Rolling contact fatigue of rails—finite element modelling of residual stresses, strains and crack initiation

2000 ◽  
Vol 214 (1) ◽  
pp. 7-19 ◽  
Author(s):  
J. W. Ringsberg ◽  
H Bjarnehed ◽  
A Johansson ◽  
B. L. Josefson
Keyword(s):  
Finite Element ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Finite Element Modelling ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Element Modelling

A Finite Element Analysis of Crack Initiation and Propagation in a Notched Disk Submitted to Rolling Contact Fatigue

1998 ◽  
Vol 120 (3) ◽  
pp. 436-441 ◽  
Author(s):  
V. Bordi ◽  
Ch. Dorier ◽  
B. Villechaise
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Crack Initiation ◽  
Crack Growth ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Crack Initiation And Propagation ◽  
Element Analysis ◽  
Initiation And Propagation

A finite element model has been developed to predict crack initiation and propagation in a notched disk submitted to rolling contact fatigue. The aim of this study is to validate the model with experimental results obtained by tests carried out on a two-disk machine. First, a three-dimensional finite element analysis is performed. A unidimensional equivalent damage stress is calculated by applying a plastic criterion in an attempt to estimate the damage location and the time necessary to initiate cracks from the notches. Then a two-dimensional calculation based on linear fracture mechanics is conducted to determine mixed mode stress intensity factors at the tip of a crack initiated from the notch. Several crack growth criteria are used to evaluate crack growth direction and rate. Numerical results are in good agreement with experimental ones.

scholarly journals A 3D Finite Element Model of Rolling Contact Fatigue for Evolved Material Response and Residual Stress Estimation

2020 ◽  
Vol 68 (4) ◽  
Author(s):  
Muhammad U Abdullah ◽  
Zulfiqar A Khan ◽  
Wolfram Kruhoeffer ◽  
Toni Blass
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Structural Changes ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Element Model ◽  
Rolling Contact ◽  
3D Finite Element ◽  
Semi Empirical

AbstractRolling bearing elements develop structural changes during rolling contact fatigue (RCF) along with the non-proportional stress histories, evolved residual stresses and extensive work hardening. Considerable work has been reported in the past few decades to model bearing material hardening response under RCF; however, they are mainly based on torsion testing or uniaxial compression testing data. An effort has been made here to model the RCF loading on a standard AISI 52100 bearing steel with the help of a 3D Finite Element Model (FEM) which employs a semi-empirical approach to mimic the material hardening response evolved during cyclic loadings. Standard bearing balls were tested in a rotary tribometer where pure rolling cycles were simulated in a 4-ball configuration. The localised material properties were derived from post-experimental subsurface analysis with the help of nanoindentation in conjunction with the expanding cavity model. These constitutive properties were used as input cyclic hardening parameters for FEM. Simulation results have revealed that the simplistic power-law hardening model based on monotonic compression test underpredicts the residual generation, whereas the semi-empirical approach employed in current study corroborated well with the experimental findings from current research work as well as literature cited. The presence of high compressive residual stresses, evolved over millions of RCF cycles, showed a significant reduction of maximum Mises stress, predicting significant improvement in fatigue life. Moreover, the predicted evolved flow stresses are comparable with the progression of subsurface structural changes and be extended to develop numerical models for microstructural alterations. Graphic Abstract

A Coupled Multibody Finite Element Model for Investigating Effects of Surface Defects on Rolling Contact Fatigue

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Zamzam Golmohammadi ◽  
Farshid Sadeghi
Keyword(s):  
Finite Element ◽  
Fatigue Life ◽  
Surface Defects ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Internal Stresses ◽  
Fe Model ◽  
Elastic Plastic ◽  
Pile Up

A coupled multibody elastic–plastic finite element (FE) model was developed to investigate the effects of surface defects, such as dents on rolling contact fatigue (RCF). The coupled Voronoi FE model was used to determine the contact pressure acting over the surface defect, internal stresses, damage, etc. In order to determine the shape of a dent and material pile up during the over rolling process, a rigid indenter was pressed against an elastic plastic semi-infinite domain. Continuum damage mechanics (CDM) was used to account for material degradation during RCF. Using CDM, spall initiation and propagation in a line contact was modeled and investigated. A parametric study using the model was performed to examine the effects of dent sharpness, pile up ratio, and applied load on the spall formation and fatigue life. The spall patterns were found to be consistent with experimental observations from the open literature. Moreover, the results demonstrated that the dent shape and sharpness had a significant effect on pressure and thus fatigue life. Higher dent sharpness ratios significantly reduced the fatigue life.

scholarly journals Observation of Flaking Process in Rolling Contact Fatigue by Laminography Using Ultra-bright Synchrotron Radiation

2018 ◽  
Vol 165 ◽  
pp. 11002
Author(s):  
Yoshikazu Nakai ◽  
Daiki Shiozawa ◽  
Shoichi Kikuch ◽  
Hitoshi Saito ◽  
Takashi Nishina ◽  
...  
Keyword(s):  
Synchrotron Radiation ◽  
Crack Initiation ◽  
Rolling Contact Fatigue ◽  
Rolling Direction ◽  
Contact Fatigue ◽  
Critical Length ◽  
Rolling Contact ◽  
Crack Initiation And Propagation ◽  
Initiation And Propagation ◽  
Damage Process

The flaking failure in rolling contact fatigue (RCF) results from crack initiation and propagation has been believed to originate from non-metallic inclusions located beneath the surface. With conventional microscopies, however, damage process in the internal region of materials could not be observed, then RCF crack initiation and propagation behaviours were observed by using synchrotron radiation computed laminography (SRCL) in the brightest synchrotron facility in Japan, and the effect of the inclusion orientation on the RCF property was examined. In our previous studies, crack initiation and propagation behaviours caused by extended MnS inclusions distributed in depth or transverse (width) direction was observed by the SRCL. In the present study, the fracture mechanism under RCF was discussed on specimens with MnS inclusions distributed in the rolling direction. As a result, vertical cracks were initiated on the surface, parallel to the ball-rolling direction in specimens. The crack propagation direction was then changed perpendicular to the rolling direction. Thereafter, similar with our previous studies, vertical cracks caused the horizontal cracks beneath the surface, when the vertical cracks reached to a critical length. The ratio of the vertical crack initiation life to the flaking life was higher than specimens with other inclusion orientation.

Investigating the Rolling Contact Fatigue in Rails Using Finite Element Method and Cohesive Zone Approach

2018 ◽  
Author(s):  
Mohamad Ghodrati ◽  
Mehdi Ahmadian ◽  
Reza Mirzaeifar
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Grain Boundaries ◽  
Fatigue Damage ◽  
Cohesive Zone ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Wheel Load ◽  
Element Method

A micromechanical-based 2D framework is presented to study the rolling contact fatigue (RCF) in rail steels using finite element method. In this framework, the contact patch of rail and wheel is studied by explicitly modeling the grains and grain boundaries, to investigate the potential origin of RCF at the microstructural level. The framework incorporates Voronoi tessellation algorithm to create the microstructure geometry of rail material, and uses cohesive zone approach to simulate the behavior of grain boundaries. To study the fatigue damage caused by cyclic moving of wheels on rail, Abaqus subroutines are employed to degrade the material by increasing the number of cycles, and Jiang-Sehitoglu fatigue damage law is employed as evolution law. By applying Hertzian moving cyclic load, instead of wheel load, the effect of traction ratio and temperature change on RCF initiation and growth are studied. By considering different traction ratios (0.0 to 0.5), it is shown that increasing traction ratio significantly increases the fatigue damage. Also by increasing traction ratio, crack initiation migrates from the rail subsurface to surface. The results also show that there are no significant changes in the growth of RCF at higher temperatures, but at lower temperatures there is a measurable increase in RCF growth. This finding correlates with anecdotal information available in the rail industry about the seasonality of RCF, in which some railroads report noticing more RCF damage during the colder months.

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