Journal of the Korean Society for Precision Engineering (한국정밀공학회지)

Korean Society for Precision Engineering (한국정밀공학회)
권호 표지

Contact Fatigue Analysis of White Etching Layer according to Thickness Variation

White etching layer의 두께변화에 따른 접촉피로수명 평가

  • Seo, Jung-Won (Vehicle/Track Research Department, Korea Railroad Research Institute) ;
  • Kwon, Seok-Jin (Vehicle/Track Research Department, Korea Railroad Research Institute) ;
  • Jun, Hyun-Ku (Vehicle/Track Research Department, Korea Railroad Research Institute) ;
  • Lee, Dong-Hyong (Vehicle/Track Research Department, Korea Railroad Research Institute)
  • 서정원 (한국철도기술연구원 차륜궤도연구실) ;
  • 권석진 (한국철도기술연구원 차륜궤도연구실) ;
  • 전현규 (한국철도기술연구원 차륜궤도연구실) ;
  • 이동형 (한국철도기술연구원 차륜궤도연구실)
  • Received : 2010.04.05
  • Accepted : 2010.06.29
  • Published : 2010.08.01
Download PDF
⟨ Previous Next ⟩

Abstract

White Etching Layer(WEL) is a phenomenon that occurs on the surface of rail due to wheel/rail interactions such as excessive braking and acceleration. Rolling Contact Fatigue(RCF) cracks on the surface of rail have been found to be associated with WEL. In this study, we have investigated RCF damages of white etching layer using twin disc testing and fatigue analysis. These tests consist of wheel flat tests and rolling contact fatigue tests. WEL has been simulated by wheel flat test. It has been founded that the WEL with a bright featureless contrast is formed on the surface of specimen by etching. Rolling contact fatigue test was conducted by using flat specimens with the WEL generated by the wheel flat test. It has been observed that two types of cracks occur within the specimen. The contact fatigue test was simulated in 2D elastic-plastic FE simulations. Based on loading cycles obtained from the finite element analysis, the fatigue life analysis according to the thickness variation of WEL was carried out. The longest fatigue life was observed from the thickness of 20um.

Keywords

References

  1. Kondo, K., Yoroizaka, K. and Sato, Y., "Cause, increase, diagnosis, countermeasures and elimination of Shinkansen shelling," Wear, Vol. 191, No. 1-2, pp. 199-203, 1996. https://doi.org/10.1016/0043-1648(95)06727-2
  2. UIC Leaflet 712, "Rail defects," 2002.
  3. Cannon, D. F. and Pradier, H., "Rail rolling contact fatigue Research by the European Rail Research Institute," Wear, Vol. 191, No. 1-2, pp. 1-13, 1996. https://doi.org/10.1016/0043-1648(95)06650-0
  4. Wang, L., Pyzalla, A., Stadlbauer, W. and Werner, E. A., "Microstructure features on rolling surfaces of railway rails subjected to heavy loading," Materials Science and Engineering A, Vol. 359, No. 1-2, pp. 31-43, 2003. https://doi.org/10.1016/S0921-5093(03)00327-7
  5. Zhang, H. W., Ohsaki, S., Ohnuma, M. and Hono, K., "Microstructural investigation of white etching layer on pearlite steel rail," Materials Science and Engineering A, Vol. 421, No. 1-2, pp. 191-199, 2006. https://doi.org/10.1016/j.msea.2006.01.033
  6. Jin, Y. and Isidha, M., "Analysis of white etching layer generated on rail surface," RTRI Report, Vol. 19, No. 9, pp. 17-22, 2005.
  7. Baumann, G., Fecht, H. J. and Liebelt, S., "Formation of white-etching layers on rail treads," Wear, Vol. 191, No. 1-2, pp. 133-140, 1996. https://doi.org/10.1016/0043-1648(95)06733-7
  8. Carroll, R. I. and Beynon, J. H., "Rolling contact fatigue of white etching layer: Part 1: Crack morphology," Wear, Vol. 262, No. 9-10, pp. 1253-1266, 2007. https://doi.org/10.1016/j.wear.2007.01.003
  9. Carroll, R. I. and Beynon, J. H., "Rolling contact fatigue of white etching layer: Part 2: Numerical results," Wear, Vol. 262, No. 9-10, pp. 1267-1273, 2007. https://doi.org/10.1016/j.wear.2007.01.002
  10. Makino, T., Yanamoto, M. and Fujimura, T., "Effect of material on spalling properties of railroad wheels," Wear, Vol. 253, No. 1-2, pp. 284-290, 2002. https://doi.org/10.1016/S0043-1648(02)00117-5
  11. Warren, A. W. and Guo, Y. B., "Numerical investigation on the effect of machining-induced white layer," Trib. Trans., Vol. 48, No. 3, pp. 436-441, 2005. https://doi.org/10.1080/05698190500225078
  12. Kato, T., Sugeta, A. and Makita, T., "Evaluation of rolling contact fatigue properties of white layer in railway wheel steel," J. of Society of material Science, Vol. 56, No. 12, pp. 1050-1155, 2007.
  13. Ok, Y. G., An, D. M., Cho, Y. J. and Lee, H. W., "Study on the Fatigue Limit at Random Contact Loading," J. of the Korean Society for Precision Engineering, Vol. 19, No. 8, pp. 84-91, 2002.
  14. Kim, T. W. and Cho, Y. J., "Stress based Fatigue Life Prediction for Ball Bearing," J. of the Korean Society for Precision Engineering, Vol. 24, No. 5, pp. 44-55, 2007.
  15. Han, C., Chen, X. and Kim, K. S., "Evaluation of multiaxial fatigue criteria under irregular loading," Int. Journal of Fatigue, Vol. 24, No. 9, pp. 913-922, 2002. https://doi.org/10.1016/S0142-1123(02)00013-0
  16. Han, C., Chen, X. and Kim, K. S., "Evaluation of multiaxial fatigue criteria under irregular loading," Int. Journal of Fatigue, Vol. 24, No. 9, pp. 913-922, 2002. https://doi.org/10.1016/S0142-1123(02)00013-0