A study on the countermeasure method for gauge corner cracking by applying the worn profiles of rail

Abstract

In Japanese railway networks, the gauge corner cracking (GCC) occurs to the head hardened rail of the high rail in curved sections of R600 to R800m. In case of the GCC propagates deeply, it will be a possibility of causes rail broken. Therefore, the appearance of GCC is considered a serious problem from the viewpoint of safety transportation. Since GCC appears mixed with head checks, it is very difficult to find GCC in the early stages. Furthermore, GCC appears in the cluster conditions, it is very difficult to remove all cracks of GCC. Hence, it is very important to control the initiation of GCC. However, the countermeasure method for GCC initiation has not been developed. The aim of this study is to examine the reduction method for GCC initiation due to the relief of the contact pressure between wheel/rail. Therefore, the wear development of rail was focused, the influence of the worn profiles of rail on wheel/rail contact condition was examined. In the beginning of this study, rolling contact fatigue (RCF) test were conducted by use of the twin disc test equipment. Secondly, wear analysis of rail with multibody dynamics which was modeled the locations of GCC appearance was conducted. Finally, the effect of the worn profiles of rail on wheel/rail contact and the suppression of RCF initiation was examined by the wheel/rail contact analysis. In summary, the worn profiles of rail were confirmed the suppression effect for RCF by reducing the contact pressure between wheel/rail.