The influence of high temperature due to high adhesion condition on rail damage

Abstract In wheel–rail contact, the locomotive adhesion variable characterizes the capability of the locomotive to convert available friction into traction at the interface. Recently developed AC (Alternating Current) drive induces a higher adhesion level compared to DC (Direct Current) drive. This can significantly affect the wheel–rail contact conditions such as high contact temperature due to the frictional rolling, wear and damage initiation of the rails. The aims of this paper are to determine the temperature rise due to high adhesion contact and the thermal influence on the wear and rail life. Three-dimensional (3D) elasto-plastic finite element model was applied to evaluate the growth of temperature, residual stress and strain. The numerical model employed the moving heat source code developed by Goldak within ANSYS/LS-DYNA. The mechanical and thermal properties of the rail material were governed by temperature. The influence of multi-passes from multiple wheels attached to the locomotives on one point of the rail was also taken into account. The results indicated that after six wheel passes, the temperature due to the high adhesion condition was sufficiently high (723 °C) to form the white etching layer (WEL) known to be associated to the rolling contact fatigue (RCF) on the rail surface. Moreover the rail material would be softened by high temperature, which resulted in the acceleration of wear process. Finally the results of thermal stress and strain from FE model were used as input to Kapoor׳s ratcheting model to determine the number of wheel rolling cycles leading to rail damage.