PSI - Issue 17

Available online at www.sciencedirect.com Structural Int grity Procedia 00 (2019) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000 – 000 Available online at www.sciencedirect.com ScienceDirect

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Procedia Structural Integrity 17 (2019) 246–253

ICSI 2019 The 3rd International Conference on Structural Integrity Effect of manufacturing residual stress on the fatigue life of railway wheels for heavy-haul transportation ICSI 2019 The 3rd International Conference on Structural Integrity Effect of manufacturing residual stress on the fatigue life of railway wheels for heavy-haul transportation

Eduardo A. Lima a , Thiago S. Martins b , Auteliano A. Santos a . a University of Campinas – UNICAMP, Mendeleyev Street, 200, Campinas, São Paulo, Brazil b Logistics Engineering Center, VALE S.A, Dante Micheline Avenue, 5500, Vitória, Espírito Santo, Brazil Eduardo A. Lima a , Thiago S. Martins b , Auteliano A. Santos a . a University of Campi as – UNICAMP, Mendeley v Street, 200, Campinas, São Paul , Brazil b Logistics Engineering Center, VALE S.A, Dante Micheline Avenue, 5500, Vitória, Espírito Santo, Brazil

Abstract Abstract

The present work aims to compare the effect of the residual stress from the thermal treatment process (TTP) on the estimate of fatigue life of railway wheels - class C, both with and without residual stresses field from thermal treatment process. A 3D finite element method model is used to calculate the thermal treatment process and the rolling contact between rail and wheel. With the stresses calculated in this region, the study estimates the life under fatigue until a crack arises. The crack, when propagated, can result in shelling, which is one of the types of failure with significant economic importance to railroad maintenance. The model primarily uses the elastoplastic approach, then adds residual stresses from the thermal treatment process of railway wheels . ABAQUS  software is used for the numerical processing, in parallel with specially developed techniques to reduce the computational cost without causing loss of accuracy of the results. The fatigue life of the railway wheel before crack initiation is determined by the modified Dang Van high-cycle fatigue criterion . Given the assumption that the wheel radius does not change during rolling, the elastic shakedown phenomenon occurs in a few loading cycles. The high-cycle life for the wheel is estimated using the variation in the stress field, both with and without residual stresses from the thermal treatment process. The results of the numerical simulation showed that the von Mises stresses in railway wheels with thermal residual stresses are lower than in wheels without thermal residual stresses. The elastic shakedown phenomenon happened in three load cycles in the wheel model with thermal residual stress and in four load cycles for in the wheel model without thermal residual stress. However, this small difference in cycles caused by the thermal treatment process has a significant effect on the fatigue life. T he modified Dang Van’s fatigue criterion showed that railway wheels with thermal treatment have 43.2% more life than railway wheels without it. The present work aims to compare the effect of the residual stress from the thermal treatm nt process (TTP) on the estimate of fatigue life of railway wheels - class C, both with and without residual stresses field from thermal treatment process. A 3D finit element method model is used to calculate the thermal treatment process and the rolling contact between rail and wheel. With the stresses calculated in this region, the study estimates the life u der fatigue until a crack arises. The crack, wh propagated, can result in shelling, which is one of the types of failure with significant economic import nce to railroad maintenance. The model primarily uses the elastoplastic approach, then adds r sidual stresses from t e thermal treatment pro ess of railway wheels . ABAQUS  software is sed for the numerical pr cessing, in parallel with specially developed techniques to reduce the computational cost without causing loss of accuracy of the results. The fatigue life of the railway whe l before crack i itiatio is etermined by t modified Dang Van high-cycle fatigue criterion . Given the assumption that th wheel radius does not change during rolling, the elastic shakedown phenomenon occurs in a few loading cycles. The high-cycle life for the whe l is estimated using the variation in the stress field, both with and without residual stresses from the thermal treatment process. The results of the numerical si ulation showed that the von Mises str sses in railway wheels with thermal residual stresses are lo er than in wheels without therm l residual stresses. The elastic shakedo n phenomenon happened in three load cycles in the wheel model with thermal residual stress and in four lo d cycles for in t e wheel model without thermal residual stress. Howev r, this small differenc in cycles caus by the thermal treatment process has a significant effect n the fatigue life. T he modified Dang Van’s fatigue criterion showed that railway wheels with thermal treatment have 43.2% more life than railway wheels without it.

© 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ICSI 2019 organizers. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ICSI 2019 organizers. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ICSI 2019 organizers. Keywords: Wheel-Rail Contact, Finite Element, Plasticity, Residual Stress. Keywords: Wheel-Rail Contact, Finite Element, Plasticity, Residual Stress.

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ICSI 2019 organizers. 2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ICSI 2019 organizers.

2452-3216  2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ICSI 2019 organizers. 10.1016/j.prostr.2019.08.033