Finite element approach toward an advanced understanding of deep rolling induced residual stresses, and an application to railway axles

Materials and Design

Volumn 83, Issue , 2015, Pages 689-703

  Hassani Gangaraj, S M ^a,b   Carboni, M ^b   Guagliano, M ^b  

^a Massachusetts Institute of Technology Cambridge   (United States)

^b POLITECNICO DI MILANO   (Italy)

Author keywords

Deep rolling; EA4T; Fatigue crack propagation; Finite element; Hole drilling; Railway axles; Residual stress; X ray diffraction

Indexed keywords

AXLES; CRACK PROPAGATION; CRACKS; FATIGUE CRACK PROPAGATION; RAILROADS; RESIDUAL STRESSES; TRANSPORTATION; X RAY DIFFRACTION;

COMPRESSIVE RESIDUAL STRESS; DEEP ROLLING; DISTRIBUTION OF RESIDUAL STRESS; EA4T; FINITE-ELEMENT APPROACH; HOLE DRILLING; RAILWAY AXLES; TECHNOLOGICAL PARAMETERS;

FINITE ELEMENT METHOD;

EID: 84941271206     PISSN: 02641275     EISSN: 18734197     Source Type: Journal    
DOI: 10.1016/j.matdes.2015.06.026     Document Type: Article

References (54)

1. Schulze V. Modern Mechanical Surface Treatment: States, Stability, Effects 2006, Wiley.
2. Altenberger I. Deep rolling - the past, the present and the future. Int. Conf. Shot Peen. 2005, 144-155.
3. Hassani-Gangaraj S.M., Moridi A., Guagliano M., Ghidini A., Boniardi M. The effect of nitriding, severe shot peening and their combination on the fatigue behavior and micro-structure of a low-alloy steel. Int. J. Fatigue 2014, 62:67-76. 10.1016/j.ijfatigue.2013.04.017.
4. Hassani-Gangaraj S.M., Moridi A., Guagliano M., Ghidini A. Nitriding duration reduction without sacrificing mechanical characteristics and fatigue behavior: the beneficial effect of surface nano-crystallization by prior severe shot peening. Mater. Des. 2014, 55:492-498.
5. Hassani-Gangaraj S.M., Moridi A., Guagliano M. Fatigue properties of a low-alloy steel with a nano-structured surface layer obtained by severe mechanical treatments. Key Eng. Mater. 2013, 577-578:469-472. 10.4028/www.scientific.net/KEM.577-578.469.
6. Nalla R.K., Altenberger I., Noster U., Liu G.Y., Scholtes B., Ritchie R.O. On the influence of mechanical surface treatments-deep rolling and laser shock peening-on the fatigue behavior of Ti-6Al-4V at ambient and elevated temperatures. Mater. Sci. Eng. A 2003, 355:216-230.
7. Juijerm P., Altenberger I. Effect of high-temperature deep rolling on cyclic deformation behavior of solution-heat-treated Al-Mg-Si-Cu alloy. Scr. Mater. 2007, 56:285-288.
8. Altenberger I., Scholtes B., Martin U., Oettel H. Cyclic deformation and near surface microstructures of shot peened or deep rolled austenitic stainless steel AISI 304. Mater. Sci. Eng. A 1999, 264:1-16.
9. Tsuji N., Tanaka S., Takasugi T. Effect of combined plasma-carburizing and deep-rolling on notch fatigue property of Ti-6Al-4V alloy. Mater. Sci. Eng. A 2009, 499:482-488. 10.1016/j.msea.2008.09.008.
10. Altenberger I., Nalla R.K., Sano Y., Wagner L., Ritchie R.O. On the effect of deep-rolling and laser-peening on the stress-controlled low- and high-cycle fatigue behavior of Ti-6Al-4V at elevated temperatures up to 550°C. Int. J. Fatigue 2012, 44:292-302.
11. Kloos K.H., Fuchsbauer B., Adelmann J. Fatigue properties of specimens similar to components deep rolled under optimized conditions. Int. J. Fatigue 1987, 9:35-42.
12. Majzoobi G.H., Azadikhah K., Nemati J. The effects of deep rolling and shot peening on fretting fatigue resistance of Aluminum-7075-T6. Mater. Sci. Eng. A 2009, 516:235-247.
13. Tsuji N., Tanaka S., Takasugi T. Evaluation of surface-modified Ti-6Al-4V alloy by combination of plasma-carburizing and deep-rolling. Mater. Sci. Eng. A 2008, 488:139-145. 10.1016/j.msea.2007.11.079.
14. Altenberger I., Stach E.A., Liu G., Nalla R.K., Ritchie R.O. An in situ transmission electron microscope study of the thermal stability of near-surface microstructures induced by deep rolling and laser-shock peening. Scr. Mater. 2003, 48:1593-1598. 10.1016/S1359-6462(03)00143-X.
15. Nikitin I., Scholtes B., Maier H.J., Altenberger I. High temperature fatigue behavior and residual stress stability of laser-shock peened and deep rolled austenitic steel AISI 304. Scr. Mater. 2004, 50:1345-1350.
16. Juijerm P., Altenberger I. Residual stress relaxation of deep-rolled Al-Mg-Si-Cu alloy during cyclic loading at elevated temperatures. Scr. Mater. 2006, 55:1111-1114.
17. Nikitin I., Besel M. Residual stress relaxation of deep-rolled austenitic steel. Scr. Mater. 2008, 58:239-242. 10.1016/j.scriptamat.2007.09.045.
18. Chien W.Y., Pan J., Close D., Ho S. Fatigue analysis of crankshaft sections under bending with consideration of residual stresses. Int. J. Fatigue 2005, 27:1-19.
19. Spiteri P., Ho S., Lee Y.L. Assessment of bending fatigue limit for crankshaft sections with inclusion of residual stresses. Int. J. Fatigue 2007, 29:318-329.
20. Choi K.S., Pan J. Simulations of stress distributions in crankshaft sections under fillet rolling and bending fatigue tests. Int. J. Fatigue 2009, 31:544-557.
21. Choi K.S., Pan J. Effects of pressure-sensitive yielding on stress distributions in crankshaft sections under fillet rolling and bending fatigue tests. Int. J. Fatigue 2009, 31:1588-1597.
22. EN13103, Railway Applications - Wheelsets and Bogies - Non Powered Axles - Design Method, CEN, 2012.
23. EN13104, Railway Applications - Wheelsets and Bogies - Powered Axles - Design Method, CEN, 2012.
24. R.A. Smith, S. Hillmansen, Monitoring fatigue in railway axles, in: 13th Int. Wheel. Congr. Roma, Italy, 2001.
25. Transportation Safety Board of Canada, Main track derailment: Canadian national train No.G-894-31-14, Railway Investigation Report R01Q0010, 2001.
26. A. Watson, Implication of axle damage onto the structural integrity of axles, ESIS TC24 Meet, Berlin, 2010.
27. Beretta S., Carboni M., Fiore G., Conte A.Lo Corrosion-fatigue of A1N railway axle steel exposed to rainwater. Int. J. Fatigue 2010, 32:952-961.
28. Zerbst U., Vormwald M., Andersch C., Mädler K., Pfuff M. The development of a damage tolerance concept for railway components and its demonstration for a railway axle. Eng. Fract. Mech. 2005, 72:209-239.
29. S. Cantini, S. Beretta, Structural Reliability Assessment of Railway Axles, LRS-Techno Ser, 4, 2011.
30. Grandt A.F. Fundamentals of Structural Integrity: Damage Tolerant Design and Nondestructive Evaluation 2003, Wiley.
31. Makino T., Kato T., Hirakawa K. Review of the fatigue damage tolerance of high-speed railway axles in Japan. Eng. Fract. Mech. 2011, 78:810-825.
32. Hirakawa K., Kubota M. On the fatigue design method for high-speed railway axles. Proc. Inst. Mech. Eng. Part F: J. Rail Rapid Transit. 2001, 215:73-82.
33. Zhang J.W., Lu L.T., Shiozawa K., Cui G.D., Zhang W.H. Fatigue properties of oxynitrocarburized medium carbon railway axle steel in very high cycle regime. Int. J. Fatigue 2010, 32:1805-1811.
34. Zhang J.W., Lu L.T., Shiozawa K., Shen X.L., Yi H.F., Zhang W.H. Analysis on fatigue property of microshot peened railway axle steel. Mater. Sci. Eng. A 2011, 528:1615-1622.
35. EN 13261, Railway Application - Wheelsets and Bogies - Axles - Product Requirements, CEN, 2011.
36. ASTM E8/E8M-11, Standard Test Methods for Tension Testing of Metallic Materials, ASTM, 2011.
37. ASTM E606/E606M-12, Standard Test Methods for Strain-Controlled Fatigue Testing, ASTM, 2012.
38. Regazzi D., Beretta S., Carboni M. An investigation about the influence of deep rolling on fatigue crack growth in railway axles made of a medium strength steel. Eng. Fract. Mech. 2014, 131:587-601. 10.1016/j.engfracmech.2014.09.016.
39. Pippan R. The growth of short cracks under cyclic compression. Fatigue Fract. Eng. Mater. Struct. 1987, 9:319-328. 10.1111/j.1460-2695.1987.tb00459.x.
40. Carboni M., Patriarca L., Regazzi D. Determination of DKth by compression pre-cracking in a structural steel. J. ASTM Int. 2009, 6:1-13.
41. R. Forman, R. McClung, NASGRO 4.0, Fracture Mechanics and Fatigue Crack Growth Analysis Software, Reference Manual, 2002.
42. Hauk V. Structural and Residual Stress Analysis by Nondestructive Methods 1997, Elsevier.
43. ASTM E837-08, Standard Test Method for Determining Residual Stresses by the Hole-Drilling strain-Gage Method, ASTM, 2008.
44. Gangaraj S.M.H., Guagliano M., Farrahi G.H. An approach to relate shot peening finite element simulation to the actual coverage. Surf. Coat. Technol. 2014, 243:39-45. 10.1016/j.surfcoat.2012.03.057.
45. Hassani-Gangaraj S.M., Guagliano M., Farrahi G.H. Finite element simulation of shot peening coverage with the special attention on surface nanocrystallization. Proc. Eng. 2011, 10:2464-2471.
46. Dassault Systemes, ABAQUS 6.10-1 User's manual, 2010.
47. Hassani-Gangaraj S.M., Guagliano M. Microstructural evolution during nitriding, finite element simulation and experimental assessment. Appl. Surf. Sci. 2013, 271:156-163. 10.1016/j.apsusc.2013.01.154.
48. Moridi A., Hassani-Gangaraj S.M., Guagliano M., Vezzu S. Fracture and Fatigue 2014, vol. 7. Springer. 10.1007/978-3-319-00765-6.
49. Gravier N., Viet J., Leluan A. Prédiction de la durée se vie des essieux-axes ferroviaires. Rev Générale Des Chemins Fer 1999, 3:33-40.
50. RSSB T728, Research Project, Impact of corrosion upon the high cycle fatigue properties of GB axle steel, 2011.
51. Beretta S., Carboni M., Cervello S. Design review of a freight railway axle: fatigue damage versus damage tolerance. Mat-Wiss U Werkstofftech 2011, 42.
52. Krautkrämer J., Krautkrämer H. Ultrasonic Testing of Materials 1990, Springer-Verlag.
53. AFGrow v. 4.0012.15, User's manual, 2008.
54. Montgomery D.C. Design and Analysis of Experiments 2008, John Wiley & Sons.