Application of local fatigue strength approach to assess and optimise the impact of deep rolling on the fatigue performance of railway axles

Pertoll, T.; Buzzi, C.; Leitner, M.; Boronkai, L.

doi:10.1016/j.ijfatigue.2024.108335

Cited by 3 publications

(3 citation statements)

References 28 publications

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“…It was found that repeated deep rolling with reduced deep rolling forces has a positive effect on the induced residual stress state. Furthermore, the fatigue strength assessment based on the residual stress state presented in [17] shows that the optimisation allows a significant increase in load capacity.…”

Section: Process Optimisationmentioning

confidence: 99%

“…The parameters are shown again in the diagram. According to [17], triple deep rolling (20 kN/10 kN/5 kN) allows a significant increase in fatigue strength. The increase in damage introduced is small and, due to the reduced forces, it is not expected that the increase in damage will have a negative effect on fatigue strength.…”

Section: Process Optimisationmentioning

confidence: 99%

“…The simulation model is used to investigate the influence of deep rolling parameters and optimisations on the residual stresses applied, and the results are presented in [15]. The influence of these on cracking behaviour [16] and fatigue strength [17] is also investigated. The application of the highest deep rolling force shows the most significant depth effect on the residual stresses applied, the best crack propagation behaviour, and also the best result in terms of fatigue strength.…”

Section: Introductionmentioning

confidence: 99%

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Strain-Based Assessment to Evaluate Damage Caused by Deep Rolling

Pertoll,

Leitner,

Buzzi

et al. 2024

Materials

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The positive effects of deep rolling on fatigue strength—reduced surface roughness, work hardening and compressive residual stress—in the near-surface region are achieved by controlled high plasticisation of the treated material. However, excessive and/or repeated plasticising poses a risk of damage to the machined component. This paper investigates the damage caused by deep rolling of a railway axle. Two sections of the axle are experimentally deep rolled repeatedly at different feed rates until damage is detected. For comparative analysis, these experiments are numerically analysed and the damage is assessed using the strain-based damage calculation. The results are compared and a damage sum of ~120% is evaluated for both tests, thus developing a reliable and conservative assessment method. The single deep rolling treatment at a feed rate of 0.25 mm causes damage of 6.1%, and at a feed rate of 0.5 mm, damage of 4.7%. The developed and experimentally validated evaluation method allows for investigating the limits of applicability of different deep rolling parameters. The influence of the deep rolling force and feed rate and a proposed optimisation with multiple deep rolling with reduced deep rolling forces are investigated.

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Section: Process Optimisationmentioning

confidence: 99%

Section: Process Optimisationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Strain-Based Assessment to Evaluate Damage Caused by Deep Rolling

Pertoll,

Leitner,

Buzzi

et al. 2024

Materials

Self Cite

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Multi-roller taper burnishing of internal chamfers and its enhancement mechanism on 7050 aluminum alloy

Keymanesh,

Ji,

Zhang

et al. 2024

International Journal of Fatigue

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Layer Approach to Model Fatigue Strength of Surface-Hardened Components

Dobberke,

Leitner,

Wiebesiek

et al. 2024

Metals

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This paper deals with a surface-hardened forged steel that is commonly used for powertrain components like gears, axles or crankshafts. In order to increase static and fatigue strength and to minimise wear, surface treatments like induction hardening lead to a significant microstructural change within heat-affected zones. The aim of this study was to elaborate a method for a reliable computational estimation of the local fatigue strength by considering local material properties. The method is based on experimental test results, where specimens were extracted from forged crankshafts and further heat-treated to investigate the fatigue strength of the unhardened and hardened material condition. The experimental test data were fundamental in defining elaborated Haigh diagrams, enabling a more reliable local fatigue assessment. The comparison of the component safety within the fatigue strength verification for a crankshaft section under alternate bending resulted in 28%-more progressive dimensioning of surface hardened layers.

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Application of local fatigue strength approach to assess and optimise the impact of deep rolling on the fatigue performance of railway axles

Cited by 3 publications

References 28 publications

Strain-Based Assessment to Evaluate Damage Caused by Deep Rolling

Strain-Based Assessment to Evaluate Damage Caused by Deep Rolling

Multi-roller taper burnishing of internal chamfers and its enhancement mechanism on 7050 aluminum alloy

Layer Approach to Model Fatigue Strength of Surface-Hardened Components

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