Abstract: The substantial similarity of fatigue mechanism in a
new test rig for rolling contact fatigue (RCF) has been investigated. A
new reduced-scale test rig is designed to perform controlled RCF
tests in wheel-rail materials. The fatigue mechanism of the rig is
evaluated in this study using a combined finite element-fatigue
prediction approach. The influences of loading conditions on fatigue
crack initiation have been studied. Furthermore, the effects of some
artificial defects (squat-shape) on fatigue lives are examined. To
simulate the vehicle-track interaction by means of the test rig, a threedimensional
finite element (FE) model is built up. The nonlinear
material behaviour of the rail steel is modelled in the contact
interface. The results of FE simulations are combined with the critical
plane concept to determine the material points with the greatest
possibility of fatigue failure. Based on the stress-strain responses, by
employing of previously postulated criteria for fatigue crack initiation
(plastic shakedown and ratchetting), fatigue life analysis is carried
out. The results are reported for various loading conditions and
different defect sizes. Afterward, the cyclic mechanism of the test rig
is evaluated from the operational viewpoint. The results of fatigue
life predictions are compared with the expected number of cycles of
the test rig by its cyclic nature. Finally, the estimative duration of the
experiments until fatigue crack initiation is roughly determined.
Abstract: A new small–scale test rig developed for rolling
contact fatigue (RCF) investigations in wheel–rail material. This
paper presents the scaling strategy of the rig based on dimensional
analysis and mechanical modelling. The new experimental rig is
indeed a spinning frame structure with multiple wheel components
over a fixed rail-track ring, capable of simulating continuous wheelrail
contact in a laboratory scale. This paper describes the
dimensional design of the rig, to derive its overall scaling strategy
and to determine the key elements’ specifications. Finite element
(FE) modelling is used to simulate the mechanical behavior of the rig
with two sample scale factors of 1/5 and 1/7. The results of FE
models are compared with the actual railway system to observe the
effectiveness of the chosen scales. The mechanical properties of the
components and variables of the system are finally determined
through the design process.