Rolling contact fatigue prediction for rails and comparisons with test rig results

Tests in a full-scale roller rig, a full-scale linear test rig, and a twin-disc machine are numerically evaluated and compared in terms of rolling contact fatigue loading. From previously evaluated contact patch sizes, a Whler curve relationship is established and matched towards experimentally established fatigue lives. In addition, non-linear finite-element simulations are carried out. Key data needed for the numerical evaluations, as well as difficulties in translating experimental data to numerical models are highlighted. A key parameter here is the interfacial wheel-rail friction. Additional simulations were carried out to establish the latter. However, the conformal contact in the linear test rig makes such simulations very uncertain.