Finite element estimation of the residual stresses in roller-straightened rail

Details

• Creators:
  Talamini, Brandon ; Gordon, Jeff ; Perlman, A. Benjamin
• Corporate Contributors:
  John A. Volpe National Transportation Systems Center (U.S.) ; Tufts University ; United States. Federal Railroad Administration
• Subject/TRT Terms:
  Rail (Railroads) Residual Stress Rolling Contact Stresses Train Track Dynamics
• Publication/ Report Number:
  IMECE2004-61850
• Resource Type:
  Proceedings
• Corporate Publisher:
  American Society of Mechanical Engineers
• Abstract:
  The purpose of this paper is to develop models to accurately predict
  
  the residual stresses due to the roller straightening of railroad rails.
  
  Several aspects of residual stress creation in rail due to roller
  
  straightening are addressed. The effect of the characteristics of the
  
  loads applied by the roller-straightener on the stress profile is
  
  examined. In addition, the analysis attempts to discern the relative
  
  influence of bending and contact on the residual stresses. The last goal
  
  is to determine how the heat treatment of rail alters the predicted
  
  roller-straightening residual stress field.
  
  The loads for the simulation are estimated from available data. To
  
  identify the most credible values, a baseline loading case is defined
  
  and modeled. These straightening loads are parameterized by
  
  considering alternative loading scenarios. Residual stresses and
  
  deformations are calculated using these loads.
  
  To separate the effects of bending and contact on the residual stress
  
  induced by the roller loads, each credible load case is analyzed with
  
  two models. One is a 2-dimensional generalized plane strain (GPS)
  
  model that accounts only for the flexural stresses. The other is a fully
  
  3-dimensional analysis that includes roll-on-rail contact to make
  
  estimates of the true residual stress field. Comparison of the residual
  
  stress results from both models reveals the relative influence of local
  
  roll-rail contact and bending on the final profile.
  
  Comparison of the 2- and 3-dimensional residual stress results reveals
  
  that the magnitude of the contact loads is a decisive influence on the
  
  stress field, even in portions of the rail web located far from the
  
  contact interface. Therefore, it is critical to obtain accurate estimates
  
  of the straightening loads to make accurate roller straightening
  
  residual stress estimates.
  
  Heat treatment of the rail prior to roller straightening primarily affects
  
  the longitudinal residual stress in the web, causing a positive shift in
  
  the stress values.
  
  
• Format:
  PDF
• Collection(s):
  Federal Railroad Administration Volpe Center
• Main Document Checksum:
  urn:sha256:aec6dc124176527898f39807f7d21b9f5f98446c5f557a11dda61119ef33b4c6
• Download URL:
  https://rosap.ntl.bts.gov/view/dot/8992/dot_8992_DS1.pdf
• File Type:
  [PDF - 370.03 KB ]