Design & Analysis of Rail Wheel Failure

Rail wheels are important components that not only support axle loads, but also enable high-speed rail travel. During service, wheels are subjected to rolling contact loads, thermal loads from braking, and cyclic fatigue loads at the wheel–rail interface. Combined, these loads may lead to material degradation in the form of wear, surface damage, or subsurface crack initiation, which ultimately may lead to failures such as tread spalling, rim fractures, or derailment. This research examines rail wheel failure mechanisms using a comprehensive finite element model (FEM) to model the dynamic loading, and contact interactions. A three-dimensional rail wheel model developed in CAD Software, is examined in ANSYS using R-16 and R-19 grade steel. The Critical Plane Approach is implemented to review multiaxial fatigue and rank zones with respect to crack initiation, and crack propagation. For this analysis, all mechanical (static/dynamic), and thermal loads are examined to assess the stress distributions, thermal gradients, and strain concentration zones. Modelling process identifies the region’s most susceptible to fatigue damage and provides insights for improvement in wheel design, material selection, and predictive maintenance strategies. The research is aimed at improving safety, performance, and reliability of rail wheels in real-world service performance.