Rolling Contact Research Articles

Track Deterioration Model—State of the Art and Research Potentials

Track deterioration models (TDMs) help to allocate maintenance work (direct costs) to vehicle runs. Furthermore, these models demonstrate the impact of rolling stock properties on infrastructure. This paper review provides an overview of the state of the art in railway track deterioration modelling and outlines the research potential in this domain. The main focus lies on ballast degradation, rail surface wear and fatigue, and their description in an empiric analytic wear formula. The basis for discussion is the wear formula of the Graz University of Technology. While the TDM demonstrates effectiveness, enhancements are sought, particularly with regard to adjusting the track parameters that vary across railway networks. Further exploration aims to refine the description of rail surface wear and rolling contact fatigue (RCF), incorporating factors such as traction energy and short-wave effects and adapting mathematical functions such as the t-Gamma function. This review underscores the need for ongoing research to develop TDMs that are both simple and detailed enough to encourage track-friendly rolling stock design.

Surface integrity and rolling contact fatigue behavior of 18CrNiMo7-6 steel subjected to ultrasonic surface rolling process

In this study, the effect of ultrasonic surface rolling process (USRP) on the surface integrity and rolling contact fatigue (RCF) behavior of 18CrNiMo7-6 steel have been conducted. The different static loads and ultrasonic amplitudes on surface morphology, surface roughness, microstructure, microhardness, and residual stress were examined. Results revealed that USRP treatment resulted in a remarkably smooth surface with the surface roughness value Ra of 0.035 μm. Moreover, USRP treatment induced the formation of nanocrystalline and ultrafine crystalline structures on the surface layer. Additionally, the sample surface was subjected to a significant layer of residual compressive stress, reaching a maximum value of approximately −1243 MPa and extending to a depth of around 1500 μm. The surface microhardness had been increased to 808 HV0.2. The comprehensive integration of grain refinement, the increase of surface microhardness, and the induction of residual compressive stress led to an improvement in RCF life.

The effect of retained austenite on rolling/sliding contact fatigue of high carbon steel

Rolling contact fatigue (RCF) is significantly influenced by retained austenite (RA). To study the impact of the RA on fatigue life and pit formation, a high carbon steel was tested with three different RA levels ranging from 5 % to 23 % (volume fraction). The variations of the RA with respect to the number of cycles and along the depth were inspected by X-ray diffraction (XRD) technique. The microstructures before and after RCF were characterized by scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD). The majority of RA was transformed into martensite at an early stage (before 3 × 104 cycles) in both surface and subsurface. And the remaining small fraction of RA was transformed during the rest of the testing life, with a final content lower than 5 %. As the depth increased, the rate of RA transformation decreased. The specimen with the highest RA level of 23 % showed the shortest life. The longest RCF life was seen in the specimen with a medium RA level of 15 % due to the formation of the well-developed hardened layer, which helps resisting the pit formation. Based on these observations, it was suggested that a medium level of RA is beneficial for the improvement of the RCF life of the present high carbon steel. The combined effect of the hardness and the RA acts together on resistance to pit formation.

Effect of surface rolling process on rolling contact fatigue behavior and failure mechanism of powder metallurgy steel

The effect of surface rolling process on the surface microstructure and rolling contact fatigue of the Fe-2Cu-0.6 C powder metallurgy steel was investigated in the present investigation. Results indicated that a densified and hardened layer with a densification depth of 330 μm and a surface hardness of 330 HV0.1 was generated in the surface layer after rolling process. Ferrite grain and pearlite lamellae became typical fibrous structures on the top surface. The microstructure of pearlite was presented by two typical features. One was that the discrete cementite plates were severely curled and wavy. The other one was that the cementite plates remained parallel to each other, but were a reticular structure at a macroscopic level. The rolling contact fatigue (RCF) test showed that the RCF life of the rolled sample was superior. The L10, L50, L63.2 life increased by 182%, 105%, 92%, respectively. Surface initiated spalling was the main fatigue failure mode. Subsurface equivalent contact stress and local equivalent stress were calculated. The results showed that surface cracks were due to the repetitive tensile stress, which caused pits. Subsurface cracks nucleated and propagated in the region where the local equivalent stress was higher than the matrix yield strength, which caused spalling as connecting with surface cracks. The surface densified layer plays an important role in improving the rolling fatigue resistance of the material.

An investigation into Belgrospi-like damage formation on a sharp curved track using finite element method

Belgrospi-like damage is a special type of rolling contact fatigue (RCF) characterized by periodically grouped crack nests with short-pitch corrugation, which has been observed on sharp curved track in China. A 3D finite element model of the elastic–plastic wheel–rail transient rolling contact on a sharp curved track is developed to investigate the dynamic rolling interaction on corrugated rail. The competitive relationship between wear and RCF under cyclic loading is evaluated. Important findings include that the slope of corrugation geometry (CG) causes the center of the upslope the greatest dynamic contact solutions, which have a phase lead with respect to the CG. Under long-term cyclic loading, the rail material failure due to the continuous accumulation of plastic shear strain is RCF.

The effect of highly elongated micro-contacts on rolling contact stress field

This study presents a boundary element model to analyze contact pressure distribution and the subsurface stress field in rough rolling elements. The methodology is demonstrated by the stress field of the backup roll and work roll in the cold/temper rolling process and characterized by a parallel orientation of roughness lay with rolling direction, resulting in a cluster of highly elongated elliptical micro-contacts. The numerical outcomes revealed that the amplitude of in-plane and out-of-plane shear stress components are strongly dependent on the ellipticity of the micro-contacts. Comparison with experimental results shows that the crack plane is oriented transversal to the rolling direction and the crack initiation location corresponds to the location where the shear stress components are maximum.

The role of microstructure on the wear and rolling contact fatigue of railway steels: The performance of bainite

This study aims to describe the wear and rolling contact fatigue (RCF) behavior of microalloyed forged railway wheel steel Class D (7NbMo), with microstructures of upper bainite (UB - 350 HV0.5), lower bainite (LB - 450 HV0.5), and pearlite (PE - 350 HV0.5), against 7C steel with a tempered martensite microstructure (660 HV0.5) in a twin-disc tribometer. The results showed that bainite (LB and UB) exhibited greater wear resistance compared to pearlite (PE). The primary wear mechanism for all three microstructures was the fatigue wear. An analysis of the PE disc revealed continuous (single-layer) RCF cracks, which were relatively large and deep. In contrast, UB and LB cracks were discontinuous (multiple layers), thin, and smaller but more numerous (higher crack density). These characteristics indicated that bainitic microstructures also had greater resistance to RCF than pearlite did. Therefore, the combination of mechanical properties and the morphological arrangement of the microstructure led bainite to develop a shallower depth of deformed layer with a higher capacity for plastic deformation per unit volume. The greater wear and RCF performance of bainite compared to those of pearlite may be associated with how they release the accumulated deformation energy after reaching saturation in relation to volume deformation absorption: regarding bainite, the material releases energy by opening crack surfaces; conversely, regarding pearlite, it is through the detachment of large and wide cracks.

Analysis of the Influence of Contact Stress on the Fatigue of AD180 High-Carbon Semi-Steel Roll

In this study, to investigate the problem of contact fatigue and the damage mechanism of an AD180 high-carbon semi-steel roll, rolling contact fatigue tests were conducted using specimens cut from the periphery of a roll ring. These specimens were characterized under different contact stresses using SEM, a profile system, an optical microscope, and a Vickers hardness tester. The results indicates that the main forms of fatigue damage of an AD180 high-carbon semi-steel roll are peeling, pitting corrosion, and plowing. Moreover, the surface of the roll exhibits delamination and plastic deformation characteristics under high contact stress. Meanwhile, the size and depth of peeling, as well as the amount of pitting corrosion, increase with the contact stress. Peeling is mainly caused by a crack that originates at the edge of the specimen surface and propagates along the pearlite structure and the interface between pearlite and cementite. High contact stress can lead to an increase in the crack propagation depth and angle, resulting in the formation of larger peeling. Under cyclic loading, the near-surface microstructure of the specimen hardens due to grain refinement and dislocation strengthening, and the depth of the hardened layer increases with the increase in contact stress. When the contact stress reaches 1400 MPa, the near surface structure of the specimen changes from pearlite to troostite.

Effects of Eccentric Errors on Sliding Velocity and Accumulative Wear Depth of Planetary Roller Screw Mechanism

Abstract The eccentric errors of planetary roller screw mechanism (PRSM) affect the contact kinematic characteristics and exacerbate the cumulative wear of thread pairs, which will reduce its transmission accuracy and reliability. Hence, it is significant to investigate the cumulative wear of PRSM with the eccentric errors. In this work, based on the conjugate surface contact condition and Archard wear theory, the sliding speed and cumulative wear depth of PRSM with eccentricity errors are modeled, respectively. The effects of eccentric errors on the sliding velocities and cumulative wear depth of PRSM are investigated. It has been determined that the eccentric errors of the screw and nut do not cause the sliding motion in the nut–roller contact region (NRCR). However, there are noticeable variations in sliding velocity and cumulative wear depth in the screw–roller contact region (SRCR). The eccentric errors of the screw and nut have a combined effect on the sliding velocity and wear between the screw and roller. This investigation and finding can provide a valuable reference for the processing and assembly of PRSM.

Rolling contact fatigue analysis of the soft zone for the main bearing in a tunnel boring machine

A hierarchical finite element modeling method is proposed to study the problem of fatigue spalling easily due to low hardness in the soft zone for the main bearing of a tunnel boring machine. Quasi-static analyses of the main bearing are performed based on the global symmetric model and verified by relative displacement tests of the rings. The invariant contact pressure is replaced by the rolling contact of the rollers in the local sub-model. The contact load is used as an input to solve the stress field, and then the effects of soft zone and hardened depth on the contact characteristics and fatigue lifetime of the sub-model are investigated. The results show there are stress peaks at the junction of the hardened and soft zones. The effect of hardened depth on the stress distribution and fatigue lifetime is relatively small. However, the optimum hardened depth is influenced by the contact load and the permissible stress of the material. The minimum lifetime of the raceway during rolling occurs in the soft zone. This paper achieves a fast and effective rolling contact fatigue analysis of the main bearing, which provides a theoretical basis for optimizing the main bearing design.

A simplified spherical roller bearing model and its application in the wind turbine main bearing system finite element modeling

Different from most bearing design guidelines, deformation of bearing rings and supporting structures usually influences the bearing performance significantly. Finite element analysis (FEA) can be used in bearing system design considering the structure deformation, but the contact region between rolling elements and raceways modeling is very complex and usually causes non-convergent problems. As to a spherical roller bearing (SRB), the model must also consider both its misalignment ability and roller contact stiffness. This paper presents a simplified SRB model considering the angular misalignment ability. In order to define the SRB roller raceway load deformation relationship, a lamina model is developed. And this simplified model is validated by solid roller model of a bearing sector. A wind turbine main bearing system is analyzed using the developed SRB model. Load distribution considering the system deformation and angular misalignment are discussed. With the help of fine meshed solid elements roller raceway contact model, the raceway contact pressure and subsurface stress distribution can also be obtained.

Multi-objective optimisation of a metro wheel profile to reduce wheel flange wear and RCF considering the distribution density of wheel−rail contact points

In this study, the problem of severe wheel flange wear and tread rolling contact fatigue (RCF) of metro wheels with two wheel profiles, i.e. the LM-30 profile and the DIN5573-30 profile, is investigated. The contact characteristics of the two profiles are compared to analyse the causes of wheel flange wear and RCF. Indices combining the density distribution of contact points are proposed to evaluate the wheel flange wear and RCF. The optimisation region of the wheel profile is defined by eight arc parameters, which is derived from the tangency of the arcs. A back-propagation neural network is constructed as a surrogate model for the design variables and the objective function. Four intelligent optimisation algorithms are compared and used to solve the optimisation problem. The vehicle—track dynamic model and the wheel wear and RCF prediction model are used to verify the performance of the optimised profile. The results show that the critical speed of the optimised profile is between that of the LM profile and that of the DIN5573 profile, and the curving performance of the optimised profile is significantly improved. At the same time, the optimised wheel profile can reduce wheel flange wear and tread RCF.

Micropitting performance and friction behaviour of DLC coated bearing steel surfaces : On the influence of Glycerol-based lubricants

A better understanding about the rolling contact fatigue and micropitting performance of machine component surfaces lubricated with environmentally friendly lubricants is critical to designing and further formulating new lubricants intended to be used in rolling–sliding contacts such as those found in gear and bearing applications. In this work, the frictional behaviour and rolling contact fatigue (RCF) performance of DLC, Cr/a-WC:H/a-C:H and a-C:Cr coatings under glycerol-based lubrication in rolling sliding contact conditions have been investigated. Traction maps, Stribeck curves, and fatigue plots have been generated by using a micropitting test rig (MPR). The initiation and progression of micropitting was monitored by means of white light optical interferometry and scanning electron microscopy (SEM). Results indicated that glycerol-based lubricants exhibited a significant friction reduction as the hydrodynamic effect is enhanced at higher rolling-speeds. Under boundary lubrication the friction coefficient was significantly higher compared to the values obtained with a commercial mineral-based transmission oil. Compared to uncoated steel surfaces, DLC coatings effectively reduced the volume loss and micropitting progression. Irrespective of the coating thickness, DLC showed an excellent tribological behaviour when the base lubricant favours the onset of mild-wear, over micropitting. When the lubricant formulation favoured the onset of micropitting, the coatings tended to prematurely fail due to debonding from the substrate, and local micro-spallation. The experiments demonstrated that friction reduction does not necessarily correspond with a reduction of micropitting.

Effect of Case Depth and Hardness Distribution on the Rolling Contact Fatigue Performance of G20CrNi2MoA Carburized Steel

This study aims to investigate the effects of the case depth and hardness distribution of carburizing on the rolling contact fatigue (RCF) properties of G20CrNi2MoA steel under deeper carburizing conditions. Four groups of specimens of different case depths are prepared and subjected to RCF tests. A 2D finite element model based on continuum damage mechanics is developed to further analyze these two factors. As the depth of the carburized case increases, the RCF life first increases and then decreases. The optimum case depth is approximately one‐quarter of the thickness of the specimen. A gentler hardness distribution due to a change in the diffusion process parameters ensures a minimal increase (8%) in the RCF performance. The proper case depth has a more notable effect on the RCF life compared with those of the gentle or steep hardness distribution. It is expected that the results can help to promote a better understanding of the heat treatment process of carburized bearings and ensure more reliable carburized bearings are produced.

Rail surface damage management through monitoring and modelling

ABSTRACT Rolling contact fatigue (RCF) cracking and wear significantly impact rail surfaces. The interaction between them is crucial; wear dominance can remove initiated cracks, while low wear rates may escalate crack propagation, elevating rail failure risks. Grinding, a preventive maintenance technique, removes remaining cracks, applied in fixed-interval or condition-based regimes. Operational constraints, favouring cyclic regimes, may potentially reduce rail life and increase costs. Thus, an optimal asset management strategy involves grinding based on current RCF condition and its predicted growth rate, considering its interaction with wear. London Underground employs diverse rail inspection methods, including advanced MRX-RSCM technology, to measure crack depth. Research used its measurements, developing a novel Combined Shakedown Map and Tγ approach. This predicts RCF growth under wear interaction, indicating the material to be removed by grinding. Its results are displayed for high and low rails of curved track sites, compared with monitoring measurements, enabling observation of changes in damage susceptibility and related grinding requirements over different rails.

Review of rolling contact fatigue life calculation for oscillating bearings and application-dependent recommendations for use

Abstract. In contrast to the multitude of models in the literature for the calculation of rolling contact fatigue in rotating bearings, literature on oscillating bearings is sparse. This work summarizes the available literature on rolling contact fatigue in oscillating bearings. Publications which present various theoretical models are summarized and discussed. A number of errors and misunderstandings are highlighted, information gaps are filled, and common threads between publications are established. Recommendations are given for using the various models for any oscillating bearing in any industrial application. The applicability of these approaches to pitch and yaw bearings of wind turbines is discussed in detail.

Effects of Lubricating Conditions on Wear Performance of U77MnCrH Rail

With the rapid development of railway towards being high speed and having heavy load capacity, the wheel–rail wear and rolling contact fatigue in the curve section with a small radius of freight have become the key problems in urban railways, which need to be solved urgently. The aims of this study were to compare the wear resistance with three different lubricating conditions on wheel–rail wear based on the wheel–rail rolling contact simulation tests. The wear loss, microhardness, and microstructure of the contacted surface of the rail were detected systematically. The results showed that the wear rates of rail were reduced by 71% for grease lubrication and 55% for solid lubrication, compared to those without lubrication. At the same time, the thickness of plastic deformation layer of rail samples were about 167 μm for the dry state, 138 μm for the solid lubrication state, and 128 μm for the oil lubrication state, respectively. It indicates that the thickness of the plastic deformation layer was significantly reduced under both grease and/or solid lubricating conditions. In addition, the microstructure of the deformation layer with two kinds of lubricated states was coarser and denser than that without lubricants. The average grain size of the deformation layer was approximately 0.22 μm under dry conditions and 0.32 μm under lubricated conditions. It also indicated that the changes in lubricants did not have a significant effect on the average grain size of the deformation layer. The results of the present study could provide theoretical reference for the development and design of lubricants used as rail materials.

The Effects of the Lubricant Properties and Surface Finish Characteristics on the Tribology of High-Speed Gears for EV Transmissions

Electric vehicle (EV) transmissions operate at high speeds. High-speed operation puts higher demands on bearings, seals, and gears. Bearings in EV transmissions are prone to electrically induced bearing damage and may exhibit signs of pitting and fluting. Surface-initiated rolling contact fatigue is another common problem gaining increased attention lately. Most EV transmissions require a coupling between an oil-lubricated gearbox to an electrical motor that runs with minimal lubrication at very high rpm. The high mechanical and thermal stresses the seals are exposed to under starved lubrication conditions have a detrimental impact on their service life. Hence, proper lubrication is critical. In general, EV transmission fluids call for a somewhat different spectrum of properties compared to conventional ATFs. Gear tribology simulations open new ways to the design and optimization of lubrication for EV transmissions. Additionally, such simulations can also provide valuable insights into the effects of different oil properties on cooling and lubrication efficiencies, thereby helping in matching the lubricant and hardware characteristics for optimal performance. In the present communication, we demonstrate the effects of different lubricants and surface finishing technologies on the tribology of high-speed gears using tribological tests and advanced thermal elastohydrodynamic (TEHD) simulations. The important roles of lubricity additives and surface finish optimization are highlighted in conjunction with a move towards ultralow viscosity EV transmission fluids.

Novel in-situ real-time line scan optical monitoring of wear and surface damage initiation in a laboratory twin disc test

A new optical monitoring system has been developed to photograph in-situ in real time the initiation of damage on the running surface of a rail steel twin-disc sample undergoing wear testing. The line-scan camera system has been demonstrated on the Sheffield University ROlling Sliding 2 (SUROS2) twin-disc machine. The results show the system can continuously track the development of wear flakes, with wear flake initiation and stabilisation of wear flake size observed without test interruption for the first time. Image analysis to quantify the total wear flake shadow pixel count showed a good correlation with the mass loss results, indicating the potential for the optical data to quantify rail steel wear without interruption to testing. Furthermore, in a water-lubricated test the new system enables observation of rolling contact fatigue (RCF) crack initiation through a water layer present on the specimens, without requiring test interruption. The improving knowledge of the wear and RCF performance of rail steels available from the new observation method can help improve understanding of steel performance and support to the selection of rail steel grades according to their performance.

The influence of asymmetric rail cant on rail corrugation in a small-radius curve section

A suitably designed rail cant can improve the wheel-rail alignment, effectively reduce the wheel-rail contact pressure and reduce the wheel-rail wear. However, the rail base cant has rarely been specifically designed for suppressing rail corrugation. Furthermore, no studies have yet been conducted on using different inner and outer rail cants in small-radius curve sections from the perspective of suppressing rail corrugations and wear. In this study, the growth rate index of rail corrugation is obtained by combining an impact hammer origin admittance test and a coupled vehicle-track multi-body dynamic model simulations. The wear depth of rail surface is obtained by combining a three-dimensional transient wheel-rail rolling contact model and Archard wear theory. From the overall perspective of preventing rail corrugation and slowing down rail wear, based on the multi-objective optimization using a particle swarm optimization algorithm, the optimal configuration of inner and outer rail cants in a small-radius curve section were determined as 1/22 and 1/40, respectively, which provided effective suppression of rail corrugation initiation and further development of rail wear.