section: Introductionmentioning

confidence: 99%

An attempt to use the results of microtomographic studies of the surface after the period of operation in the numerical analysis of wheel-rail contacts

Bąkowski

Anderson

Brodny

2020

mech

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“…Considering the surface roughness of the wheel and rail materials, and using a multiscale finite element model, Daves et al. 10 simulated the rail surface material deformation under rolling–sliding–loading to calculate the initiation of rail surface-initiated RCF cracks. Ringsberg 11 presented a method to predict the life of the initiated RCF cracks based on the elastoplastic finite element analysis, a multiaxial fatigue crack initiation model, etc.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of rail surface-initiated rolling contact fatigue in the switch panel of railway turnouts

Wang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part F:

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Considering the complex characteristics of the track structure in railway turnouts, it is difficult and also expensive to experimentally study rail damages; therefore, numerical methods are an effective alternative. This study presents a numerical method to simulate rail surface-initiated rolling contact fatigue in the switch panel of railway turnouts. This method includes simulation of the vehicle–turnout wheel–rail dynamic interaction, analysis of the wheel–rail multipoint non-Hertzian rolling contact that considers the relative motion between the switch and stock rails, and calculation of the accumulated rail surface-initiated rolling contact fatigue. The accumulated rail surface-initiated rolling contact fatigue after the vehicles passed a turnout switch panel 80 times (the average number of vehicles running on the Chinese high-speed railway lines per day) in the through route with facing move was simulated based on this procedure. The result showed that the maximum surface-initiated rolling contact fatigue damage of the switch rail and the stock rail was 1.57 × 10−2 and 0.62 × 10−2, respectively. Surface-initiated rolling contact fatigue in the switch rail mainly occurred at the gauge angle, and in the stock rail it mainly occurred at the center of the rail. In addition, the influence of track parameters (rail inclination, track gauge, and friction coefficient) is analyzed. The friction coefficient influenced the rail surface-initiated rolling contact fatigue. When the coefficient exceeded 0.3 in particular, the rail rolling contact fatigue damage increased sharply. Hence, suitable friction control measures should be taken during rail maintenance in order to mitigate the rail surface-initiated rolling contact fatigue damage, e.g. by keeping the wheel–rail friction coefficient below 0.3.

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“…[16]. Tyfour and Beynon [17], Daves et al [18] and Wang and coauthors [19] explored the effect of rolling direction reversal, surface roughness, and spherical dents on crack and plastic strain, which may play certain roles in the fatigue life of wheels and rails. Izciler and Tabur [20] did a group of wear tests of gas carburized AISI 8620 on a pin-on-disc test machine and suggested that a thicker case depth subjected to a long gas carburized time could enhance the wear resistance, similar to the experiment results by Sun and Bell [14].…”

Section: Introductionmentioning

confidence: 99%

Contact Yield Initiation and Its Influence on Rolling Contact Fatigue of Case-Hardened Steels

Mengqi

Xie

et al. 2020

Journal of Tribology

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Stress distributions and plastic deformation zones are factors directly influencing the fatigue life of components under cyclic contact. An effective approach to improving the resistance of a steel to contact fatigue failure is surface hardening, which builds gradient yield strength from the surface of the steel to the bulk. When using the distortion energy theory as the criterion to identify failure initiation for a case-hardened steel, contact yield starts in the subsurface wherever the von Mises stress reaches the local material strength, rather than at the point of the maximum von Mises stress in the subsurface. If the yield strength changes from the surface to the bulk following a straight line, the location of yield initiation should occur at the tangency of the strength line and the von Mises stress curve. Analyses on circular, rectangular, and elliptical contacts are presented to reveal the locations of contact yield initiation for such case-hardened steels subjected to rolling contact stresses, for which the influence of friction can be ignored. A group of formulas relating contact yield initiation, in terms of the critical pressure, location of the first yield, and plasticity index (transition to plasticity) to case-hardening parameters, such as the case slope, the minimum case depth, and surface and bulk strengths, are derived to facilitate contact element designs using case-hardened materials. The results are applied to examine the rolling contact behaviors of several case-hardened steels, and the data correlation suggests that their rolling contact fatigue lives are related to a nondimensional case-hardening slope besides external loading.

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A finite element model to simulate the physical mechanisms of wear and crack initiation in wheel/rail contact

Cited by 43 publications

References 28 publications

An attempt to use the results of microtomographic studies of the surface after the period of operation in the numerical analysis of wheel-rail contacts

An attempt to use the results of microtomographic studies of the surface after the period of operation in the numerical analysis of wheel-rail contacts

Numerical simulation of rail surface-initiated rolling contact fatigue in the switch panel of railway turnouts

Contact Yield Initiation and Its Influence on Rolling Contact Fatigue of Case-Hardened Steels

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