Estimation of residual stresses in railroad commuter car wheels following manufacture

969900Duplicate. sorry.PDFProceedingsCreepFinite element methodHeat transferManufacturingMechanical analysisRailroad carsResidual stressSimulationViscoelasticityWheelsAmerican Society of Mechanical EngineersGordon, JeffPerlman, A. BenjaminJohn A. Volpe National Transportation Systems Center (U.S.)Tufts UniversityUnited States. Federal Railroad Administration. Office of Research and DevelopmentVolpe National Transportation Systems Center, Technical Reference CenterA finite element simulation is presented for the prediction ofresidual stresses resulting from the heat treatment of railroadcommuter car wheels during manufacture. The quenching andannealing segments of the wheel manufacturing process are simulatedusing a decoupled heat transfer and stress analysis. A set of baselineparameters which characterize geometry, material properties andquench characteristics is developed which are representative of currentrim-quenching practice. Results indicate the formation of a layer ofresidual circumferential (hoop) compression to a depth of about 4 cm(1.5 inch) from the tread surface. Variations of these parameterswhich account for expected ranges in the manufacturing process areshown to have little influence on this finding. The as-manufacturednet rim compressive residual stress may be reversed when subjected toservice loading in railroad commuter operations. This situation isexamined in a companion paper. Tensile stresses at the wheel treadcreate an environment conducive to the formation of surface cracksthat may threaten the safety of train operations. The results of thestudies presented in this paper are required to define the initialconditions for analyses of how service conditions may act to changethe as-manufactured residual stress state