Effect of compressive residual stress and press fitting on residual life assessment of deep-rolled EA4T steel railway axles.

• The UPM and PI iterative methods can accurately reconstruct the residual stress field induced by rolling processing. • The extended finite element method and the weight function method are applied to solve the stress intensity factor. • The necessity of deep rolling treatment for axles is verified. • The influence of interference and initial crack position on the remaining life of axle is explored. • The damage tolerance analysis of the axle was carried out. Deep rolling surface strengthening is an effective way to introduce compressive residual stress (CRS) along the railway axle, which can improve the fatigue resistance of the material. The CRS field was rebuilt adopting the proportional-integral (PI) iteration method and the unit pressure method (UPM) to study the fatigue cracking behavior of deep-rolled EA4T railway axles. The remaining life prediction model and the stress intensity factor (SIF) solution method were then validated using simulations and testing with small-sized specimens. The remaining life of the EA4T railway axle was then calculated by applying a realistic vertical load spectrum. The results showed that CRS prevented crack propagation, enhanced the critical propagation size of railway axle cracks, and prolonged the remaining life of the axle. Additionally, the remaining life of the axle may not support the following maintenance period if a crack with an extendable size emerges at the unloading groove of the railway axle. This work provides a theoretical basis for the optimization of the non-destructive testing (NDT) interval of deep-rolled EA4T railway axles. [ABSTRACT FROM AUTHOR]