Table Of ContentRAILQUALITYANDMAINTENANCEFORMODERNRAILWAYOPERATION
Rail Quality and
Maintenance for
Modem Railway Operation
International Conference on
Rail Quality and Maintenance for
Modern Railway Operation
Delft June 1992
edited by
U .KALKER
T.U.Delft,
Delft,TheNetherlands
D.F.CANNON
BRResearch,
Derby, UnitedKingdom
and
O.ORRINGER
USDepartmentofTransportation,
Cambridge, MA, U.S.A.
Springer-Science+Business Media, B.V
Library ofCongressCataloging-in-PublicationData
Rail qual ity and maintenance for modern railway operation / edited by
J.J. Kalker and D.F. Cannon and O. Orringer.
p. em.
Papers from the International Conference on Rail Quality and
Maintenance for Modern Railway Operations. held in June 1992 at the
Technical University, Delft.
1. Railroads--Rails--Congresses. I. Kalker. J. J. II. Cannon.
D. F. <David F.) III. Orringer. Oscar.
TF258.R325 1993
625.1'5--dc20 93-893
ISBN 978-90-481-4267-5 ISBN 978-94-015-8151-6 (eBook)
DOI 10.1007/978-94-015-8151-6
Printedonacid-freepaper
AllRights Reserved
©1993Springer Science+BusinessMedia Dordrecht
Originally publishedbyKluwerAcademic Publishers in 1993.
Softcoverreprint ofthehardcover Istedition 1993
Nopartofthe material protectedbythiscopyrightnotice maybereproducedor
utilizedinany form orbyanymeans, electronicormechanical,
includingphotocopying,recordingorbyanyinformationstorage and
retrieval system,withoutwritten permissionfromthecopyrightowner.
TABLE OF CONTENTS
Introduction ix
RAIL DEVELOPMENTS AND FUTURE REQUIREMENTS
Future Rail Requirements 3
C.O.Frederick
Rail Developments and Requirements for Heavy Haul Railways 15
DB. Stone
RAIL METALLURGY AND PROCESSING
Rail Metallurgy and Processing 29
WB. Hodgson
A Review of Bainitic Steels for Wheel/Rail Contact 41
P. Clayton, R. Devanathan,N. Jin andRK.Steele
An Off-Line Heat Treatment Process Results in Quality DHH Rails at Sydney
Steel Corporation 53
T.E.Burke, B. George andB.E. St.John
Residual Stresses in Rail 61
WHo Hodgson
RAIL MAINTENANCE
Strategies for Maximizing Rail Life 77
RK. Steele
Noncontact Ultrasonic Inspection of Train Rails for Stress 99
R.E. Schramm, A. Van Clark, T.J. McGuire,B.J.Fi//a, D.V. Mitrakovic and
P.T. Purtscher
Experiences in Ultrasonic Measurements of Stresses in Rails 109
J. Deputat, J. Szelazek and M. Adamski
Rail Side Wear Problem on Chinese Railways 119
Z. Shen
Rail Rectification Specifications and Modem Grinding Stone Technology 127
J. Cooper and Jc-C, Schaffner
In Track Quality Control and Assessment of Rails 137
C. Esveld
vi
CONTACT PHENOMENA
Computational Contact Mechanics of the Wheel-Rail System 151
JJ. Kalker
Dynamic Models of the Track and Their Uses 165
SL. Grassie
Rail Service Load Environment by Measurement and Modeling 185
DR. Ahlbeck
Analytical and Numerical Treatment of Flange Contact 203
M.T.Hanson andL.M. Keer
On an Approach to Prediction of Contact Loading of Rail for Two-Point Contact
Between Wheel and Rail 215
J. Piotrowski
Experimental Tribe-Analysis of Rai1/WheelInterface 225
J.Kalousek
Shakedown, Residual Stress and Plastic Flow in Repeated Wheel-Rail Contact 239
AF. Bower and KL.Johnson
RESIDUAL STRESSES
How Residual Stresses can Affect Rail Performance 253
O.Orringer
Predication of Residual Stress in Rails: Practical Benefits from Theoretical
Approach 273
J. Orkisz and M. Holewinski
A New Approach to Enhancement of Experimental Data 287
W.Karmowski, J. Magiera andJ. Orkisz
Effect of Grinding Strategy on Residual Stress in the Rail Head 297
A.B.Perlman, J.E. Gordon and O. Orringer
Residual Stress Measurements in Rails by Neutron Diffraction 307
PJ. Webster, G. Mills,X. Wang and WP. Kang
Neutron Diffraction Measurements of Residual Stress in Rails 315
J.H. Root, TM. Holden, R.I. Klassen, C.Smallman, B.Maxfield andNR. Gore
Residual Stresses and Catastrophic Rail Failure 325
J.O.lgwemezie, SL.Kennedy andNR. Gore
Beneficial Residual Stresses at Bolt Holes by Cold Expansion 337
L.Reid
Residual Stress Analysis in Rolling Contact 349
H. Sehitoglu and YR. Jiang
CRACK PROPAGATION
Fatigue Crack Growth in Rail Steels 361
A.W.Thompson,D.E.Albert and G.T. GrayIII
vii
Crack Behaviour under Rolling Contact Fatigue 373
M.C. Dubourg and JJ. Kalker
Numerical Analysis of 3D Cracks Propagating in the Rail-Wheel Contact Zone 385
M. Olzak,J. Stupnicki and R. Wojcik
Modelling of 3D Rail Head Rolling Contact Fatigue Cracks 397
P.E.Bold
Tribological Investigations of Crack Development on the Rail on an Energetical
B~ ~
G. Fleischer, H.-D. Grohmann and D.Weinhauer
The Effect of Head Checking on the Bending Fatigue Strength of Railway Rails 425
J. Eisenmann and G. Leykauf
Rolling Contact Fatigue Cracks on S.N.C.F. Conventional Tracks . 435
R.Y.Deroche, J.P. Bettembourg, B. Prasil, J.P. Bertrand and C.Juckum
List of Participants 449
INTRODUCTION
In April 1990 a conference was held at the Cracow Institute of Technology, Cracow,
Poland. The title of that conference was "Residual Stresses in Rails - Effects on Rail
Integrity and Railroad Economics" anditsthemeswere themeasurement and prediction
of residual stresses in rails, but, as the sub-title suggests, the intention was also to
provide a link between research and its application to the practical railway world. At
the Cracow conference there were 40 participants with 5 railways and 5 rail makers
beingrepresented and25papersweregiven. TheCracowconferencewasasuccess, and
by March 1991 its off-spring, "The International Conference on Rail Quality and
Maintenance for Modern Railway Operations",was conceived and birth was ultimately
given in June 1992 at the Technical University, Delft. It turned out to be some baby,
with 112 delegates from 24 countries taking part! As with its predecessor, the
conference was to provide a forum for the exchange of ideas between research
investigators, rail makers and railway engineers. A cursory examination of the list of
participants suggests that about 57% were from the railway industry, 34% from
universities and other research institutions and 9% from the steel industry. Bearing in
mind that some of the railway industry participantswere from their respective research
and development organisations the balance of interests was about right.
The aim of the Delft conference was rail integrity, with the emphasis being on rolling
contact fatigue, which is a failure mode increasingly recognised as a threat to the
reliability of modern heavy freight and high speed railway systems. A measure of this
recognition can be seen from the large number of conference participants from the
railway industry and thatsubstantial research programmes are being undertaken in this
area in Europe and North America.
ix
x
The conference began with two keynote papers representing European and North
American views and then each session was introduced by an overview. The session
subjects were Rail Maintenance, Rail Metallurgy and Processing, Contact Phenomena,
Residual Stress, and Crack Propagation. 28 papers were presented within the sessions
and the conference concluded with a general discussion which was led by a panel of
railwayengineers. The conferenceproceedingsprovide anindicationofthe development
of our understanding of the problem and what rail steel technology and maintenance
procedures have to offer to combat it.
Thanks are due to many for making this conference a success and they include; the
UnitedStatesFederal Railroad Administration, theEuropean Railway Research Institute
(formally ORE), Professor JJ Kalker and Mrs van der Windt-Krose and the authorities
of the Technical University of Delft, Mrs Komen-Zimmerman and her staff at ASD,
members of the Scientific and Local Conference Committees and our many sponsors
who generously provided financial support. The most thanks must however go to the
authors of the papers and the delegates who attended and participated in the conference.
David F Cannon
Member ofthe Conference Scientific Committee
Chairman, ERRI Committee D173 "Rail Rolling Contact Fatigue"
Derby, England
February 1993
The conference organisers wish to thank the following sponsors for their generous
financial support:
British Rail Research
British Steel Track Products
Fatigue Technology Inc.
Loram Rail Ltd.
Metallurgique et Miniere de Rodange-Athus
N.V. Nederlandse Spoorwegen
Speno International SA
Thyssen Stahl AG
Unimetal
US Department of Transportation
Van Welzenes Spoorbouw B.V.
