Analysis of deep crack formation and propagation in railway brake discs

Xie, Xiaodong; Li, Zhiqiang; Domblesky, Joseph P.; Yang, Zebin; Liu, Xiaolong; Li, Weijing; Han, Jingtao

doi:10.1016/j.engfailanal.2021.105600

Cited by 17 publications

(9 citation statements)

References 22 publications

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“…For railway vehicles, the air braking system is the ultimate guarantee of operation safety 1 . Being a critical component of the air braking system, the brake disc is essential for braking safety 2 . Under the action of thermomechanical service loading, the brake disc is subjected to alternating tension‐compression stress, which leads to severe damage to the brake disc 3 .…”

Section: Introductionmentioning

confidence: 99%

“…The high temperature can cause plastic deformation and metal phase transition, 3 which changes the fatigue fracture mode 14 and eventually lead to premature fatigue failure 15 . Besides, the uneven heating and heat dissipation structure will cause a violent surface temperature gradient and warpage deformation, which will affect the thermal stress field of the brake disc and ultimately lead to unstable fatigue crack propagation 2 . At the same time, the local macroscopic hot spots will develop on the brake disc's surface with uneven temperature distribution 6 .…”

Section: Introductionmentioning

confidence: 99%

“…1 Being a critical component of the air braking system, the brake disc is essential for braking safety. 2 Under the action of thermomechanical service loading, the brake disc is subjected to alternating tension-compression stress, which leads to severe damage to the brake disc. 3 The railway brake discs' typical damage is shown in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

“…15 Besides, the uneven heating and heat dissipation structure will cause a violent surface temperature gradient and warpage deformation, which will affect the thermal stress field of the brake disc and ultimately lead to unstable fatigue crack propagation. 2 At the same time, the local macroscopic hot spots will develop on the brake disc's surface with uneven temperature distribution. 6 The generation of hot spots will induce thermal fatigue microcracks in the brake disc, 5 and the formed thermal cracks will increase the surface roughness of the brake disc and cause local stress concentration.…”

Section: Introductionmentioning

confidence: 99%

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Influence of braking sequence on railway brake disc's radial crack propagation behavior

Shen

et al. 2023

Fatigue Fract Eng Mat Struct

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The influence of braking sequence on railway brake disc's radial crack propagation behavior is analyzed considering the effect of crack geometry features, material elastoplasticity, and crack closure. The results show that when the residual stress generated in the initial braking is low, the peak stress in the subsequent braking will be low, and the average response state is more inclined to compression. The influences of the braking sequence are mainly reflected in the mid‐late stage of crack growth. In the early stage, the radial cracks almost synchronously expand inward and outward. While in the mid‐late stage, the cracks mainly expand inward. When the initial braking is relatively mild, the brake disc's stress–strain response and crack propagation behavior can be improved. It is beneficial to extend the brake disc's service life by designing a suitable prefabricated working condition or introducing an appropriate residual stress field through surface treatment.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Influence of braking sequence on railway brake disc's radial crack propagation behavior

Shen

et al. 2023

Fatigue Fract Eng Mat Struct

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“…However, due to the complexity of applying and controlling any automated remeshing algorithm, the extended finite element method (XFEM) and meshless methods have been extensively and effectively applied to crack propagation. In XFEM [22][23][24], re-meshing is avoided by enriching the finite element interpolation functions using asymptotic expansions, which allows for an accurate representation of the crack propagation trajectories and singularity fields near the crack apex. Nevertheless, a priori knowledge of these enrichments is required, and complexities may arise in formulating finite elements and performing numerical integrations [25].…”

Section: Introduction 1backgroundmentioning

confidence: 99%

Linear Elastic Fracture Mechanics Assessment of a Gas Turbine Vane

et al. 2022

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This work assesses the crack propagation at the most critical point of a second stage of a gas turbine blade by means of linear elastic fracture mechanics (LEFM). The most critical zone where the crack may nucleate, due to a combination of thermo-mechanical loads, is detected with an uncracked finite element (FE) model pre-analysis. Then the sub-modelling technique is used to obtain more precise results in terms of stresses within the area of interest. Simulations of the state of stress at the crack apex are performed through an FE model, using the Fracture Tool within ANSYS Workbench, and the stress intensity factors (SIFs) are determined accordingly. The Fracture Tool was previously verified on a simple model, and the results were compared with its analytical solution. Finally, the evaluation of the crack growth due to fatigue stress, creep, and oxidation is performed through in-house software called Propagangui. The crack behavior is estimated along with the component life. Results show an unexpected decrease in KI with increasing crack length and slowing of the crack growth rate with crack propagation. A detailed analysis of this behavior emphasizes that the redistribution of the stresses at the crack apex means that unstable propagation is not expected.

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