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Chinese Journal of Materials Research  2024, Vol. 38 Issue (9): 711-720    DOI: 10.11901/1005.3093.2023.431
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Stress-Strain Field at the Fatigue Crack Tip of Pearlite Heavy Rail Steel
CEN Yaodong(), JI Chunjiao, BAO Xirong, WANG Xiaodong, CHEN Lin, DONG Rui
School of Materials Science and Engineering, Inner Mongolia University of Science and Technology, Baotou 014010, China
Cite this article: 

CEN Yaodong, JI Chunjiao, BAO Xirong, WANG Xiaodong, CHEN Lin, DONG Rui. Stress-Strain Field at the Fatigue Crack Tip of Pearlite Heavy Rail Steel. Chinese Journal of Materials Research, 2024, 38(9): 711-720.

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Abstract  

The fatigue crack propagation of heavy rail steel has a very complex relationship with the stress and strain at the crack tip, but there is currently little research on this mechanism. This article takes pearlite heavy rail steel as the research object under three conditions (increasing cooling rate): online rolling state, online heat treatment state, and laboratory heat treatment state. The pearlite layers at different cooling rates were observed using scanning electron microscopy, and the tensile fatigue crack and stress field cloud map at the crack tip of the heavy rail steel were measured using fatigue testing machines and strain gauges. Then, a stress and strain model was established based on Abaqus, the results indicate that as the cooling rate increases, the interlayer spacing of pearlite decreases; With the fatigue crack propagation, the stress field strength around the crack and the Stress intensity factor k at the crack tip increase, and the stress field is more significant in the "butterfly" shape. The Stress intensity factor of the laboratory heat treated heavy rail steel at the crack length of 1, 2, 3 mm is 13.53, 14.58, and 15.54 MPa·m1/2, respectively, which is far greater than that of the rolled and heat treated heavy rail steel at the same crack length; As the fatigue crack length increases, the equivalent strain area near the crack tip increases. At the same crack length, the equivalent strain at the crack tip of three kinds of heavy rail steels with cooling rate decreases with the decrease of pearlite lamellae. The simulation results of equivalent strain at a longer crack length of 3 mm are 0.074, 0.067 and 0.055 respectively, while the strain experimental results are 0.082, 0.064 and 0.058 respectively. The maximum error between the simulation results and the strain field experimental results is 5.1%, which verifies the model. Both simulation and experimental results show that the smaller the pearlite lamella is, the larger the Stress intensity factor at the crack tip is during the fatigue crack growth process of heavy rail steel, the smaller the equivalent strain area is, the stronger the fracture resistance is, and the better the fatigue performance is.

Key words:  metallic materials      heavy rail steel      organization      fatigue fracture      crack propagation      stress-strain     
Received:  30 August 2023     
ZTFLH:  TG111  
Fund: Inner Mongolia Autonomous Region Science and Technology Program(2023YFHH0036);Natural Science Foundation of Inner Mongolia(2024LHMS05033);Basic Scientific Research Fees for Colleges and Universities Directly under the Inner Mongolia(2023QNJS002, 2023YXXS007, 2024YXXS039);National Natural Science Foundation of China(52161008)
Corresponding Authors:  CEN Yaodong, Tel: (0472)5951536, E-mail: cydtgyx@163.com

URL: 

https://www.cjmr.org/EN/10.11901/1005.3093.2023.431     OR     https://www.cjmr.org/EN/Y2024/V38/I9/711

CSiMnVCrRE (Ce and La ratio)
0.760.610.890.070.280.002
Table 1  Chemical composition of pearlite heavy rail steel (mass fraction, %)
Fig.1  CT fatigue test (a) sampling location and actual specimen; (b) specimen size (mm); (c) fatigue loading process and strain measurement; (d) strain acquisition
Samples1#2#3#
Elastic modulus/MPa196000210000230000
Poisson's ratio (ν)0.270.30.3
Table 2  Elastic modulus and poisson's ratio of samples
Fig.2  Technical roadmap
Fig.3  Grid model diagram and grid stress diagram of CT specimen
Fatigue load spectrumLoad / kNStress ratio, RFrequency / HzLoad form
Load Ⅰ80.545Sine wave
Load Ⅱ40.545Sine wave
Table 3  Franc3D model parameters
Fig.4  Franc 3D diagram
Fig.5  OM metallographic structure of three samples (a) 1# sample; (b) 2# sample; (c) 3# sample
SamplesCooling processMicrostructureLayers spacing / nmGrain size / μm
1#Air coolingPearlite324.620.73
2#Wind CoolingPearlite133.913.38
3#560oC-30 sPearlite105.97.90
Table 4  Microstructure type, lamellar size and grain size of samples
Fig.6  SEM microscopic structure of three samples (a) 1# sample; (b) 2 # sample; (c) 3# sample
Fig.7  Pearlite layers of three samples (a) 1# sample; (b) 2# sample; (c) 3# sample
Fig.8  Stress nephogram of crack tip of 1#, 2#, 3 # specimen with different crack lengths (a, a1, a2) 1 mm; (b, b1, b2) 2 mm; (c, c1, c2) 3 mm
Crack lengths1 mm2 mm3 mm
1#10.0111.1413.53
2#10.5712.8014.58
3#11.2013.6515.54
Table 5  Maximum stress intensity factor K at fatigue crack tip (MPa·m1/2)
Crack lengths1 mm2 mm3 mm
1#181123235634281811
2#233184362216451513
3#373151560202706745
Table 6  Cycle times of samples
Fig.9  Strain nephogram of crack tip of 1#, 2#, 3# specimen with different crack lengths (a, a1, a2) 1 mm; (b, b1, b2) 2 mm; (c, c1, c2) 3 mm
Fig.10  Variation of strain field at crack tip with different crack lengths
Crack lengths1 mm2 mm3 mm
1#8 × 10413 × 10415 × 104
2#12 × 10420 × 10422 × 104
3#40 × 10450 × 10453 × 104
Table 7  Cycle times of samples
Fig.11  Strain nephogram of crack tip of 1#, 2#, 3# specimen with different crack lengths (a, a1, a2) 1 mm; (b, b1, b2) 2 mm; (c, c1, c2) 3 mm
Fig.12  Equivalent strain at crack tip
Crack length1 mm2 mm3 mm
Method and error rateSimulationStrain testError rateSimulationStrain testError rateSimulationStrain testError rate
1#0.0490.0513.9%0.0690.06113.1%0.0740.0829.7%
2#0.0420.03616.7%0.0600.05020%0.0670.0644.7%
3#0.0210.02100.0350.04928.6%0.0550.0585.1%
Table 8  Maximum equivalent strain results
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