Multi-scale finite element modeling to describe rolling contact fatigue in a wheel–rail test rig

Finite element models on different length scales are presented for the loading of rails. A 3-D model of the full-scale test rig of the voestalpine company is developed. Results of the model include the full elastic–plastic deformations of rail and wheel, the contact pressure, shear stresses and slip. Results of this model are transferred to (a) a 2-D crack model that calculates the crack tip loading of an inclined surface crack and (b) a 2-D model with rough surfaces calculating cyclic near-surface deformations. On the rail profile two locations in the contact patch with different pressure/slip loads are analyzed separately in the 2-D models. The used multi-scale approach is essential for a realistic description of rolling contact related damage mechanisms. •Multi-scale modeling of local rail-head loading.•Calculation of crack growth during cyclic incremental plastic deformation.•Calculation of local near surface deformation due to roughness.•The model is a basis for quantitative prediction of RCF and wear.