Multi-scale finite element modeling to describe rolling contact fatigue in a wheel-rail test rig

Finite element models on different length scales are presented for the loading of rails. A 3-D model of the full-scale test rig of the voestalpine company is developed. Results of the model include the full elastic-plastic deformations of rail and wheel, the contact pressure, shear stresses and slip. Results of this model are transferred to (a) a 2-D crack model that calculates the crack tip loading of an inclined surface crack and (b) a 2-D model with rough surfaces calculating cyclic near-surface deformations. On the rail profile two locations in the contact patch with different pressure/slip loads are analyzed separately in the 2-D models. The used multi-scale approach is essential for a realistic description of rolling contact related damage mechanisms.