scholarly journals Implementation of a damage calculation in a numerical wheel-rail contact simulation

2021 ◽  
Vol 1 (1) ◽  
Author(s):  
Christian Buzzi ◽  
◽  
Andreas Dutzler ◽  
Martin Leitner ◽  
◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Great Distance ◽  
Rolling Contact ◽  
Local Damage ◽  
Post Processing ◽  
Element Analysis ◽  
Finite Element Software

Railways can transport cargo and persons a great distance. The combination of high axle loads, and the rigid wheels and rails made of steel results in high stresses at the wheel-rail contact. These high stresses cause rolling contact fatigue. To prevent and to forecast the rolling contact fatigue, the knowledge of the stresses and their effect on the local damage are important. One possible way to achieve results of the stresses is based on a finite element analysis. The calculation of the rolling contact fatigue is conducted subsequently. This paper will present one possibility to implement the damage calculation into a finite element software and use the post-processing to enable a fast assessment of rolling contact fatigue on the surface and the adjacent volume of a rail.

Finite Element Analysis Simulation of the Effect of Induction Hardening on Rolling Contact Fatigue

2018 ◽  
Vol 140 (6) ◽  
Author(s):  
Nguyen Hoa Ngan ◽  
Philippe Bocher
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Induction Hardening ◽  
Rolling Contact ◽  
Limiting Factor ◽  
Residual Tensile Stress ◽  
Element Analysis ◽  
Finite Element Analysis Simulation

The objective of this research is to conduct a finite element analysis to better understand the effects of induction hardening on rolling contact fatigue (RCF). The finite element analysis was developed in three-dimensional to estimate the maximal loading and the positions of the crack nucleation sites in the case of cylinder contact rolling. Rolling contact with or without surface compressive residual stress (RS) were studied and compared. The RS profile was chosen to simulate the effects of an induction hardening treatment on a 48 HRC tempered AISI4340 steel component. As this hardening process not only generates a RS gradient in the treated component but also a hardness gradient (called over-tempered region), both types of gradients were introduced in the present model. RSs in compression were generated in the hard case (about 60 HRC); tension values were introduced in the over-tempered region, where hardness as low as 38 HRC were set. In order to estimate the maximal allowable loadings in the rotating cylinders to target a life of 106 cycles, a multiaxial Dang Van criterion and a shear stress fatigue limit were used in the positive and negative hydrostatic conditions, respectively. With the proposed approach, the induction hardened component was found to have a maximal allowable loading significantly higher than that obtained with a nontreated one, and it was observed that the residual tensile stress peak found in the over-tempered region could become a limiting factor for fatigue rolling contact life.

Finite Element Analysis to Ceramic Ball Pure Rolling Contact Stresses

2012 ◽  
Vol 503-504 ◽  
pp. 667-670
Author(s):  
Jing Ling Zhou ◽  
Wei Nan Zhu ◽  
Guo Qing Wu ◽  
Yu Song Ren
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Contact Stresses ◽  
Rolling Contact ◽  
Shear Stresses ◽  
Element Analysis ◽  
Contact Fatigue Life

The RCF (Rolling Contact Fatigue) life of bearing balls is a main method, to evaluate the performance of bearing materials and their production technology. In general, The RCF life of ceramic balls is a reliable technique to asses whether or not they are suitable to be used in rolling bearings. The RCF life of ceramic balls is depend on contact stresses chiefly. It applies the finite element analysis to calculate the surface stresses and subsurface stresses, including 1st principal tensile stresses and shear stresses. The theory results are compared with the finite element solutions. Very good agreement is observed. The finite element results in this paper have an important applied value. The results provided theoretical basis for rolling contact fatigue life prediction of the ceramic balls.

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.

Finite Element Analysis of the Rolling Contact Fatigue Life of Railcar Wheels

2008 ◽  
Vol 575-578 ◽  
pp. 1461-1466
Author(s):  
Byeong Choon Goo ◽  
Jung Won Seo
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Element Analysis ◽  
Railway Vehicles ◽  
Contact Fatigue Life

Railcar wheels and axles belong to the most critical components in railway vehicles. The service conditions of railway vehicles have been more severe in recent years due to speed-up. Therefore, a more precise evaluation of railcar wheel life and safety has been requested. Wheel/rail contact fatigue and thermal cracks due to braking are two major mechanisms of the railcar wheel failure. One of the main sources influencing on the contact zone failure is residual stress. The residual stress in wheels formed during heat treatment in manufacturing changes in the process of braking. Thus the fatigue life of railcar wheels should be estimated by considering both thermal stress and rolling contact. Also, the effect of residual stress variation due to manufacturing process and braking process should be included in simulating contact fatigue behavior. In this paper, an evaluation procedure for the contact fatigue life of railcar wheels considering the effects of residual stresses due to heat treatment, braking and repeated contact load is proposed. And the cyclic stressstrain history for fatigue analysis is simulated by finite element analysis for the moving contact load.

A Rational Approach to Automated Pre- and Post-Processing of Offshore Structure Global Strength Finite Element Analysis

2011 ◽  
Author(s):  
Zhiyong Yang ◽  
Otto DaSilva
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Rational Approach ◽  
Strength Analysis ◽  
Complex Nature ◽  
Post Processing ◽  
Offshore Structure ◽  
Element Analysis ◽  
Finite Element Software ◽  
Global Strength

Offshore structure global strength analysis based on finite element plate model is a requirement for today’s classification societies and designers. Wave, wind, current loads have to be applied to the global strength model as a pre processing step to allow the analysis to take place. After the analysis, code checking must be performed to verify if the structure meets class or other requirements. Due to its complex nature, a large amount of engineering hours have to be spent for the pre and post processing. This is not only lengthy if performed manually or semi-automatically, but also mistake prone. General guidelines from classification societies exist, but general purpose commercial software is scarce and often still requires significant amount of engineering time to perform these tasks. This paper shows a rational approach to automate the pre and post processing of offshore structure global strength finite element analysis. Utilizing the FEMAP Application Program Interface (API), a complete automatic pre and post processing is implemented in one integrated program, Exmar Design Suite (EDS). The program will load the model from WAMIT generated wave pressure, apply internal pressure induced from motions to internal tanks, and also apply other environmental loads. After the finite element analysis, the program can execute strength code checking including yielding and buckling for the model. Both beam and stiffened plate panels can be identified using an automatic search algorithm, which is not a function available for general finite element software. The panels and beams are then checked against various common codes such as API/AISC/ABS/DNV. In addition, fatigue analysis can also be performed in either spectral or simplified approach. The benefits of automation are timesaving, accuracy and reliability. It also makes the check of whole model possible. Instead of relying more on “screening” or experience based structure check, engineers will have more confidence in the results by going through the whole model.

An Approach for Modeling Material Grain Structure in Investigations of Hertzian Subsurface Stresses and Rolling Contact Fatigue

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Nick Weinzapfel ◽  
Farshid Sadeghi ◽  
Vasilios Bakolas
Keyword(s):  
Finite Element ◽  
Current Model ◽  
Rolling Contact Fatigue ◽  
Voronoi Tessellation ◽  
Contact Fatigue ◽  
Theory Of Elasticity ◽  
Rolling Contact ◽  
Hertzian Contact ◽  
Grain Structure ◽  
Finite Element Software

The continuum theory of elasticity and/or homogeneously discretized finite element models have been commonly used to investigate and analyze subsurface stresses in Hertzian contacts. These approaches, however, do not effectively capture the influence of the random microstructure topology on subsurface stress distributions in Hertzian contacts. In this paper, a finite element model for analyzing subsurface stresses in an elastic half-space subjected to a general Hertzian contact load with explicit consideration of the material microstructure topology is presented. The random internal geometry of polycrystalline microstructures is modeled using a 3D Voronoi tessellation, where each Voronoi cell represents a distinct material grain. The grains are then meshed using finite elements, and an algorithm was developed to eliminate poorly shaped elements resulting from “near degeneracy” in the Voronoi tessellations. Hertzian point and line contacts loads are applied as distributed surface loads, and the model’s response is evaluated with commercial finite element software ABAQUS. Internal stress results obtained from the current model compare well with analytical solutions from theory of elasticity. The influence of the internal microstructure topology on the subsurface stresses is demonstrated by analyzing the model’s response to an over rolling element using a critical plane approach.

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