Gaps, challenges and possible solution for prediction of wheel–rail rolling contact fatigue crack initiation

Zhang, Shuyue; Liu, Qiyue; Spiryagin, Maksym; Wu, Qing; Ding, Haohao; Wen, Zefeng; Wang, Wenjian

doi:10.1007/s40534-023-00302-8

Cited by 13 publications

(4 citation statements)

References 84 publications

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“…According to the studies in Ref. (Zhang and Yao, 2010), bolt hole cracks in rail joint are mostly oblique upward crack. Considering the symmetry of the circle hole, oblique cracks are considered with a crack direction of 0°-90°.…”

Section: Numerical Analysismentioning

confidence: 99%

Analysis of ultrasonic nonlinearity for bolt hole crack detection in rail joints by wavelet packet decomposition

Zhang

Wang

et al. 2023

Advances in Structural Engineering

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This paper proposes a crack detection method for rail joint screw holes based on the ultrasonic nonlinearity. Experimental and numerical studies are conducted to validate the performance of the proposed approach. The ultrasonic signals excited and received at the rail head are processed by spectral analysis and Wavelet Packet Decomposition (WPD). The third harmonic can be clearly observed from the spectrum analysis, which is supposed to be the nonlinearity of structures. Further, WPD is used to decompose the frequency components of the received signals. A damage index (DI) is defined based on the energy percentage of the energy in the WPD node containing the third harmonic with respect to the total energy of the received signal. It is found that the DI relating to the third harmonic increases with an approximately linear relationship when the crack grows bigger. It can provide a basis for the crack detection and quantification for the rail joint screw holes. A finite element model of the experimentally tested rail is also developed and numerical studies are conducted to verify the ultrasonic nonlinearity in the rail structure. Numerical results have the same trend with the experimental results, which verifies the effectiveness of the proposed method for crack detection in rail joints based on the high order ultrasonic nonlinear harmonics.

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Section: Numerical Analysismentioning

confidence: 99%

Analysis of ultrasonic nonlinearity for bolt hole crack detection in rail joints by wavelet packet decomposition

Zhang

Wang

et al. 2023

Advances in Structural Engineering

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“…In the literature, shakedown maps were introduced to predict the fatigue response to cyclic loading [90][91][92][93]. An example of a shakedown map is illustrated in Figure 2 [90].…”

Section: Introductionmentioning

confidence: 99%

Examining Wear Mechanisms in Railway Wheel Steels: Experimental Insights and Predictive Mapping

Zani,

Mazzù,

Solazzi

et al. 2024

Lubricants

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Railway systems play a pivotal role in modern transportation networks, contributing to both efficiency and environmental sustainability. This study investigated the multifaceted aspects of wear phenomena in railway engineering, focusing on their significant implications for environmental costs and operational efficiency. Experimental trials were conducted using a high-performance bi-disc apparatus, evaluating a range of materials, contact pressures, and lubrication conditions. Shakedown maps were employed to assess ratcheting behaviour, while the wear rate was analysed as a function of the fatigue index (FI). The results reveal the intricate interplay of contact pressure, slip ratio, material properties, and lubrication in determining wear and ratcheting behaviour. Oxidative and mild wear mechanisms were identified, and wear debris composition and morphology were characterised. The outcomes from this research clarify the pivotal role that wear processes play within railway systems and the far-reaching environmental repercussions they entail. This exploration contributes to the ongoing optimisation of railway operations, offering valuable insights aimed at mitigating unavoidable pollution sources and strengthening sustainability efforts. By delving into the intricate dynamics of wear phenomena within wheel–rail material, this research paves the way for innovative solutions that not only enhance operational efficiency but also minimise the ecological footprint of railway transportation.

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“…Low-cycle fatigue (LCF) and ratcheting are usually considered competitive mechanisms, while predictions give characteristics of the initiated crack [20]. For the LCF mechanism, a suitable fatigue criterion that considers plastic deformation is generally applied [23], unlike the prediction of bearing RCF crack initiation [24], where stress-based approaches are usually acceptable. The most popular critical plane criterion considering the LCF mechanism in RCF crackinitiation prediction is that of Jiang and Sehitoglu [25].…”

Section: Introductionmentioning

confidence: 99%

Two Contributions to Rolling Contact Fatigue Testing Considering Different Diameters of Rail and Wheel Discs

Šmach,

Halama,

Marek

et al. 2023

Lubricants

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Scaled rolling contact fatigue tests, used to practically simulate the wear of the wheel and rail material under laboratory conditions, are typically classified into two categories. Tests in the first category use twin-disc stands, while the second group of test rigs use two discs of different diameters considering the rail disc as the larger one. The latter setup is closer to the real situation, but problems can occur with high contact pressures and tractions. The focus of this paper is on two main contributions. Firstly, a case study based on finite element analysis is presented, allowing the optimization of the specimen geometry for high contact pressures. Accumulated plastic deformation caused by cycling is responsible for abrupt lateral deformation, which requires the use of an appropriate cyclic plasticity model in the finite element analysis. In the second part of the study, two laser profilers are used to measure the dimensions of the specimen in real time during the rolling contact fatigue test. The proposed technique allows the changes in the specimen dimensions to be characterized during the test itself, and therefore does not require the test to be interrupted. By using real-time values of the specimen’s dimensional contours, it is possible to calculate an instantaneous value of the slip ratio or the contact path width.

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Gaps, challenges and possible solution for prediction of wheel–rail rolling contact fatigue crack initiation

Cited by 13 publications

References 84 publications

Analysis of ultrasonic nonlinearity for bolt hole crack detection in rail joints by wavelet packet decomposition

Analysis of ultrasonic nonlinearity for bolt hole crack detection in rail joints by wavelet packet decomposition

Examining Wear Mechanisms in Railway Wheel Steels: Experimental Insights and Predictive Mapping

Two Contributions to Rolling Contact Fatigue Testing Considering Different Diameters of Rail and Wheel Discs

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