Three-dimensional finite element analysis

of residual stresses in railway wheels

INTRODUCTION

RESULTS AND CONCLUSIONS

Manufacturing process such as casting or forging used in

forming railway wheels induce a wide variety of residual
stresses.
Wheels are heat treated (Quenched or Annealed) which
induces circumferential compressive residual stress in the
upper rim thus increasing its surface hardness.
Under service conditions, thermal brakes induces higher
tensile residual stress which results in the formation of rim
fatigue cracks.
The stress analysis in railway rim wheel is done using threedimensional elasticplastic finite element method
Fig 1. shows finite element model used in residual stress
analysis.

The heat treatment process cools the rim of the wheel much faster
than the plate of the wheel. The rim-quenched wheels induces
desirable residual compressive stresses in the upper rim, and
improve the wear resistance which help prevent the formation of
fatigue cracks at the tread surface of rim.
According to Fig 2. the effects of water spray on the wheel rim
cooling is visible. At the end of the quench, the minimum
temperature in the wheel rim is 326 oC and the maximum is 802 oC
, reduced little from the initial temperature of 869 oC.
Fig 3. illustrates contour plots of the Von Mises stresses on wheel
tread. For rail wheel, the magnitude of von Mises stress appears to
be 553 MPa after heat-treatment. The magnitude of this stress is
higher than the yield strength of the steel , which leads to plastic
deformation. Thus, this analysis shows that the fatigue cracks
initiate at a depth 45 mm below the tread surface for railway
wheel.

Fig 1. Finite element modeling of wheel.

FINITE ELEMENT MODELLING

Simulation for residual stress is done in two parts:
non-linear thermal analysis
- determines the temperature distribution of the wheel
non-linear static structural analysis
- distribution of stress over the wheel rim
Thermal analysis consist of four phases
high temperature step with water spray on the tread
surface of rim (about 3 min)
put in room temperature (about 6 min)
elevated temperature draw (about 6 h)
cooling in room temperature (about 7 h).

Fig 2. Contour plots of the temperature

distribution (in C) due to the heat treatment
process: (a) first phase,
(b) second phase, (c) third phase, and (d) forth
phase.

Fig 3. Contour plots of the von Mises stress due to the

heat treatment process of railway wheel analysis: (a)
first phase,
(b) second phase, (c) third phase and (d) forth phase.