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Computational methods to predict RCF crack initiation hot spots in rails using critical plane SWT damage indicator parameter
KTH, School of Engineering Sciences (SCI), Engineering Mechanics, Vehicle engineering and technical acoustics.ORCID iD: 0000-0002-3414-4163
KTH, School of Engineering Sciences (SCI), Engineering Mechanics.ORCID iD: 0000-0002-6346-6620
KTH, School of Engineering Sciences (SCI), Engineering Mechanics, Material and Structural Mechanics.ORCID iD: 0000-0001-8068-2360
KTH, School of Engineering Sciences (SCI), Engineering Mechanics, Vehicle engineering and technical acoustics.ORCID iD: 0000-0003-1583-4625
2025 (English)In: Railway Engineering Science, ISSN 2662-4745Article in journal (Refereed) Epub ahead of print
Abstract [en]

Predicting rolling contact fatigue crack hot spots or regions with increased local driving forces in rails is challenging due to the wide range of factors that influence crack initiation. Rail sections experience fluctuating creepage conditions, contact positions, and loads throughout their lifespan, influencing the development and location of fatigue cracks. A new computational method is proposed that predicts the orientation and regions prone to rolling contact fatigue cracks under realistic service loading. It combines multi-body simulations, finite element analysis, and critical plane approaches. A novel multi-variable sampling technique simplifies loading spectra into representative traction profiles, which are then analyzed using finite element analysis and the Smith–Watson–Topper damage indicator parameter (DIP<inf>SWT</inf>). The maximum DIP<inf>SWT</inf> value identifies the critical plane and potential crack orientation. A case study on the Swedish heavy haul train line (Malmbanan) considers measured traffic and loading conditions, analyzing the wheel load spectrum for a 384 m long section of a R = 450 m curve. Results show that the DIP<inf>SWT</inf> is highest for the locomotive with a loaded payload configuration, with a maximum value of 3.84 × 10<sup>−8</sup> located at 38.59 mm from the lower gauge face corner. The DIP<inf>SWT</inf> critical plane aligns with experimental measurements of RCF cracks orientations near the gauge corner. This computational method, when combined with other predictive tools, can efficiently identify conditions that lead to RCF cracks and determine their possible locations and orientations in railway tracks.

Place, publisher, year, edition, pages
Springer Nature , 2025.
Keywords [en]
Contact mechanics, Critical plane method, Damage parameters, Fatigue crack initiation, Rolling contact fatigue
National Category
Applied Mechanics
Identifiers
URN: urn:nbn:se:kth:diva-371621DOI: 10.1007/s40534-025-00405-4ISI: 001581677300001Scopus ID: 2-s2.0-105017404172OAI: oai:DiVA.org:kth-371621DiVA, id: diva2:2007056
Note

QC 20251017

Available from: 2025-10-17 Created: 2025-10-17 Last updated: 2025-10-17Bibliographically approved

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Leung, Jonathan F.W.Hossein Nia, SaeedOlsson, MårtenCasanueva, Carlos

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