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Scott Simson
BE (Man & Mat), ME, PhD
Bradken, NSW, Australia
SUMMARY
Bradken has been asked by its clients to investigate wheel RCF (Rolling Contact Fatigue) occurring in
standard gauge coal rollingstock. In particular high impact wheel occurrence from rail squat like surface
initiated sub surface RCF. In the USA similar RCF issues have been under investigation by the AAR with a
considerable amount of publications in the last five years.
In the USA wheel RCF issues has been linked to sharper curvatures and profile mismatch. The USA study
has drawn a link to asymmetric wheel wear with worn rail profiles exhibiting the shapes of the asymmetric
worn wheels. These worn rails then exhibit deteriorating contact stresses with most wheels increasing the
likelihood of rolling contact fatigue. Canadian experience associates wheel RCF shelling with the occurrence
of metal pickup in tread braking.
Bradken and other parties have investigated RCF occurrences and the wheel steel manufacture in
Australian coal operations. The higher material hardness has appeared to increase wheel RCF occurrence
over wear. Brake shoe metal pickup and slip damage appear closely associated with RCF occurrences. The
uni-directional Australian operations develop distinct worn wheel profiles. Worn Profiles include asymmetry
and a groove beyond the normal running surface. The wheel profile maintenance in Australia has not been
subject to optimisation and is far removed from the international best heavy haul practice.
INTRODUCTION
In the USA Coal haulage there has been extensive
research done on the occurrence of RCF damage
that results in high impacts wheels (HIW). These
wheels have subsurface RCF initiated from the
surface often from flange side RCF bands. The
next identified wheel failure mode in the USA coal
haulage is asymmetric wheel flange wear,
(AWFW). Similar problems have been experienced
in Australia standard gauge coal. The large sub
surface RCF cracks have similarities to rail squats
and in Australian operations they coexist with
brake shoe metal pickup and slip damage. A range
of related literature is presented as bearing on the
observed damage.
RCF LITERATURE
Rolling contact fatigue RCF has been extensively
investigated. The "Wheel-rail interface handbook"
edited by R. Lewis and U. Olofsson (2009) [1] is
the most comprehensive text on the topic. The Triannual international conference on contact
mechanics is the main forum. Rolling contact
fatigue has been largely split in to two major
definitions being surface and sub surface initiated
fatigue. The major exception to this definition is the
Rail Squat which is surface or near surface
initiated but progresses as a subsurface crack.
Flange
Side
Centre of
Tread
Field
Side
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Flange
Side
Crack
Band
Field
Side
Crack
Band
Sub-surface
length
Extended
Crack width
Figure 10 Centre of Tread Extended RCF, crack width ~20 mm, from a field crack band of ~10 mm
width with a sub-surface growth, length ~40 mm
Visual Ultrasonic Inspections of HIW
Inspection on HIW wheels suggest multiple
initiation sources. Other evident damage on HIW
associated with the subsurface cracks has been
sliding damage Figure 8, thermo mechanical
cracking in the centre of tread Figure 11, Field side
RCF cracking Figure 9, Error! Not a valid
bookmark self-reference.. Of greatest concern
has been what has been termed extended cracks,
Figure 10, Figure 9. This is where a crack extends
from the field side cracking band into the centre of
tread. Extended cracks are the most common
features found with sub surface crack growth.
crack
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relationship to distance
occurrences, Figure 13.
travelled
and
HIW
HIW
Percent
Occurrence
Km of Service
Figure 13 HIW occurrence distribution with
distance, Hunter Valley
Information on brake rigging alignment and wheel
profile wear was not available with the occurrence
data. Recent observations have shown brake
show alignments to be ~10-12 mm off centre with
alignments depending on rigging arrangements.
The wagons operating over the Blue Mountains
have both HIW and flange side shelling damage
occurring on leading wheels with no damage to
trailing wheels. Initial train inspection of these
wagon anecdotally report that train position was of
great impact with the front of the train experiencing
heavier RCF damage and the wheelsets at the
back of the train consist exhibiting asymmetric
wheel wear. AWFW is not triggering wheel
renewals in these wagon rather asymmetric tread
wear is causing wheelsets to be removed for tread
hollowing on one wheel of the wheelset.
Scott Simson
Bradken
Wheel
Position
Flange
side
Centre
Field
side
Shell
Leading Left
29.3
1.3
36.5
5.4
Leading Right
21.0
0.2
41.2
4.1
Trailing Left
6.5
0.4
6.1
2.2
Trailing Right
2.2
1.4
4.0
1.1
Scott Simson
Bradken
Flange
side
Centre
Field
side
Shell
Leading Left
7.3
0.5
0.0
0.0
Leading Right
2.6
0.0
39.1
0.0
Trailing Left
1.0
0.0
0.0
0.0
Trailing Right
1.0
0.5
2.1
0.0
Scott Simson
Bradken
Scott Simson
Bradken