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Article history: A finite element (FE) method was used to study the formation of residual stresses in low carbon
Received 7 December 2010 bainitic–martensitic rail wheels. The FE model combines a commercially available heat treatment
Received in revised form 12 April 2011 software DANTE to the finite element analysis software ABAQUS. Material data which include thermo-
Accepted 14 April 2011
mechanical properties and kinetics of phase transformations for low carbon bainitic–martensitic (LCBM)
Available online 22 April 2011
steels were obtained from dilatometry experiments and added to DANTE material library. The results
showed that quenching conditions can be designed to promote the development of compressive residual
Keywords:
stresses in the rim of LCBM rail wheels making it possible to produce LCBM steel rail wheels, which have
Residual stress
Quenching
superior properties compared to conventional pearlitic steels.
Railway wheels © 2011 Elsevier B.V. All rights reserved.
Low-carbon bainitic–martensitic steels
Finite element modelling
1. Introduction to both retard fatigue crack growth and guard against sudden catas-
trophic failure from large overloads.
During manufacture, rail wheels are quenched to achieve Performance of pearlitic steel rail wheels has been improved
favourable mechanical properties as well as to promote beneficial mainly by the removal of impurities in steels and strengthening of
residual compressive circumferential stress in the rim of the wheel. wheel steels through the additions of alloying elements as demon-
Mutton and Lynch (2004) have shown the importance of compres- strated by Yokoyama et al. (2002). Lonsdale and Stone (2002) have
sive residual stresses in rail wheels and their role in increasing the shown the advantages of micro-alloying elements in rail steels in
life of rail wheels by retarding the formation and growth of cracks. which hardness levels have been increased up to 321 HB and wear
Conventional rail wheels are made of medium to high carbon resistance has also been improved by 20–25% over conventional rail
steels and have a characteristic pearlitic–ferritic microstructure as steels. However, the current trend in heavy haul traffic for heavier
reported by Zhang and Gu (2008) and Devanathan and Clayton axle loads and higher speeds for passenger trains have seen the
(1991). A variety of grades are used within the Australian rail indus- conventional pearlitic steel pushed to their limit and urged the
try ranging from the AAR Class A (nominally 0.47–0.57% C), Class B development of new, stronger and more fatigue resistant steels.
(0.57–0.67% C) and Class C (0.67–0.77% C) depending on the type As a result, low carbon bainitic–martensitic (LCBM) steels have
of service and degree of tread braking involved. Kwon et al. (2006) recently been developed as a promising material for rail wheels
have demonstrated that conventional pearlitic wheels are suscep- as reported by Constable et al. (2006). Constable et al. (2006)
tible to the initiation of thermal fatigue cracks at the wheel/rail have shown that LCBM steels have superior hardness and strength,
contact zone. Significant thermal loads which occur during heavy toughness and ductility compared to conventional pearlitic steels.
tread braking transform the pearlitic steel into brittle martensite High hardness levels up to 415 HB have been recorded in LCBM
after subsequent rapid cooling of the wheels. Although theories steels which is an increase of 18% compared to conventional
for the formation of such cracks differ as reported by Mutton and pearlitic steels. LCBM steels have also showed superior resistance
Boelen (1989), there is evidence that pearlitic steels with higher both to thermal fatigue and formation of cracks which are benefi-
carbon content are more susceptible to this problem. Therefore, cial for reliability and safety in railway wheels. Lonsdale and Stone
compressive residual stresses within the rim of the wheel are seen (2002) have shown that martensitic rail wheels could significantly
improve wear resistance of rail wheels. However, the effects of
austenitic to martensitic phase transformation which causes a net
∗ Corresponding author. Tel.: +61 03 990 53647. volumetric expansion during quenching of LCBM steel rail wheels
E-mail addresses: siva.lingamanaik@monash.edu on the residual stress distribution in the rim of rail wheel have not
(S.N. Lingamanaik), Bernard.Chen@monash.edu (B.K. Chen). been adequately evaluated.
0924-0136/$ – see front matter © 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2011.04.007
1548 S.N. Lingamanaik, B.K. Chen / Journal of Materials Processing Technology 211 (2011) 1547–1552
2. Methods
Table 1
Quenching conditions for pearlitic and LCBM steel rail wheels.
Case A (conventional quenching for pearlitic wheels) 120 Tread Yes Yes N/A N/A Yes
Case B (conventional quenching for LCBM wheels) 120 Tread Yes Yes Yes
Case C (Alternate quenching for LCBM wheels) 120 Tread, Inner Hub N/A N/A 1100 Tread Yes
In Case A, hot austenite in the tread section of the wheel cools Mutton and Lynch (2004) quantified residual stress distribu-
and transforms to pearlite. The rim of the wheel shrinks and a dif- tions in common rail wheel grades using ultrasonic methods
ferential change in volume is created between the inner rim and the obtained by summing the stresses along the path of the ultrasonic
tread section which results in the inner rim being in tension and wave and plotted as averaged stress values at different locations
the tread of the rim to be in compression. The final distribution of below the tread of the wheel (Fig. 3(b)). The results predicted for
residual stresses predicted by the present model for conventional AAR Class A (0.55% C) rail wheels by the present model at various
pearlitic rail wheels is in agreement with finite element analysis of locations in the rim have also been averaged (in a similar fash-
pearlitic rail wheels by Lonsdale and Stone (2002). ion) such that they can be compared against experimental data as
Fig. 3. (a) Circumferential stress for AAR Class A (0.55% C) rail wheel under conventional quenching conditions (Case A). (b) Ultrasonic residual stress measurements on
various rail wheel grades as reported by Mutton and Lynch (2004). (c) Circumferential stress for low carbon bainitic–martensitic steel (0.21% C) wheels under conventional
quenching procedure (Case B). (d) Circumferential stress for low carbon bainitic–martensitic steel (0.21% C) wheels under alternate quenching procedure (Case C).
S.N. Lingamanaik, B.K. Chen / Journal of Materials Processing Technology 211 (2011) 1547–1552 1551
reported by Mutton and Lynch (2004). Fig. 3(b) shows the resid- residual compressive stresses in the rim of the wheel are expected
ual stresses predicted by the ABAQUS/DANTE FE model are in good to relax. Further work is being undertaken to evaluate more pre-
agreement with experimental residual stress measurements in rail cisely the changes to the residual stress distribution brought about
wheels. by the machining process.
Fig. 3(c) shows the residual stresses predicted for LCBM rail
wheels under conventional quenching procedure (Case B). High
4. Conclusion
tensile residual stresses (>550 MPa) were predicted in the rim of
LCBM steel rail wheel which are probably high enough to cause
Dilatometry experiments for different grades of LCBM steels
cracking as the value is of the order of yield stress of LCBM steel
were undertaken to quantify the volumetric changes occurring
(≈860 MPa).
during martensite phase transformation and the results were incor-
During quenching of LCBM rail wheels (Case B), the rim shrinks
porated in an ABAQUS/DANTE FE model. The residual stresses
due to thermal contraction but experiences a net outward expan-
predicted by ABAQUS/DANTE FE model were found to be in
sion due to the martensite phase transforming in the rim, plate and
agreement with published experimental results. Conventional
hub of the wheel. This behaviour is expected in LCBM steels due to
quenching process for as-forged pearlitic steel rail wheels resulted
a net volumetric expansion for martensite phase transformation.
in favourable compressive residual stresses being formed in the
Martensite transformation occupies a higher net volumetric expan-
rim of the wheel whereas the conventional quenching process was
sion compared to pearlite transformation in conventional pearlitic
found to be unsuitable for LCBM steel rail wheels due to the for-
rail wheels as reported by Lonsdale and Stone (2002).
mation of high levels of tensile stresses in the rim of the wheel.
These results predicted in Case B have been found to be consis-
However, this work has demonstrated that altering the quench-
tent with results of experimental work undertaken by Lonsdale and
ing parameters (heat transfer coefficients, quenching duration and
Ishler (2001) on 420 monobloc rail wheels which were quenched
quenching locations) can promote favourable compressive residual
at the tread for 240 s and tempered for 4 h. Cuts made in the rim of
stresses in the rim of LCBM rail wheels.
the wheel showed a net 0.4 mm (positive) opening displacement in
the tread’s surface which suggests that significant tensile residual
stresses were formed due to quenching in the rim of the wheel. Acknowledgements
Quenching conditions (quenching durations, spray locations
and spray configuration) for LCBM steel rail wheels selected in Case The authors would like to thank CRC for Rail Innovation
C were shown to result in favourable compressive residual stresses (established and supported under the Australian Government’s
(≈−300 MPa) in the rim of the wheel. Tensile residual stresses rang- Cooperative Research Centres program) for the funding of this
ing from 70 MPa to 200 MPa were predicted in the plate of the research. Project No. R3.101 New Wheel Steel and also Tim Con-
wheel. However, they are not detrimental since cracks tend to form stable for supporting this work.
mainly in the outer rim of the wheel.
As described in Case B, the hub, plate and the inner rim con-
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