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Fatigue Fracture and Fatigue Life Assessment of Railway Wheel Using Non
Fatigue Fracture and Fatigue Life Assessment of Railway Wheel Using Non
Fatigue fracture and fatigue life assessment of railway wheel using non-
linear model for fatigue crack growth
Reza Masoudi Nejad a, *, Filippo Berto b
a
School of Mechanical and Electrical Engineering, University of Electronic Science and Technology of China, Chengdu 611731, China
b
Department of Mechanical and Industrial Engineering, NTNU – Norwegian University of Science and Technology, Trondheim, Norway
A R T I C L E I N F O A B S T R A C T
Keywords: In this paper, the fatigue behavior of railway wheel specimens subjected to cyclic loading have been investigated
Fatigue fracture via experimental tests and numerical analysis. The material behaviour of the wheel specimen has been modelled
Boundary element by means of the Ramberg-Osgood equation. The non-linear Kujawski-Ellyin (KE) model has been adopted for the
Railway wheel
fatigue crack propagation under small-scale yielding (SSY) conditions. The formulation of the rigid-insert crack
Cyclic loading
Crack closure
closure (RICC) model has been applied to a specimen of railway wheel that has the same conditions as a real
instance. The results indicate that the fatigue life of specimens decreases with any increase in load level.
* Corresponding author.
E-mail addresses: masoudinejad@uestc.edu.cn (R. Masoudi Nejad), filippo.berto@ntnu.no (F. Berto).
https://doi.org/10.1016/j.ijfatigue.2021.106516
Received 22 July 2021; Received in revised form 25 August 2021; Accepted 27 August 2021
Available online 31 August 2021
0142-1123/© 2021 Elsevier Ltd. All rights reserved.
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
rolling contact fatigue failure in railway wheels subjected to operational tween rail/wheel is essential, which this stress distribution could be
loading. A sensitivity analysis revealed a strong influence of the fatigue obtain using numerical method. Stress–strain curves are also approxi
strength and the material defect distribution on the probability of fa mated by the well-known Ramberg-Osgood relation. The Ramberg-
tigue failure. Huang et al. [35] analyzed the residual stress, mechanical Osgood equation is expressed in Eq. (1) [7]:
stress, and fatigue in six types of wheel plate shapes. Results showed that σ ( σ )n
(1)
yields
the residual stress was lowest and highest in the S-shaped and double S- ε = εe + εp ̅̅→ ε = + K
E E
,
shaped wheel plates, respectively. To optimize the design and operation ( )n
the various types of damage occurring in the wheel must be considered. In this equation term of Eσ represents the linear region and K Eσ is
Thermal cracks, shelling, surface fatigue, and wear are the most com the plastic region in which K and n depend on material and E is elasticity
mon [36–40]. Crack growth acceleration occurs immediately after modulus.
applying a tensile overload in some other materials [41–45]. On the According to the RICC model, the closure phenomenon is the inter
other hand, acceleration in FCG rate are usually observed by application action between the specimen and the residual material in the propaga
of a compressive under-loading [45,46]. Crack closure, crack blunting, tion of crack tip, which results from crack penetration in the specimen.
and the compressive residual stresses of the crack tip are among the The standard effective stress intensity range is defined as follows [15]:
parameters that interrupt the effect of overloading on FCC [47–52]. To
assess the retardation effect, introduced by overloading, an effective ΔKeff = Kmax − Kop or ΔKeff = Kmax − Kcl , (2)
stress intensity factor range was suggested by Elber [53]. Regarding the
crack closure and size of the residual plastic zone, Matsuoka [54] where ΔKeff , the effective stress intensity factor is defined as the dif
developed a model to illustrate the retardation, caused by single and ference between the maximum stress intensity factor of mode-I (Kmax )
multiple overloading. The wheeler’s model [55] and its modified and stress level where the crack first opens (Kop ) and Kcl is the closure
version were also introduced to impose the retarded FCG affected by stress intensity factor.
overloading, considering the increased yield zone ahead of the crack tip The gradual closure can also continue with the compressive area of
induced. A semi-empirical model was suggested by Lu and Li [56] to the loading cycle, so that the crack mouth is not completely closed at
appraise the effects of several overloading related parameters, on FCG. zero load. The following geometric relationship can be written during
Masoudi Nejad et al. [57] investigated an experimental study on fatigue the gradual closure of the crack surfaces using the similar triangles rule
fracture performance of rail steel used in railway applications. They [22]:
carried out a series test that includes fatigue, fracture toughness, and Γ ϕ + a − at
fatigue crack growth and checked by fractography studies on fractured = , (3)
ν a+ϕ
specimens.
Despite experimental research existent in the field of fatigue fracture where Γ is the middle material thickness, ν is the crack mouth opening
behavior of the railway wheel steel, information about the performance displacement (CMOD), and ϕ is the distance between the axis of rotation
of fatigue due to the crack initiation and fracture behavior does not exist. in crack tip and surface. a is the true crack length and at is the transient
In this paper, different experimental tests for fatigue fracture and fatigue crack length.
life assessment of a railway wheel steel using non-linear model are Masoudi Nejad and Liu [14] presented a new applied method for
carried out using the CT specimens. The numerical simulations are estimating the fatigue life of the railway rail specimens using the rigid-
performed using the Ramberg-Osgood equation for material behaviour insert crack closure (RICC) model under mixed-mode cyclic loading
of the railway wheel specimen and distributions of stress intensity fac conditions. Shariati et al. [22] provided a new method for analyzing and
tors as well as load ratios under various cyclic loading conditions are evaluating the fatigue crack closure load and estimated the life of en
determined. The non-linear Kujawski-Ellyin model has been adopted for gineering components using rigid insert crack closure model (RICC),
the FCG under SSY conditions. Also, the formulation of the RICC model non-destructive replica technique. After applying the boundary condi
has been applied to a standard specimen of the railway wheel that has tion (P = 0; ν = νr ) and determining λ, the load-CODII is obtained [22]:
{ [ ( )] ( )
2EB ν − νr 25 3νcl ϕ + 3aν + 2acνϕ 4 νcl + acνϕ + aν
P= (1 − cϕ) 2
− νcl ϕ2
c ln − ln , (4)
3 3 + 5cϕ + 2c2 ϕ2 a(3 + 2cϕ)2 3νcl ϕ + 3aνr + 2acνr ϕ a(1 + cϕ)2 νcl + acνr ϕ + aνr
the same conditions as a real instance. where B is the thickness of the specimen, νr is residual CODII value in
( )/
zero load, c = 1 + ϕa W, and W is the specimen width.
2. Proposed model for fatigue life assessment
P is obtained by any value ν. So, the following values are substituted
Many types of research are performed in the field of evaluating fa in Eq. (4) [22]:
tigue fracture behavior. Analytical methods are used to determine the
Pcl
fatigue life of railway components. Most analytical methods are verified P = Pcl ; νcl = , (5)
S
by experimental and numerical methods. To have a more accurate
determination of the fatigue strength of railway components, having where S is specimen stiffness and Pcl is closure force. After substituting,
knowledge about the stress distribution around the contact area be the Eq. (6) is obtained [22]:
{ ( ) [ ( )] ( )
2EB (1 − cϕ)2 Pcl Pcl ϕ2 c 25 Pcl (3ϕ + 3a + 2acϕ) 4 Pcl (a + acϕ + ϕ)
Pcl = − νr − ln − ln , (6)
3 3 + 5cϕ + 2c2 ϕ2 S S a(3 + 2cϕ)2 3Pcl ϕ + 3aSνr + 2acSνr ϕ a(1 + cϕ)2 Pcl ϕ + acSνr ϕ + aSνr
2
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
ductility and strength coefficients, respectively. The local mean stress, In order to study the fatigue fracture behavior in experimental tests,
which can be obtained as follows [58]: the CT specimens were tested. The specimens were machined from an 8
[ ]
(1 + Rs ) mm-thick sheet of the railway wheel in Two different orientations. The
σm = *σ max , (13) notch is oriented in the radial direction and a direction parallel to the
2
tangent of the contact area with rail. In linear elastic fracture mechanics
where the stress ratio, Rs , is not generally coincident with the stress (LEFM), fatigue life is usually estimated for a cracked specimen by using
ratio, R, which is linked to the remote tensile load. Also, the maximum an exponential function of SIFs. In this study, the non-linear Kujawski-
cyclic stress can be obtained as follows: Ellyin (KE) model was used to estimate the fatigue crack propagation
′
under small-scale yielding (SSY) conditions. The loading device was
{ }
made of steel alloy. The fatigue crackgrowth tests were carried out for
n
′
2
Kmax (1+n )
(14)
′
σ max = σ y , different loading conditions on the Zwick/Roell HB 100 machine. In
(1 + n′ )πσ′y δ*
order to study the crack growth rate, a sinusoidal waveform was used
and three different load ratios Rratio = 0.1, Rratio = 0.3, and Rratio = 0.5
where σ y is the cyclic yield strength.
′
The following value is substituted in Eq. (12) [58]: Railway 203 15 0.31 493 831
wheel
3
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
Table 2 selected for this test. A 1.3 mm fatigue precrack was generated for all
Material data of railway wheel specimen. specimens under cycling loading before fatigue fracture test according to
Material n
′
σf (MPa)
′ ′
εf c b δ* (mm) ASTM E647 [60]. The precrack measuring was performed using portable
digital microscopes. Fig. 3 shows the experimental test setup at the pure
Railway wheel 0.142 1681 0.68 − 0.718 − 0.112 0.93 mode-I loading condition for the initial fatigue precracking of the
specimen.
4. Numerical analysis
Fig. 2. The CT specimen for experimental test under cyclic loading (dimensions in mm).
4
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
stress field is determined with the stress intensity factors (SIFs). The use
Table 3 of stress intensity factors (SIFs) for describing the stress field is limited to
Boundary element results for different number of elements for the railway wheel
linear elastic fracture mechanics (LEFM). The stress intensity factors
specimen.
(SIFs) ratios have direct effects on the characteristics of the formation of
Mesh Total number of KI at crack front KI at crack front crack surfaces and the critical loads which are necessary for unstable
√̅̅̅̅ √̅̅̅̅
specimen elements center, MPa. m edge, MPa. m
fracture. Therefore, the accurate assessment of a cracked structure with
1 3456 24.11 21.79 regard to its safety and mechanical life under cyclic loading condition is
2 4679 24.26 21.56 significantly important. Fig. 6 shows a comparison of Load-CODll
3 5908 24.37 21.43
experimental results and the behavior predicted by Eq. (6) for the rail
4 7623 24.45 21.36
5 9467 24.49 21.32
way wheel specimen. As can be seen in Fig. 6, the behavior of the Load-
CODll curve is acceptable for both experimental tests and analytical
solution. The experimental and theoretical results for the load and the
5. Results and discussion closure stress intensity factor in terms of normalized crack length are
shown in Fig. 7. According to Fig. 7, a good consistency is observed
Fatigue fracture performance of the railway wheel is a function of between the analytical solutions and the experimental test results for the
many factors, including service conditions, loading, material properties, load and the closure stress intensity factor.
environmental factors, and manufacturing processes. The interaction of In this paper the subsurface fatigue crack growth under rolling
three different fracture mechanisms known as tension, shear and tearing contact fatigue (RCF) of the railway wheel is modelled. By moving away
modes can be observed in many structures containing defects such as from the wheel surface and increasing the depth of crack placement
cracks. The cyclic loading condition produces a complex stress state at from the surface, the effect of contact stresses is reduced and the fatigue
the region around the crack tip. The singularity at the crack tip in this crack growth rate is reduced. Also, according to the fatigue life diagrams
5
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
Fig. 5. The steps of fatigue crack growth simulation using boundary element method.
Fig. 6. Comparison of the Load-CODII results in terms of obtained from Fig. 7. Comparison of Pcl and Kcl results in terms of obtained from experi
experimental tests and analytical behavior for the railway wheel specimen. mental tests and analytical behavior for the railway wheel steel in various
cracks length.
for different modes of wheel profile geometry and its contact with the of stress intensity factor (SIF) increase by decreasing the load ratio for
rail, it can be concluded that controlling the wheel-rail contact geometry two different orientations for the railway wheel specimens under the
to reduce contact stresses is the best way to control roller contact fatigue cyclic loading conditions. As can be seen in Fig. 9, the minimum fatigue
defects. The fatigue crack growth rate in terms of equivalent stress in life is related to the railway wheel specimen with radial direction notch
tensity factor for each load ratio angle for the railway wheel specimen under the load ratio of 0.1. Comparing the results of fatigue life for this
under cyclic loading conditions are shown in Fig. 8. As can be seen, the specimen, it was found that the difference between the results of nu
range of effective stress intensity factor is smaller than the stress in merical analysis and experimental test is 7% and the difference between
tensity factor range. Especially with increasing the fatigue crack length, the results of analytical solution and experimental tests is 15%. Also, the
their differences increase. Considering the effect of the fatigue crack final fatigue life for the railway wheel specimen with tangential direc
closure, the specimen has a longer life. The effect of the load ratio on the tion notch under the load ratio of 0.5 is longer than the other specimens.
fatigue crack growth rates is also more pronounced for the railway Comparing the results of fatigue life for this specimen, it was found that
wheel specimen under cyclic loading conditions. Fig. 9 compares fatigue the difference between the results of numerical analysis and experi
life in terms of crack length for the experimental tests, numerical anal mental test is 9% and the difference between the results of analytical
ysis, and analytical solution (Eq. (17) based on Eq. (10)). The phe solution and experimental tests is 16%. As can be seen in Fig. 9, a good
nomenon of rolling contact fatigue crack has become one of the most consistency is observed between the analytical solutions, numerical
important issues in railway and a problem of intensive research in many analysis, and the experimental test results for the fatigue life of the
scientific centers. This process is not slow and uncontrolled. Thus, it railway wheel specimen under cyclic loading conditions in each load
causes sudden break in rolling member. According to Fig. 9, the values ratio.
6
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
Fig. 9. Comparison of the fatigue life results in terms of obtained from analytic
solution, numerical analysis and experimental tests for the railway wheel
Fig. 8. Crack growth rate in terms of stress intensity factor range for the rail specimen; a) R = 0.1, b) R = 0.3, and c) R = 0.5.
way wheel specimen; a) R = 0.1, b) R = 0.3, and c) R = 0.5.
7
R. Masoudi Nejad and F. Berto International Journal of Fatigue 153 (2021) 106516
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