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• The contact load between the roller and the raceway in the bearing is measured. • Proposing a life prediction method for the bearing under variable load conditions. • Bearings at different locations of one wheelset show different fatigue lives. In this paper, a life prediction method for axle box bearing rolling contact fatigue under wheel-rail excitation conditions is present. The dynamic contact load between the rollers and the outer raceway was considered the critical mechanical parameter for rolling contact fatigue of the bearing and measured based on strain detection of the bearing outer ring. In the bench test, the different excitation frequencies were simulated by a polygonal roller with varying rotation speeds. Then, the load spectrums of the measured loads were compiled and used as the input data for the life prediction model of rolling contact fatigue. Since the subsurface material element of the raceway is subject to the complex multiaxial stress state during service, the fatigue life was estimated based on the improved moment of the load path model. Besides, the linear damage accumulation rule was applied to evaluate the fatigue life of the bearings, considering the varying contact load that the outer raceway was subject to. Finally, the predicted fatigue lives of two double-row tapered roller bearings under different excitation conditions were present based on the proposed method. [ABSTRACT FROM AUTHOR]

• The wear performance of the defected rail materials under various slip ratios and contact stresses was investigated. • The surface damage of the defected rail materials under various slip ratios and contact stresses was studied. • The effect of slip ratio and contact stress on crack propagation mechanisms near the dent was discussed. The defects on rail surface may have negative effects on the rolling contact fatigue (RCF) performance of the rail materials. This investigation researched on the RCF behaviors of the defected rail materials under various slip ratios and contact stresses. The results show that both the wear loss and the average crack length increase if the slip ratio or the contact stress increases. Moreover, the surface damage characteristics change from simple adhesion spots to significant fatigue crack grouping when slip ratio and contact stress rise. Finally, the experimental results also highlight that the slip ratio provides the deformation area for crack initiation whereas the contact stress accelerates the crack propagation by emphasizing the geometric effects. [ABSTRACT FROM AUTHOR]

• A Voronoi finite element model for crack initiation life of RCF is built. • The coupling damage model considers the microstructure of material. • The impact mechanism of grain characteristics and material defects is revealed. The material microstructure of plays an important role in crack initiation of rolling contact fatigue. To address crack initiation of tapered roller bearings, the inhomogeneous characteristic of material is considered. The random distribution of material grains is simulated with Voronoi graph, and a Voronoi finite element model of rolling contact fatigue is given. Numerical analysis of damage-life constitutive relation is carried out with finite element analysis. The effect of material microstructure inhomogeneity on initiation life of fatigue crack is studied. Researches show that the smaller the grain size, the more difficult the fatigue crack appearing. The larger the difference of elasticity modulus between non-metallic inclusions and matrix material, the greater the impact on fatigue life of crack initiation. The angular and sharp non-metallic inclusions reduce fatigue life more than rounded shape inclusions. Initiation life of fatigue crack has a minimum value on a critical depth of nonmetallic inclusion. The longer distance between two laterally arranged inclusions, the greater it affect the initiation life of fatigue crack. The effect of distance between two vertically arranged inclusions on fatigue crack initiate depends on the depth of inclusions. [ABSTRACT FROM AUTHOR]

• The UPM and PI iterative methods can accurately reconstruct the residual stress field induced by rolling processing. • The extended finite element method and the weight function method are applied to solve the stress intensity factor. • The necessity of deep rolling treatment for axles is verified. • The influence of interference and initial crack position on the remaining life of axle is explored. • The damage tolerance analysis of the axle was carried out. Deep rolling surface strengthening is an effective way to introduce compressive residual stress (CRS) along the railway axle, which can improve the fatigue resistance of the material. The CRS field was rebuilt adopting the proportional-integral (PI) iteration method and the unit pressure method (UPM) to study the fatigue cracking behavior of deep-rolled EA4T railway axles. The remaining life prediction model and the stress intensity factor (SIF) solution method were then validated using simulations and testing with small-sized specimens. The remaining life of the EA4T railway axle was then calculated by applying a realistic vertical load spectrum. The results showed that CRS prevented crack propagation, enhanced the critical propagation size of railway axle cracks, and prolonged the remaining life of the axle. Additionally, the remaining life of the axle may not support the following maintenance period if a crack with an extendable size emerges at the unloading groove of the railway axle. This work provides a theoretical basis for the optimization of the non-destructive testing (NDT) interval of deep-rolled EA4T railway axles. [ABSTRACT FROM AUTHOR]