PSI - Issue 57

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2022) 000 – 000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 57 (2024) 250–261

© 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers Abstract Deep rolling is an efficient technique to increase the fatigue life of railway axles. The application introduces compressive residual stresses into the area near the surface, which are the most effective positive influence on fatigue behaviour and remaining service life in presence of a crack. This paper investigates the remaining service life of deep rolled railway axles. Previous research studies are used as basis for this work whereas, firstly, an elaborated crack growth model for common railway axle steels was developed. This model is based on experimental crack propagation results and can consider crack closure as well as load sequence effects and local residual stress conditions. Secondly, a numerical deep rolling simulation model validated with experimental residual stress measurements to determine the introduced residual stress state and to investigate the influence of various process parameters. In this study, the comprehensive outcome of both studies is connected in order to evaluate and compare the residual life of railway axles with the presence of different deep rolling-induced residual stress distributions in depth. The crack growth study involves combinations of the deep rolling force as one of the most influencing process parameters, load scenarios as well as initial crack sizes and finally discusses the comprehensive results. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers Keywords: Mechanical surface treatment; Deep (cold) rolling; Railway axle; 34CrNiMo6; Residual stress; Crack propagation Fatigue Design 2023 (FatDes 2023) Residual life assessment of deep rolled railway axles considering the effect of process parameters Tobias Pertoll a, *, Christian Buzzi a , Martin Leitner a , David Simunek b , László Boronkai b a Graz University of Technology, Institute of Structural Durability and Railway Technology, Inffeldgasse 25/D, 8010 Graz, Austria b Siemens Mobility Austria GmbH, Eggenberger Straße 31, 8020 Graz, Austria

* Corresponding author. Tel.: +43-316-873-1367. E-mail address: tobias.pertoll@tugraz.at

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers

2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers 10.1016/j.prostr.2024.03.027