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<p>The wheel-rail interface is frequently subjected to the intrusion of external solid particles such as sand. These particles not only alter the adhesion characteristics at the contact zone but also contribute to rail surface damage. To investigate the damage mechanisms and mutual coupling effects of rail material and sand particle when sand is present at wheel-rail interface, this investigation employs an integrated methodology, combining laboratory experiments with computational simulations, to analyze the failure mechanisms of rail material, failure process of sand particle, and variation of stress in the contact zone under sandy condition. The results show that under sand-contaminated condition, the rail surface exhibits typical damage features such as flaking spallation, oblique and horizontal cracks, and embedded abrasive layer. The damage mechanism involves a coupled effect of rolling contact fatigue and abrasive wear. Additionally, the failure process of sand particle can be divided into four stages: stress concentration, crack propagation and fracture, fragmentation, and grinding-embedding. During the initial failure stage, the maximum von Mises stress inside the sand particle reaches 481&#xa0;MPa, which gradually decreases after particle fragmentation. Upon intrusion into the contact zone, the von Mises stress on the rail surface first decreases from 444.8 to 196.3&#xa0;MPa and then gradually rises to 1001 MPa, forming a localized damaged area in rail surface layer with a depth of 0.12&#xa0;mm and a length of 3.52 mm, demonstrating clear wear-fatigue coupling damage phenomena. This research delineates the progressive failure mechanisms of sand particle and their damage mechanisms on rail material, providing a theoretical basis for rail maintenance, material selection, and service life assessment in sandy and windy environments.</p>

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Study on the Damage Mechanisms and Wear-Fatigue Coupling Effects at the Sand Particle-Rail Interface

  • 期刊论文

  • 发表日期：

    2026年2月21日

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  • Yunpeng Wei,
  • Zexin Wang,
  • Yingkang Li,
  • Zhidong Chen,
  • Haitao Li

摘要

The wheel-rail interface is frequently subjected to the intrusion of external solid particles such as sand. These particles not only alter the adhesion characteristics at the contact zone but also contribute to rail surface damage. To investigate the damage mechanisms and mutual coupling effects of rail material and sand particle when sand is present at wheel-rail interface, this investigation employs an integrated methodology, combining laboratory experiments with computational simulations, to analyze the failure mechanisms of rail material, failure process of sand particle, and variation of stress in the contact zone under sandy condition. The results show that under sand-contaminated condition, the rail surface exhibits typical damage features such as flaking spallation, oblique and horizontal cracks, and embedded abrasive layer. The damage mechanism involves a coupled effect of rolling contact fatigue and abrasive wear. Additionally, the failure process of sand particle can be divided into four stages: stress concentration, crack propagation and fracture, fragmentation, and grinding-embedding. During the initial failure stage, the maximum von Mises stress inside the sand particle reaches 481 MPa, which gradually decreases after particle fragmentation. Upon intrusion into the contact zone, the von Mises stress on the rail surface first decreases from 444.8 to 196.3 MPa and then gradually rises to 1001 MPa, forming a localized damaged area in rail surface layer with a depth of 0.12 mm and a length of 3.52 mm, demonstrating clear wear-fatigue coupling damage phenomena. This research delineates the progressive failure mechanisms of sand particle and their damage mechanisms on rail material, providing a theoretical basis for rail maintenance, material selection, and service life assessment in sandy and windy environments.