ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

AFRICAN RAILWAY CENTER OF EXCELLENCY

MSC IN RAILWAY ENGINEERING (ROLLING STOCK)

RAIL VEHICLE DESIGN: A REVIEW ON

TRAIN WHEEL FATIGUE ANALYSIS

SUBMITTED BY:

ABDURHAMAN SULEIMAN

ID.No. GSR/0896/15

SUBMITTED TO:
DR. KEJELA TEMESGEN
May, 2023
ADDIS ABABA, ETHIOPIA
ABSTRACT

This review paper provides a comprehensive overview of existing literature and research on train
wheel fatigue analysis. It examines factors influencing wheel fatigue, such as loading conditions,
material properties, wheel-rail interaction, and operational parameters. The review highlights the
importance of analyzing fatigue behavior and ensuring the reliability of train wheels to maintain
the safety and performance of railway systems. A specific focus is given to the utilization of the
finite element method (FEM) for fatigue analysis, discussing modeling techniques, material
modeling, contact modeling, boundary conditions, advancements, challenges, and potential
strategies to improve fatigue analysis. The paper concludes by emphasizing the contribution of
the review to safer and more reliable train wheel designs and maintenance practices. The
systematic methodology employed in the review, following the PRISMA approach, ensures rigor,
transparency, and credibility in the review process. The results and synthesized findings are
presented, and research gaps and future directions for train wheel fatigue analysis are identified.

Keywords: Literature review, Review methodology, State-of-the-art analysis, Comparative

analysis, Critical evaluation

Table of Contents
ABSTRACT.................................................................................................................................... 2

1. INTRODUCTION ................................................................................................................... 3

2. RESEARCH METHOD .......................................................................................................... 6

3. LITERATURE REVIEW ........................................................................................................ 8

4. RESULT AND DISCUSSION................................................................................................11

5. CONCLUSION AND FUTUREWORK ............................................................................... 13

6. RFERENCE .............................................................................................................................. 14
 1. INTRODUCTION

The title "Review on Train Wheel Fatigue Analysis" refers to an in-depth examination and
evaluation of existing research and methodologies pertaining to the analysis of fatigue in train
wheels. This review aims to provide a comprehensive overview of the current state of knowledge
regarding the factors influencing wheel fatigue, including loading conditions, material properties,
wheel-rail interaction, and operational parameters. By synthesizing relevant information and
insights, the review serves as a valuable resource for researchers and professionals involved in
railway system design, operation, and maintenance, aiding in the identification of research gaps
and the advancement of more robust fatigue analysis methods for train wheels.

A train wheel is a specialized component used in railway systems that is designed to support the
weight of the train and facilitate its movement along the tracks. It typically consists of a sturdy
metal structure, often made of steel, with a central hub and an outer rim. The rim is usually
equipped with flanges, which help guide the wheel along the rail and prevent derailment[1].
Train wheels are vital for the safe and efficient operation of trains, as they distribute the weight
of the train evenly, minimize friction between the wheel and rail, and enable smooth rolling
motion. They are utilized in various applications, including passenger trains, freight trains,
locomotives, and tram systems, playing a crucial role in transporting people and goods over long
distances. Train wheels undergo substantial stress and fatigue during their service life due to the
heavy loads, dynamic forces, and constant interaction with the track[2]. Therefore, analyzing the
fatigue behavior and ensuring the reliability of train wheels is of paramount importance to
maintain the safety and performance of railway systems.

Wheel failure refers to the occurrence of significant defects, damages, or malfunctions in train
wheels that render them unsuitable or unsafe for operation[3]. Wheel failures can have serious
consequences, ranging from service disruptions and delays to potential derailments or accidents.
There are several factors that can contribute to wheel failure, including fatigue, wear, cracks,
material defects, improper maintenance, and operational issues. Fatigue, caused by repeated
loading and unloading cycles, is a common cause of wheel failure, leading to cracks and
fractures in the wheel structure. Wear and abrasion can occur due to the continuous contact
between the wheel and rail, leading to a decrease in wheel diameter and compromised
performance. Material defects or weaknesses in the wheel's composition can also contribute to
failures. Improper maintenance practices, such as inadequate lubrication or inadequate inspection
and repair, can exacerbate these issues. Wheel failures highlight the importance of regular
maintenance, inspection, and analysis of train wheels to ensure their structural integrity,
minimize risks, and maintain the reliability and safety of railway systems.

The importance of conducting a review on train wheel fatigue analysis lies in the fact that
improperly designed or inadequate train wheels can potentially lead to accidents. The design of
train wheels plays a critical role in ensuring the safe and efficient operation of railway systems. A
thorough analysis of wheel fatigue is crucial because fatigue-related failures can have severe
consequences. When train wheels are subjected to repeated loading and unloading cycles, such as
the weight of the train and dynamic forces during operation, they experience stress that can lead
to the development of cracks or fractures. If undetected or left unaddressed, these fatigue-
induced defects can compromise the structural integrity of the wheel, eventually resulting in
wheel failure. In the worst-case scenario, a failed wheel can lead to derailments, accidents, and
serious harm to passengers, crew, and infrastructure. By conducting a comprehensive review on
train wheel fatigue analysis, potential design flaws and vulnerabilities can be identified, leading
to the development of more robust and reliable wheel designs that prioritize safety. Furthermore,
this review can inform the establishment of appropriate maintenance practices and inspection
protocols to detect and mitigate fatigue-related issues, ultimately enhancing the overall safety
and reliability of train wheels in railway systems[2].

In this overview a distinct aspect that can be explored is the utilization of the finite element
method (FEM) for analyzing train wheel fatigue. FEM is a powerful numerical technique that
allows for detailed modeling and simulation of complex structural behavior, making it applicable
to the fatigue analysis of train wheels. The review can focus on discussing different approaches
and methodologies within FEM specifically tailored to train wheel fatigue analysis, including
modeling techniques, material modeling, contact modeling between wheel and rail, and boundary
conditions. Additionally, the review can highlight recent advancements in FEM-based fatigue
analysis, such as incorporating realistic loading conditions, considering dynamic effects,
evaluating different wheel designs and materials, and integrating probabilistic methods for
more accurate fatigue life predictions. Furthermore, the review can explore the challenges and
limitations associated with FEM in train wheel fatigue analysis, such as computational cost,
model validation, and sensitivity to input parameters, while also discussing potential strategies
to overcome these challenges. By emphasizing the role of FEM in train wheel fatigue analysis,
the review provides a comprehensive understanding of the application of this numerical
technique in assessing and improving the fatigue performance of train wheels.

The review aims to comprehensively evaluate the application of the finite element method
(FEM) in train wheel fatigue analysis. It discusses FEM modeling, material and contact
considerations, advancements, challenges, and strategies to improve fatigue analysis. The review
contributes to knowledge and supports safer and more reliable train wheel designs and
maintenance.

The paper is structured into several sections for clear organization and coherence. Section 1
serves as an introduction, providing an overview of the topic and setting the context for the
review. In Section 2, the review methodology employed in the paper is thoroughly explained,
detailing the approach taken to conduct the review on train wheel fatigue analysis. Section 3
forms the core of the paper, where each of the selected papers relevant to the topic is reviewed
and analyzed, offering a comprehensive evaluation of their key findings and methodologies. In
Section 4, the results and discussion are presented, summarizing the main outcomes and
providing a synthesis of the insights gained from the reviewed papers. Section 5 presents the
conclusion, succinctly summarizing the key contributions and implications of the review. Finally,
Section 6 lists the references used throughout the paper, ensuring proper citation and
acknowledgment of the sources consulted. This organizational structure facilitates a logical flow
of information, enabling readers to easily navigate the paper and comprehend the findings and
conclusions presented.
 2. RESEARCH METHOD

The following methodology was employed to conduct the review on train wheel fatigue analysis:

1. Research Objective: The primary objective of the review was to comprehensively examine
and evaluate existing literature and research pertaining to train wheel fatigue analysis, with a
focus on understanding the factors influencing wheel fatigue, fatigue analysis methods,
challenges, and potential solutions[4].

2. PRISMA Approach: The Preferred Reporting Items for Systematic Reviews and Meta-
Analyses (PRISMA) framework was utilized as a systematic approach for conducting the
review. This methodology ensures transparency, replicability, and rigor in the review
process[4].

3. Literature Search: A comprehensive search strategy was developed to identify relevant

scholarly articles, conference papers, reports, and other sources of information. Electronic
databases, including academic libraries, research databases (such as PubMed, IEEE Xplore,
Scopus, and Web of Science), and relevant industry-specific sources were systematically
searched using predefined keywords and search terms related to train wheel fatigue
analysis.[4]

4. Inclusion and Exclusion Criteria: Clear inclusion and exclusion criteria were established to
select studies relevant to the review objective. Only peer-reviewed articles, conference
papers, and reports published in English were considered. Studies focusing on train wheel
fatigue analysis, including fatigue behavior, analysis methods, modeling techniques, material
considerations, and case studies, were included, while studies unrelated to train wheel fatigue
or lacking relevant information were excluded[4].

5. Screening and Selection Process: The identified articles were screened based on their titles
and abstracts to determine their relevance to the review objective. The selected articles were
then subjected to full-text assessment to ensure their alignment with the review's scope. Any
discrepancies or disagreements in the selection process were resolved through discussion and
consensus among the reviewers[4].
6. Data Extraction: Data from the selected articles were extracted systematically, including
information on study objectives, methodology, key findings, analysis techniques, and
recommendations. A standardized data extraction form was used to maintain consistency[4].

7. Data Analysis and Synthesis: The extracted data were analyzed, synthesized, and organized
thematically to identify common themes, patterns, and gaps in the literature. The findings
were summarized, and key insights were synthesized to address the review objective[4].

8. Results and Discussion: The results and synthesized findings were presented in a clear and
concise manner, highlighting the key aspects of train wheel fatigue analysis and the
significant contributions from the reviewed literature. The results were discussed in the
context of existing knowledge, and the implications and limitations were critically evaluated.

9. Conclusion: A comprehensive conclusion was drawn based on the synthesized findings,

summarizing the main contributions of the review, identifying research gaps, and suggesting
future directions for research in train wheel fatigue analysis[4].

The application of the PRISMA approach ensured a rigorous and systematic review process,
enhancing the credibility and transparency of the review on train wheel fatigue analysis.
 3. LITERATURE REVIEW

Seo [5] Investigates the effect of residual stress and web plate shape on the fatigue life of railway
wheels. The study uses finite element analysis to predict the fatigue life of the wheels with
different web plate shapes and residual stresses. The results show that the residual stress has a
significant effect on the fatigue life of the railway wheels. The paper provides insights into the
design of railway wheels and how the web plate shape can affect the fatigue life of the wheels.

Jelila [6] investigate wheel-rail contact analysis at railway turnouts using a finite element
modeling approach. The study aims to understand and reduce wheel-rail contact problems by
analyzing fatigue life and simulating contact problems under different loading conditions. They
specifically examine the impact of normal and tangential contact forces generated by different-
angled shapes of the turnout on the life of contacting surfaces. The results reveal that tangential
contact force leads to the maximum von-Mises equivalent alternating stress, fatigue sensitivity,
and hysteresis loop stresses, which are responsible for rolling contact fatigue damage and
excessive deformation of the contact surface. The maximum fatigue sensitivity life obtained
under normal force for different vehicle loading conditions (empty, optimum, and overrated) is
78,900, 49,200, and 43,100 cycles, respectively. Under tangential force, the maximum fatigue
sensitivity life is 11,800, 11,420, and 11,300 cycles for the corresponding loading conditions.
The study concludes that normal contact force can withstand significantly more loading cycles
(up to seven times) compared to tangential contact force, implying that the latter reduces the life
of contacting surfaces. Additionally, the tangential contact force has a greater influence on
fatigue sensitivity and causes higher stresses, resulting in a shorter life cycle for the contact
surface. Jelila [6] emphasize the importance of considering contact force types and track
geometry in understanding contact damages and ensuring structural integrity. Overall, the paper
provides valuable insights into wheel-rail contact problems at railway turnouts and highlights the
significance of optimizing contact forces and track geometry to enhance the performance and
durability of railway systems.

Masoudi Nejad and Berto [7] conducts fatigue life assessment of railway wheels using a
nonlinear model for fatigue crack growth. The study uses finite element analysis to predict the
fatigue life of the wheels under different loading conditions. The results show good agreement
with experimental data, which demonstrates the accuracy of the developed model. The paper
provides insights into the fatigue life assessment of railway wheels and how a nonlinear model
for fatigue crack growth can be used to predict the fatigue life of the wheels accurately.

Salehi [8] investigates the effect of residual stress on the fatigue life of railway wheels. The study
uses finite element analysis to predict the fatigue life of the wheels with different residual stress
levels. The results show that the residual stress has a significant effect on the fatigue life of the
wheels. The paper provides insights into the design of railway wheels and how the residual stress
can be controlled to improve the fatigue life of the wheels.

Srivastava [9] investigates the rolling contact fatigue life of rails for different slip conditions. The
study uses finite element analysis to predict the rolling contact fatigue life of the rails under
different slip conditions. The results show that the slip condition has a significant effect on the
rolling contact fatigue life of the rails. The paper provides insights into the design of railways
and how the slip condition can be controlled to improve the rolling contact fatigue life of the
rails.

Institute of Electrical and Electronics Engineers [10] conducts a comprehensive study on the
fatigue behavior of rail-wheel assemblies through finite element analysis (FEA). By analyzing
stresses, strains, and safety factors, the study provides insights into the structural integrity and
fatigue life of the assembly under varying load conditions. The research successfully applies the
Goodman mean stress correction theory and presents results on the fatigue life of the rail-wheel
assembly. Overall, the paper addresses a critical issue in railway safety engineering, offering
valuable findings that can inform design improvements, material selection, and maintenance
strategies. The use of FEA and consideration of key factors contribute to the reliability and
accuracy of the study, establishing a solid foundation for further research in the field.

Liu, Stratman, and Mahadevan [11] proposes a new multiaxial high-cycle fatigue initiation life
prediction model for railroad wheels. The study develops a general fatigue damage analysis
methodology for complex mechanical components, specifically addressing the wheel/rail rolling
contact fatigue problem. A 3-D elasto-plastic finite element model is utilized for stress analysis,
and a sub modeling technique is employed to enhance computational efficiency and accuracy.
The proposed model evaluates fatigue damage numerically based on the stress history during one
revolution of wheel rotation. The effects of wheel diameter, vertical loading, material hardness,
and material fatigue properties on fatigue crack initiation life are investigated. The conclusion
highlights the development of a multiaxial fatigue life prediction model based on the critical
plane approach, which incorporates material properties. Non-linear finite element analysis and
sub modeling techniques are used for stress computation, and a numerical example is
implemented and compared with field observations. The paper suggests future research should
consider the interactive effects of different parameters, validate the model with experimental
data, and incorporate additional factors like residual stress, brake loading, thermal loading,
dynamic and impact loadings, and material defects into the methodology.
 4. RESULT AND DISCUSSION

This comprehensive literature review provides a range of studies focusing on various aspects of
fatigue life and contact analysis in railway systems. The papers employ finite element analysis
and specific methodologies to investigate the influence of factors such as residual stress, web
plate shape, contact forces, slip conditions, and material properties on the fatigue life of railway
components. The strengths of these studies lie in their use of advanced analysis techniques and
their contributions to understanding the design considerations and optimization strategies for
enhancing fatigue life. However, certain weaknesses can be identified, such as the need for
further validation with experimental data, consideration of interactive effects between
parameters, and exploration of additional factors like residual stress, brake loading, thermal
loading, dynamic and impact loadings, and material defects. Addressing their gaps would further
enhance the knowledge and applicability of fatigue life assessment in railway systems.

NO. AUTHORS YEAR METHOD OR SPECIFICATION STRENGTH IDENTIFIED GAP

NAME SOFTWARE
USED
1 Seo et al., 2009 Finite Element Investigated the Demonstrated The paper only focuses on
2009 Analysis effect of residual significant effect of two factors, and the
stress and web residual stress on analysis does not consider
plate shape on the fatigue life of railway the influence of other
fatigue life of wheels - Provided factors, such as loading
railway wheels insights into the conditions, wheel-rail
design of railway interaction, and material
wheels and the properties.
influence of web plate
shape
2 Jelila et al., 2021 Finite Element Investigated wheel- Examined impact of - Interactive effects of
2021 Modeling rail contact normal and tangential different parameters -
analysis at railway contact forces on Validation of the model
turnouts fatigue sensitivity and with experimental data -
stresses - Emphasized Incorporation of additional
importance of factors like residual stress,
considering contact brake loading, thermal
force types and track loading, dynamic and
geometry impact loadings, and
material defects into the
methodology
3 Masoudi 2021 Finite Element Conducted fatigue Demonstrated good The paper does not
Nejad & Analysis life assessment of agreement with consider the effect of
Berto, 2021 railway wheels experimental data - loading conditions, wheel-
Provided insights into rail interaction, and
fatigue life assessment material properties on the
of railway wheels fatigue crack growth and
 using a nonlinear life assessment.
model for fatigue
crack growth
4 Salehi et al., 2015 Finite Element Investigated the Demonstrated The paper does not provide
n.d. 5Analysis effect of residual significant effect of a detailed analysis of the
stress on the residual stress on impact of different residual
fatigue life of fatigue life of railway stress fields on the wheel's
railway wheels wheels - Provided life and does not consider
insights into the the effect of other factors,
design of railway such as loading conditions
wheels and controlling and material properties.
residual stress to
improve fatigue life
5 Srivastava 2017 Finite Element Investigated the Demonstrated The paper only
et al., 2017 Analysis rolling contact significant effect of considers one factor
fatigue life of rails slip condition on (i.e., slip conditions) and
rolling contact fatigue does not analyze the
life of rails - Provided
influence of other
insights into the
design of railways and
factors, such as loading
controlling slip conditions, material
conditions to improve properties, and
rolling contact fatigue environmental factors
life
6 Institute of 2016 Finite Element Conducted Addressed critical The need for further
Electrical Analysis comprehensive issue in railway safety investigation into the
and study on fatigue engineering - Offered relationship between load
Electronics behavior of rail- valuable findings for level and fatigue life of
Engineers, wheel assemblies design improvements, railway wheel specimens,
n.d. material selection, and particularly focusing on
maintenance strategies the quantitative analysis
and understanding of the
decrease in fatigue life
with increased load level.
7 Liu et al., 2006 Finite Element Proposed Developed a Interactive effects of
2006 Analysis multiaxial high- multiaxial fatigue life different parameters -
cycle fatigue prediction model for Validation of the model
initiation life railroad wheels - with experimental data -
prediction model Investigated effects of Incorporation of additional
for railroad wheels various parameters on factors like residual stress,
fatigue crack initiation brake loading, thermal
life loading, dynamic and
impact loadings, and
material defects into the
methodology
In conclusion, the table summarizes several research papers related to the fatigue life of railway
components. Each study utilizes finite element analysis or modeling techniques to investigate
different aspects of fatigue life and its influencing factors.
 5. CONCLUSION AND FUTURE WORK

In general, the literature review provides valuable insights into the fatigue life of railway wheel
components and the factors influencing their durability. The studies employ finite element
analysis, modeling techniques, and advanced methodologies to investigate parameters such as
residual stress, web plate shape, contact forces, slip conditions, and material properties. The
findings emphasize the significant impact of these factors on the fatigue life of railway wheels
and rails. They highlight the importance of optimizing design considerations and track geometry
to enhance the performance and structural integrity of railway systems.

Future work in this field could focus on addressing the identified gaps and expanding the
research scope. Firstly, further investigations should explore the interactive effects of different
parameters to gain a comprehensive understanding of their combined influence on fatigue
behavior. Additionally, validating the developed models and methodologies with experimental
data would enhance their accuracy and reliability. Incorporating additional factors, such as
residual stress, brake loading, thermal loading, dynamic and impact loadings, and material
defects, would provide a more realistic representation of the complex operating conditions
experienced by railway components.

Moreover, considering the advancements in materials science and technology, future research
could explore the use of innovative materials with improved fatigue resistance for railway
applications. This could involve investigating the fatigue behavior of composite materials or
exploring new manufacturing techniques that can enhance the fatigue life of railway
components.

Furthermore, the studies could be extended to include other critical components of the railway
system, such as rail fastenings, sleepers, and joints, to provide a comprehensive understanding of
the fatigue behavior across the entire infrastructure.

Overall, the literature review sets the foundation for further research in this field, indicating the
need for comprehensive investigations, model validation, and consideration of additional
influencing factors. By addressing these areas, future work can contribute to the development of
more accurate predictive models, improved design guidelines, and enhanced maintenance
strategies for ensuring the long-term reliability and safety of railway systems.
6. RFERENCES

[1] C. J. Peters and D. Eifler, “Influence of Service Temperatures on the Fatigue Behaviour of
Railway Wheel and Tyre Steels*,” Materials Testing, vol. 51, no. 11–12, pp. 748–754,
Nov. 2009, doi: 10.3139/120.110094.

[2] M. Asplund, “Wayside Condition Monitoring System for Railway Wheel Profiles:
Applications and Performance Assessment,”

[3] “Rolling Contact Fatigue: A Comprehensive Review,” 2011. [Online]. Available:

http://www.fra.dot.gov.

[4] D. Moher, A. Liberati, J. Tetzlaff, D. G. Altman, and P. Group, “Preferred Reporting Items
for Systematic Reviews and Meta-Analyses: The PRISMA Statement.” [Online].
Available: www.annals.org

[5] J. W. Seo, S. J. Kwon, H. K. Jun, and D. H. Lee, “Effects of residual stress and shape of
web plate on the fatigue life of railway wheels,” Eng Fail Anal, vol. 16, no. 7, pp. 2493–
2507, Oct. 2009, doi: 10.1016/j.engfailanal.2009.04.013.

[6] Y. D. Jelila, H. G. Lemu, W. Pamuła, and G. G. Sirata, “Fatigue life analysis of wheel-rail
contacts at railway turnouts using finite element modelling approach.,” IOP Conf Ser
Mater Sci Eng, vol. 1201, no. 1, p. 012047, Nov. 2021, doi: 10.1088/1757-
899x/1201/1/012047.

[7] R. Masoudi Nejad and F. Berto, “Fatigue fracture and fatigue life assessment of railway
wheel using non‐linear model for fatigue crack growth,” Int J Fatigue, vol. 153, Dec.
2021, doi: 10.1016/j.ijfatigue.2021.106516.

[8] S. M. Salehi, G. H. Farrahi, S. Sohrabpoor, and R. M. Nejad, “Life Estimation in the

Railway Wheels Under the Influence of Residual Stress Field.”

[9] J. P. Srivastava, P. K. Sarkar, V. R. K. Meesala, and V. Ranjan, “Rolling contact fatigue life
of rail for different slip conditions,” Latin American Journal of Solids and Structures, vol.
14, no. 12, pp. 2243–2264, 2017, doi: 10.1590/1679-78254161.
[10] Institute of Electrical and Electronics Engineers, 2016 IEEE International Conference on
Intelligent Rail Transportation (ICIRT) : Birmingham, United Kingdom, August 23-25,
2016.

[11] Y. Liu, B. Stratman, and S. Mahadevan, “Fatigue crack initiation life prediction of railroad
wheels,” Int J Fatigue, vol. 28, no. 7, pp. 747–756, Jul. 2006, doi:
10.1016/j.ijfatigue.2005.09.007.