Measured dynamic load distribution of high-speed train axlebox bearing with spalling-type faults

Determining the residual safe service life of high-speed train axlebox bearings with spalling faults has become an increasingly critical concern for Chinese railway operators. Crucially, measured dynamic load distributions within bearings exhibiting incipient spalling enable predictive modeling of spall progression and remaining usable life. This study employed a strain-based methodology to quantify internal dynamic load distributions within axlebox bearings with spalling-type faults. By establishing definitive spatiotemporal mappings between strain response characteristics and fault-specific signatures (outer-ring, inner-ring, roller), decoupled identification of all three fault types is achieved. The result of measured dynamic load distribution indicates that outer ring faults induce M-distributed radial loads that amplify adjacent stresses, accelerating spalling propagation. The bearing row with inner ring/roller faults maintain arched distributions but exhibit wider contact load fluctuations than the faultless row, while compound faults manifest hybrid signatures. Besides, compared to the significant impact of bearing misalignment, spalling-type faults exert negligible influence on inter-row load allocation. Position-specific contact load spectra are compiled based on measured roller-raceway contact load histories, providing critical inputs for failure progression models across various bearing fault types.