Subsurface initiated rolling contact fatigue of railway wheels as generated by rail corrugation

A fracture mechanics based fatigue index for rolling contact fatigue (RCF) initiated at deep (10–25 mm) defects is derived and employed together with a fatigue index for more shallow (4–10 mm) subsurface RCF initiation. Integrated simulations of high-frequency dynamic train–track interaction and prediction of RCF impact are then carried out to evaluate the influence of short-pitch rail corrugation on RCF of railway wheels. Parametric studies are carried out to identify operational conditions likely to generate high RCF impact. Simulation results show how rail corrugation causes a major increase in RCF impact at high-speed operations and that corrugation magnitudes measured in-field are sufficient to generate subsurface initiated RCF. At high speeds the main cause for increased fatigue impact is the increase in dynamic load magnitudes. At lower speeds and higher axle loads also the effect of poor contact geometry will have an influence.