IF 5.3 1区工程技术

Wear Pub Date : 2025-06-24 DOI: 10.1016/j.wear.2025.206223

Toru Takeuchi , Daiki Kagiwata , Hikaru Okubo , Kohji Ohno , Yoshinobu Tsujii , Ken Nakano

{"title":"Relationship between layered structure and wear behavior of concentrated polymer brushes","authors":"Toru Takeuchi , Daiki Kagiwata , Hikaru Okubo , Kohji Ohno , Yoshinobu Tsujii , Ken Nakano","doi":"10.1016/j.wear.2025.206223","DOIUrl":"10.1016/j.wear.2025.206223","url":null,"abstract":"<div><div>Concentrated polymer brushes (CPBs)—super-low-friction polymeric coatings composed of densely grafted polymer chains on a solid substrate—hold great promise for use in mechanical tribological components such as bearings and seals. However, their durability must be further improved before they can be deployed across a wide range of tribological applications. This study investigated the relationship between the wear mechanisms of poly(methyl methacrylate)-CPBs (PMMA-CPBs) and their layered structure, which comprises dilute, middle, and concentrated layers. Using a custom-built surface force apparatus, we examined the influence of the counterface bearing steel material's relative vertical position on the wear process, particularly focusing on the role of the dilute layer in lubrication film formation. The results showed that thickening of the dilute layer during sliding contributes to the formation of the lubrication film, which reduces the wear rate of the PMMA-CPB. Furthermore, the wear volume of the PMMA-CPB was found to be proportional to the characteristic quantity <em>δ</em><sup>1/2</sup><em>L</em>, where <em>δ</em> is the indentation depth and <em>L</em> is the sliding distance, based on a modified version of Archard's wear model tailored for this study. The findings suggest that improving the durability of PMMA-CPBs can be achieved by controlling the layer structure, such as thickening the dilute layer to reduce indentation depth and increasing the hardness of the concentrated layer. These insights offer crucial design guidelines for enhancing the durability of PMMA-CPBs in tribological applications.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206223"},"PeriodicalIF":5.3,"publicationDate":"2025-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502779","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

High-temperature tribological performance of superalloys and silicon carbide: exploring ceramic materials for tribological interfaces in next-generation gas turbines 高温合金和碳化硅的高温摩擦学性能：探索下一代燃气轮机摩擦学界面的陶瓷材料

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-23 DOI: 10.1016/j.wear.2025.206220

Marie-Laurence Cliche , Andre R. Mayer , Gihoon Cha , Silke Christiansen , Pantcho Stoyanov

{"title":"High-temperature tribological performance of superalloys and silicon carbide: exploring ceramic materials for tribological interfaces in next-generation gas turbines","authors":"Marie-Laurence Cliche , Andre R. Mayer , Gihoon Cha , Silke Christiansen , Pantcho Stoyanov","doi":"10.1016/j.wear.2025.206220","DOIUrl":"10.1016/j.wear.2025.206220","url":null,"abstract":"<div><div>To address the environmental challenges associated with greenhouse gas (GHG) emissions in aviation, gas turbine engines must significantly reduce CO<sub>2</sub> emissions. Achieving this will require a comprehensive redesign of engines to enhance thermal efficiency using materials that can withstand higher temperatures and pressures. This will increase the demand for high-performance materials with strong mechanical and tribological properties to prevent premature degradation of components. Additionally, understanding material interactions is crucial for effective tribological performance in engine assemblies like bearings, seals, and gears. Thus, the objective of this study is to comprehensively analyze the tribological behaviour of Inconel 718 when in contact with various counterfaces, including superalloys and ceramics, under conditions replicating those found in engine operations (at elevated temperatures of 450 °C and 800 °C under fretting conditions). This investigation focused on three selected counterface materials: a nickel-based superalloy (Inconel 718), a cobalt-based superalloy (Haynes 25), and a highly corrosion-resistant ceramic (silicon carbide). Overall, both superalloy counterfaces and the corresponding Inconel 718 surfaces demonstrated a reduction in wear, attributed to a transition in wear mechanisms from a gross-sliding regime at 450 °C to a stick regime at 800 °C; however, this transition led to an increase in friction force. In contrast, the silicon carbide counterface tested at 800 °C exhibited a gross-sliding fretting regime and friction force behavior similar to that observed at lower temperatures. Thus, the consistency in performance of silicon carbide in terms of friction and wear behavior compared to nickel-based and cobalt-based superalloys underscores its potential for further development in gas turbine engines.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206220"},"PeriodicalIF":5.3,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144517033","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Investigation on the evolution of surface integrity induced by corundum wheel wear during creep feed grinding of nickel-based superalloy 镍基高温合金蠕变进给磨削过程中刚玉砂轮磨损诱发表面完整性演变的研究

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-21 DOI: 10.1016/j.wear.2025.206219

Yihui Song , Kaining Shi , Zhe He , Shuai Wang , Danni Lu , Yaoyao Shi

{"title":"Investigation on the evolution of surface integrity induced by corundum wheel wear during creep feed grinding of nickel-based superalloy","authors":"Yihui Song , Kaining Shi , Zhe He , Shuai Wang , Danni Lu , Yaoyao Shi","doi":"10.1016/j.wear.2025.206219","DOIUrl":"10.1016/j.wear.2025.206219","url":null,"abstract":"<div><div>Abrasive wheel wear inevitably occurs in the process of grinding nickel-based superalloys, which contributes to the deterioration of processing conditions and affects the surface quality. However, the existing research available on the influence mechanism of wheel wear on grinding surface integrity is limited. In this study, the development of thermal-mechanical load in the life cycle of a grinding wheel was explored. The changes in surface integrity resulting from wheel wear were analyzed by investigating surface topography, microstructure and micromechanics, and were verified through fatigue life test. It was observed that slight wear and good self-sharpening significantly decrease the grinding load during the initial and steady wear stages, while maintaining a low surface roughness. The enhanced plastic deformation and low thermal effect lead to the increase of the residual compressive stress and nano-hardness. As abrasive wheel wore following the steady wear stage, the grinding force and temperature increased swiftly and displayed unstable time-domain characteristics. The high thermal-mechanical load induced by attritious wear and material adhesion lead to obvious oxidation and material smearing on the surface. In addition, the subsurface underwent severe plastic deformation and dynamic recrystallization. In terms of mechanical properties, the dominant thermal effect cause residual stress to shift from compressive stress to tensile stress and the degree of work hardening decreased. It was verified that the samples processed by the normally worn wheel exhibited better fatigue performance owing to excellent surface integrity. In contrast, severe wear resulted in a substantial decline in fatigue life.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206219"},"PeriodicalIF":5.3,"publicationDate":"2025-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144364711","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Cavitation erosion induced by tip leakage cavitating flow: Numerical assessment and mechanism analysis 叶尖泄漏空化流引起的空化侵蚀：数值评估与机理分析

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-21 DOI: 10.1016/j.wear.2025.206214

Mingzhe Zhou , Yantao Cao , Huaiyu Cheng , Bin Ji

{"title":"Cavitation erosion induced by tip leakage cavitating flow: Numerical assessment and mechanism analysis","authors":"Mingzhe Zhou , Yantao Cao , Huaiyu Cheng , Bin Ji","doi":"10.1016/j.wear.2025.206214","DOIUrl":"10.1016/j.wear.2025.206214","url":null,"abstract":"<div><div>Tip leakage cavitating flow is evidenced to severely erode blade tips, where however erosion has been seldom studied up to date as a consequence of complex cavitating structures within leakage regions. In this paper, cavitation erosion assessment is performed using an improved energy method which introduces a threshold dependent on the intrinsic flow field. This threshold distinguishes cavity collapse from cavity movement via cavity interface velocity and excludes the latter from the computation of radiated energy, therefore eliminating calculation distortion in erosion assessment. Based on the assessment results in good agreement with experimental observations concerning both erosion scale and intensity, we draw detailed insights into the correlation between cavitating structures and erosion areas and reveal four major types of erosion patterns which are respectively epitomised by the collapse of secondary shedding cavities, downstream shedding clouds and of the attached cavity's closure line, and the oscillation of the attached cavity at the hydrofoil leading edge. They properly correspond to where structural fracture of blades often begins under cavitation conditions, providing a valuable reference for relevant structure design and the suppression of erosion damage.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206214"},"PeriodicalIF":5.3,"publicationDate":"2025-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144470921","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Application of a contact fatigue life model to assess the relative risk of surface versus subsurface initiated fatigue in gears 应用接触疲劳寿命模型评估齿轮表面与地下引发疲劳的相对风险

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-20 DOI: 10.1016/j.wear.2025.206216

G.E. Morales-Espejel , B. Wainwright , A. Kadiric

{"title":"Application of a contact fatigue life model to assess the relative risk of surface versus subsurface initiated fatigue in gears","authors":"G.E. Morales-Espejel , B. Wainwright , A. Kadiric","doi":"10.1016/j.wear.2025.206216","DOIUrl":"10.1016/j.wear.2025.206216","url":null,"abstract":"<div><div>This paper presents a method to assess the relative risk of surface-initiated contact fatigue versus subsurface-initiated fatigue failures under conditions pertinent to gear teeth contacts. The relative risk of surface fatigue is expressed through a parameter S<sub>R</sub> which is defined as a ratio of near-surface stress integral to total stress integral and calculated using an existing gear fatigue life model. The surface risk parameter is plotted on a failure chart as a function of specific film thickness, Λ and a newly derived surface fatigue criterion, χ which includes effects of surface roughness, Hertz pressure and sliding magnitude on surface fatigue. Parameter χ is expressed as a reciprocal of the well-known plasticity index scaled with applied pressure and slide/rolling ratio. Experimental data is used to validate the predicted chart and identify regions of operating conditions where either micropitting or surface-initiated macropitting or subsurface-initiated spalling are the most likely failure mode. The experimental results are seen to fit well with the trends predicted by the model. The use of new parameter χ together with specific film thickness Λ provides the means for a more comprehensive assessment of the relative risk of micropitting, macropitting and subsurface-initiated spalling in gear teeth contacts than is achievable with simpler parameters. Provided failure charts give an approximate but a simple way to help in assessing the relative risk of surface versus subsurface fatigue failure for a given set of operating conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206216"},"PeriodicalIF":5.3,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144364710","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Experimental investigation on dynamic adhesion characteristics of wheel-rail under various media conditions at a large slip ratio range 大滑移比范围下不同介质条件下轮轨动态黏附特性试验研究

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-20 DOI: 10.1016/j.wear.2025.206217

Xinxin Song , Shuyue Zhang , Mengnan Xu , Haohao Ding , Jun Guo , Xin Zhao , Hongfeng Qi , Qiyue Liu , Wenjian Wang , Roger Lewis

{"title":"Experimental investigation on dynamic adhesion characteristics of wheel-rail under various media conditions at a large slip ratio range","authors":"Xinxin Song , Shuyue Zhang , Mengnan Xu , Haohao Ding , Jun Guo , Xin Zhao , Hongfeng Qi , Qiyue Liu , Wenjian Wang , Roger Lewis","doi":"10.1016/j.wear.2025.206217","DOIUrl":"10.1016/j.wear.2025.206217","url":null,"abstract":"<div><div>Due to the fact that trains operate in a complex environment with the presence of the third-body media (e.g., rain, leaves, oil, and antifreeze for track inspection in winter), low adhesion can occur at the wheel-rail interface, leading to a large slip ratio, which could cause severe wheel and/or rail damage. To help find a solution to this problem, wheel-rail dynamic adhesion characteristic tests were conducted under various third-body media conditions (dry, water, oil, leaves, and antifreeze) using wheel-rail rolling wear and contact fatigue testing machines. The results indicated that the adhesion curve exhibited a double peak in the loading stage under both dry and water conditions. However, under the other conditions (oil, leaves, and antifreeze), the adhesion characteristic curves were all single peak curves. Under the water conditions, the adhesion coefficient in the unloading stage was higher than in the loading stage, and the second peak point in the loading stage was higher than the first peak point. This phenomenon was related to the water volume at the wheel-rail interface, which affected the thickness of the water film. However, under dry conditions, the adhesion coefficient in the unloading stage was lower than in the loading stage, attributed to the formation and removal of oxides on the wheel-rail surface. Additionally, a wheel-rail adhesion model for the large slip ratio range was established, which provided the foundation for theoretical research on wheel-rail adhesion and for the design of locomotive adhesion control methods.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"580 ","pages":"Article 206217"},"PeriodicalIF":5.3,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144632372","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Tribological modeling and erosion wear compensation in valve-controlled hydraulic motor systems 阀控液压马达系统的摩擦学建模与冲蚀磨损补偿

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-20 DOI: 10.1016/j.wear.2025.206215

Xiaochao Liu , Honghui Liao , Dingbo Li , Peiyao Hou , Lu Bing , Xinqi Ma , Zongxia Jiao

{"title":"Tribological modeling and erosion wear compensation in valve-controlled hydraulic motor systems","authors":"Xiaochao Liu , Honghui Liao , Dingbo Li , Peiyao Hou , Lu Bing , Xinqi Ma , Zongxia Jiao","doi":"10.1016/j.wear.2025.206215","DOIUrl":"10.1016/j.wear.2025.206215","url":null,"abstract":"<div><div>Valve-controlled hydraulic motor systems are widely used in hydraulic servo systems but are prone to erosion wear caused by contamination particles, which degrade valve port performance and reduce system precision. In this study, based on the traditional E/CRC erosion wear model, a prediction model for the orifice throttling coefficient in liquid-solid flow is established. The main parameters of the model include particle concentration, spool opening, and differential pressure, which are easy to obtain in engineering applications, effectively addressing the challenges in applying the E/CRC erosion wear model in engineering. Additionally, an adaptive robust controller is designed, incorporating a feed-forward compensation term derived from the predictive model to address valve erosion wear. The effectiveness of the proposed compensation control method is verified through erosion wear experiments and torque control tests on hydraulic motors. Experimental results show a maximum relative error of 6.24 % between predicted and measured throttling coefficients, while the feed-forward compensation control method improves torque tracking performance by reducing the average error by more than 30 %.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206215"},"PeriodicalIF":5.3,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144491607","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Research on cutting tools edge grinding damage of nano cemented carbide 纳米硬质合金刀具刃磨损伤研究

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-18 DOI: 10.1016/j.wear.2025.206213

Yimin Jiang , Ming Zhou , Lifeng Zhan , Yu Tian , Mingyang Yang , Yan Zhu , Xiaobo Yuan , Wenwu Xu , Junqi Li

{"title":"Research on cutting tools edge grinding damage of nano cemented carbide","authors":"Yimin Jiang , Ming Zhou , Lifeng Zhan , Yu Tian , Mingyang Yang , Yan Zhu , Xiaobo Yuan , Wenwu Xu , Junqi Li","doi":"10.1016/j.wear.2025.206213","DOIUrl":"10.1016/j.wear.2025.206213","url":null,"abstract":"<div><div>This paper investigates the damage issues of nano, submicron, and fine cemented carbide tools during the grinding process. Through theoretical analysis of grinding, a grinding force model was established, and the concept of subsurface deformation zone leading to tool edge defects was proposed. Theoretical calculations indicated that nano cemented carbides exhibit minimal grinding damage and superior edge quality. Surface grinding and tool edge grinding experiments were designed and conducted. The results showed that, with the increase in tungsten carbide grain size, the mean free path values increased from 0.034 μm to 0.123 μm and 0.195 μm, the thickness of the subsurface deformation layer increased from 0.7 μm to 1.5 μm and 2.4 μm, the tool edge chipping increased from 1.204 μm to 1.758 μm and 2.560 μm, and the surface roughness of the flank face increased from 0.047 μm to 0.056 μm and 0.070 μm. These findings validated the scientific and effective nature of nanostructured cemented carbides in enhancing tool edge quality. Moreover, the study revealed that among the grinding parameters, grinding depth had the most significant impact on edge chipping, while feed rate and grinding wheel speed had relatively smaller effects. This paper provides theoretical support and experimental data for the application of nano cemented carbides in high-precision tool manufacturing, contributing to the advancement of technology in the field of precision manufacturing.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206213"},"PeriodicalIF":5.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144320871","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Laser-energy-density-dependent anisotropic tribological behaviour of 18Ni300 steel fabricated by selective laser melting 选择性激光熔化制备18Ni300钢的激光能量密度相关各向异性摩擦学行为

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-18 DOI: 10.1016/j.wear.2025.206212

U. Klanjšček, M. Kalin

{"title":"Laser-energy-density-dependent anisotropic tribological behaviour of 18Ni300 steel fabricated by selective laser melting","authors":"U. Klanjšček, M. Kalin","doi":"10.1016/j.wear.2025.206212","DOIUrl":"10.1016/j.wear.2025.206212","url":null,"abstract":"<div><div>Laser powder-bed fusion has become one of the most popular additive-manufacturing (AM) techniques for producing complex-shaped, metal engineering parts. However, to fully harness the advantages of AM for engineering steels, a deeper understanding and precise control over how the processing parameters influence the structure and properties of manufactured components are crucial. At present they remain insufficiently well explored. In this study, we systematically investigated the tribological performance of 18Ni300 steel fabricated via selective laser melting (SLM) with three distinct energy densities of the laser. The wear behaviour was evaluated on both the top (XY-plane) and side surfaces (XZ-planes) relative to the build direction to assess the degree of anisotropy. The porosity increased to 22 % with a decreasing energy density, with fully dense specimens being achieved at the highest energy density. The energy density influenced the dendrite morphology, with predominantly circular dendrites observed on the top surfaces and columnar dendrites on the side surfaces. Tribological tests were conducted at three contact pressures using a reciprocating ball-on-plate setup (100Cr6 counter ball). Optimal wear performance occurred when sliding perpendicular to the melt-pool boundaries and dendrites. Our results, which link energy density to microstructural evolution and wear mechanisms, demonstrate that strategic print orientation can reduce energy consumption by 300 % without compromising tribological performance—enabling more sustainable and cost-effective process optimization.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206212"},"PeriodicalIF":5.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144331092","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Influence of a highly deformed surface layer on RCF predictions for rails in service 高度变形的面层对服役轨道RCF预测的影响

IF 5.3 1区工程技术

Wear Pub Date : 2025-06-16 DOI: 10.1016/j.wear.2025.206173

Nasrin Talebi, Björn Andersson, Magnus Ekh, Knut Andreas Meyer

{"title":"Influence of a highly deformed surface layer on RCF predictions for rails in service","authors":"Nasrin Talebi, Björn Andersson, Magnus Ekh, Knut Andreas Meyer","doi":"10.1016/j.wear.2025.206173","DOIUrl":"10.1016/j.wear.2025.206173","url":null,"abstract":"<div><div>Rolling Contact Fatigue (RCF) cracks often initiate from the surface layer of rails, where large accumulated plastic deformations influence the mechanical and fatigue properties of the rail material. Additionally, changes in profile geometry due to both plasticity and wear result in alternating contact locations and conditions. The goal of this study is to investigate the importance of considering these effects when predicting surface RCF crack initiation in rails. We analyze their individual impact on stress and strain fields, as well as fatigue crack initiation, by finite element simulations of railheads subjected to a mixed traffic situation. To account for deformation-dependent material behavior, an anisotropic plasticity model is calibrated against experiments with different amounts of accumulated shear strains measured in field samples. Finally, a recently developed crack initiation criterion is employed that accounts for the influence of plastic deformations. Under extreme loading conditions, i.e., full slip with a traction coefficient of 0.4, it is shown that both deformed near-surface material and deformed geometry reduce the predicted RCF fatigue damage significantly, by factors of about 5 and 30, respectively. Furthermore, not accounting for the combined effect of deformed material state and geometry leads to approximately 150 times larger predictions of RCF damage.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"578 ","pages":"Article 206173"},"PeriodicalIF":5.3,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144470923","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

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