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This study aims to analyze the rolling contact fatigue influenced by residual stresses caused by the contact of the wheel and rail and its manufacturing process. For this purpose, a rail available in Iran railway is used with an exact profile geometry. The location of maximum stress caused by the contact of wheel/rail for rail profiles can be calculated by three-dimensional elastic-plastic finite element model. Then, in order to estimate the stress distribution caused by rail manufacturing process, a thermal analysis with finite element method will be performed. Afterwards, the results of performed stress analysis will be used as input for three-dimensional crack growth and rail fatigue life estimation model to calculate the stress intensity factors and fatigue life according to the set of related parameters with boundary element method. Finally, three-dimensional finite element analysis results obtained show good agreement with those achieved in field measurements.

Rolling contact fatigue analysis of rails under the influence of residual stresses induced by manufacturing