Abstract
Rail materials with different shear yield strengths can exhibit different rolling contact fatigue (RCF) damage response during cyclic contact loading. The objective of this work is to achieve the actual shakedown limits in the shakedown map for rail materials with different shear yield strengths through RCF simulation tests of wheel-rail, and to investigate the relationship between the shear yield strength (ke) and the shakedown limit. Rolling-sliding tests were performed to investigate the RCF damage states of three types of rail materials with different shear yield strengths. Then, according to the differences of RCF damage states for each rail material and the method of nonlinear curve fitting, the actual shakedown limits for three types of rail materials were obtained. The actual shakedown limits for the three types of rail materials were lower than the original one in the classical shakedown map. With an increase in the shear yield strength (ke) of the rail material, the actual shakedown limit is reduced. Moreover, a relationship emerged which allowed a simple method to be proposed to obtain the actual shakedown limit based on the shear yield strength. The changing process and differences in the impact of different shear stress levels on the microstructural damage transformation of rail materials from the perspective of contact mechanics have been discussed. The behavior of severe accumulation of residual stresses during cyclic loading and more likely initiation of microcracks are the main reasons why rail materials with a higher shear yield strength (ke) under great contact loads are more prone to developing RCF crack damages. That is, the shakedown limit for the material with a higher shear yield strength (ke) is much lower. In view of the application of the shakedown map in the evaluation and prediction for RCF damage of rail materials with different shear yield strengths, different shakedown limits should be applied to different rail materials when analyzing their likely performance.
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