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Search Results (3)

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Keywords = solid railway axle

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17 pages, 1978 KiB  
Article
Analysis of Acoustic Emission Waveforms by Wavelet Packet Transform for the Detection of Crack Initiation Due to Fretting Fatigue in Solid Railway Axles
by Marta Zamorano, María Jesús Gómez, Cristina Castejon and Michele Carboni
Appl. Sci. 2025, 15(15), 8435; https://doi.org/10.3390/app15158435 - 29 Jul 2025
Viewed by 266
Abstract
Railway axles are among the most safety-critical components in rolling stock, as their failure can lead to catastrophic consequences. One of the most subtle damage mechanisms affecting these components is fretting fatigue, which is a particularly challenging damage mechanism in these components, as [...] Read more.
Railway axles are among the most safety-critical components in rolling stock, as their failure can lead to catastrophic consequences. One of the most subtle damage mechanisms affecting these components is fretting fatigue, which is a particularly challenging damage mechanism in these components, as it can initiate cracks under real service conditions and is difficult to detect in its early stages, which is vital to ensure operational safety and to optimize maintenance strategies. This paper focuses on the development of fretting fatigue damage in solid railway axles under realistic service-like conditions. Full-scale axle specimens with artificially induced notches were subjected to loading conditions that promote fretting fatigue crack initiation and growth. Acoustic emission techniques were used to monitor the damage progression, and post-processing of the emitted signals, by using wavelet-based tools, was conducted to identify early indicators of crack formation. The experimental findings demonstrate that the proposed approach allows for reliable identification of fretting-induced crack initiation, contributing valuable insights into the in-service behavior of railway axles under this damage mechanism. Full article
(This article belongs to the Special Issue Structural Health Monitoring, Damage Diagnosis, and Damage Prognosis: New Technologies and Applications)
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12 pages, 3018 KiB  
Article
Design of a Lightweight Multifunctional Composite Railway Axle Utilising Coaxial Skins
by Preetum J. Mistry, Michael S. Johnson, Charles A. McRobie and Ivor A. Jones
J. Compos. Sci. 2021, 5(3), 77; https://doi.org/10.3390/jcs5030077 - 7 Mar 2021
Cited by 5 | Viewed by 4740
Abstract
The rising economic and environmental pressures associated with the generation and consumption of energy necessitates the need for lightweighting of railway vehicles. The railway axle is a prime candidate for lightweighting of the unsprung mass. The reduction of unsprung mass correlates to reduced [...] Read more.
The rising economic and environmental pressures associated with the generation and consumption of energy necessitates the need for lightweighting of railway vehicles. The railway axle is a prime candidate for lightweighting of the unsprung mass. The reduction of unsprung mass correlates to reduced track damage, energy consumption and total operating costs. This paper presents the design of a lightweight multifunctional hybrid metallic-composite railway axle utilising coaxial skins. The lightweight axle assembly comprises a carbon fibre reinforced polymer composite tube with steel stub axles bonded into either end. The structural hybrid metallic-composite railway axle is surrounded by coaxial skins each performing a specific function to meet the secondary requirements. A parametric sizing study is conducted to explore the sensitivity of the design parameters of the composite tube and the stub axle interaction through the adhesive joint. The optimised design parameters of the axle consist of a; composite tube outer diameter of 225 mm, composite tube thickness of 7 mm, steel stub axle extension thickness of 10 mm and a bond overlap length of 100 mm. The optimised hybrid metallic-composite railway axle design concept has a mass of 200 kg representing a reduction of 50% over the solid steel version. Full article
(This article belongs to the Special Issue Recent Advances in Composite Process Modeling and Characterization)
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21 pages, 8742 KiB  
Article
A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills
by Zbigniew Pater
Materials 2020, 13(14), 3084; https://doi.org/10.3390/ma13143084 - 10 Jul 2020
Cited by 13 | Viewed by 2853
Abstract
The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature [...] Read more.
The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature and damage criterion in rolled axles are determined, and loads and torques acting on the tools during rolling are estimated. An innovative concept of calibrating hollow axles by the rotary compression technique developed at the Lublin University of Technology is presented. Experimental tests of rolling solid axles in a 3-roll rolling mill (in a scale of 1:5) are performed, and basic force parameters of the rolling process are measured. Numerical and experimental loads and torques show a high agreement in terms of both quality and quantity. Full article
(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)
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