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 Wöhler 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.