A model for plasticity assessment in rolling contact is introduced, aimed at simulating the effect of the application of thousands of load cycles in a reasonable time. It is based on the non-linear kinematic and isotropic hardening model of Lemaitre and Chaboche in a simplified formulation suitable for contact problems and allows the calculation of accumulated plastic strain under the contact surface. Wear is introduced as an independent phenomenon, interacting with the plasticization process by removing material layers from the surface and modifying during the load process the stresses which each point is subjected to. The typical material responses to cyclic loading (elastic shakedown, plastic shakedown, and ratchetting) can be obtained by application of the present method; moreover, the effect of wear in stabilizing the strain field for a large number of cycles is shown. The model is validated through comparison with results obtained by other methods and by experiments.
DonzellaG.FaccoliM.GhidiniA.MazzùA.RobertiR.The competitive role of wear and RCF in a rail steel. Engng Fracture Mechanics, 2005, 72, 287–308.
2.
DonzellaG.FaccoliM.MazzùA.RobertiR.Experimental investigation on competition between wear and RCF in a rail steel. In Proceedings of the 11th International Conference on Fracture, Turin, Italy, 20–25 March 2005.
3.
HydeR. S.Contact fatigue of hardened steels. In ASM handbook, Vol.19, 1996, pp. 691–703 (ASM International Materials Park, Ohio).
4.
TallianT. E.Failure atlas for Hertz contact machine elements, 2nd edn, 1999 (American Society for Mechanical Engineers, New York).
5.
MurakamiY.EndoM.Effect of defects, inclusions and inhomogeneities on fatigue strength. Fatigue, 1994, 16, 163–182.
6.
BormettiE.DonzellaG.MazzùA.Surface and subsurface cracks in rolling contact fatigue of hardened components. Tribology Trans., 2002, 45(3), 274–283.
7.
GuaglianoM.VerganiL.Experimental and numerical analysis of sub-surface cracks in railway wheels. Engng Fracture Mechanics, 2005, 72, 255–269.
8.
NéliasD.DumontM. L.ChampiotF.VincentA.GirodinD.FougèresR.FlamandL.Role of inclusions, surface roughness and operating conditions on rolling contact fatigue. Trans. ASME J. Tribology, 1999, 121(2), pp. 240–251.
9.
PapadopoulosI. V.DavoliP.GorlaC.FilippiniM.BernasconiA.A comparative study of multiaxial high-cycle fatigue criteria for metals. Int. J. Fatigue, 1997, 19(3), 219–235.
10.
JohnsonK. L.Plastic flow, residual stress and shakedown in rolling contact. In Contact mechanics and wear of rail/wheel systems II (Eds GladwellG. M. L.GhonemH.KalousekJ.), 1987, pp. 83–97 (University of Waterloo Press, Waterloo, Ontario).
11.
KapoorA.A re-evaluation of the life to rupture of ductile metals by cyclic plastic strain. Fatigue Fracture Engng Mater. Structs, 1994, 17(2), 201–219.
12.
JohnsonK. L.Contact mechanics and the wear of metals. Wear, 1995, 190, 162–170.
13.
YangY.TorranceA. A.Wear by plastic ratchetting; an experimental evaluation. Wear, 1996, 190, 147–155.
14.
KapoorA.JohnsonK. L.WilliamsJ. A.A model for the mild ratchetting wear of metals. Wear, 1996, 200, 38–44.
15.
ClaytonP.SuX.Surface initiated fatigue of pearlitic and bainitic steels under water lubricated rolling/sliding contact. Wear, 1996, 200, 63–73.
16.
PengX.FanJ.YangY.A microstructure-based description for cyclic plasticity of pearlitic steel with experimental verification. Int. J. Solids Structs, 2002, 39, 419–434.
17.
BernasconiA.DavoliP.FilippiniM.FolettiS.An integrated approach to rolling contact sub-surface fatigue assessment of railway wheels. Wear, 2005, 258, 973–980.
18.
LemaitreJ.ChabocheJ. L.Mechanics of solid materials, 1994 (Cambridge University Press, Cambridge).
19.
BowerA. F.Cyclic hardening properties of hard-drawn copper and rail steel. J. Mechanics Physics Solids, 1989, 37(4), 455–470.
20.
Abdel-KarimM.OhnoN.Kinematic hardening model suitable for ratchetting with steady state. Int. J. Plasticity, 2000, 16, 225–240.
21.
FedeleR.FilippiniM.MaierG.Constitutive model calibration for railway wheel steel through tension-torsion tests. Computers Structs, 2005, 83, 1005–1020.
22.
McDowellD. L.MoyarG. J.A more realistic model of nonlinear material response: Application to elastic-plastic rolling contact. In Contact mechanics and wear of rail/wheel systems II (Eds GladwellG. M. L.GhonemH.KalousekJ.), 1987, pp. 99–116 (University of Waterloo Press, Waterloo, Ontario).
23.
SakaeC.KeerL. M.Application of direct method for a nonlinear-kinematic-hardening material under rolling/sliding line contact: Constant ratchetting rate. J. Mechanics Physics Solids, 1997, 45(9), 1577–1594.
24.
KapoorA.FranklinF. J.Tribological layers and the wear of ductile materials. Wear, 2000, 245, 204–215.
25.
RingsbergJ. W.Loo-MorreyM.JosefsonB. L.KapoorA.BeynonJ. H.Prediction of fatigue crack initiation for rolling contact fatigue. Int. J. Fatigue, 2000, 22, 205–215.
26.
FranklinF. J.WidiyartaI.KapoorA.Computer simulation of wear and rolling contact fatigue. Wear, 2001, 251, 949–955.
27.
KapoorA.BeynonJ. H.FletcherD. I.Loo-MorreyM.Computer simulation of strain accumulation and hardening for pearlitic rail steel undergoing repeated contact. J. Strain Analysis, 2004, 39(4), 383–396.
28.
FranklinF. J.KapoorA.Modelling wear and crack initiation in rails. Proc. IMechE, Part F: J. Rail and Rapid Transit, 2007, 221(1), 23–33.
YangL. J.A test methodology for the determination of wear coefficient. Wear, 2005, 259, 1453–1461.
31.
TyfourW. R.BeynonJ. H.KapoorA.The steady state behaviour ofnpearlitic rail steel under dry rolling-sliding contact conditions. Wear, 1995, 180, 79–89.
32.
DonzellaG.MazzùA.PetrogalliC.Analisi di fenomeni di ratchetting nel contatto ruota — rotaia. In Proceedings of the 19th National Congress of the Italian Group of Fracture, Milan, Italy, 2–4 July 2007, 169–176.
