Review on Ultra-High-Cycle Fretting Fatigue Damage Mechanism of Press-Fitted Structure of Wheel Axles
DOI:
https://doi.org/10.54097/w9mmk873Keywords:
EMU wheel axle, interference press-fitting, fretting fatigue, ultra-high-cycle fatigue, micro-slip, damage evolution, life prediction, interface coupling damageAbstract
As the core load-bearing components of high-speed train running gears, electric multiple unit (EMU) wheel axles are generally connected by interference press-fitting, and their service reliability directly determines the train operation safety. During the long-term high-frequency and long-mileage service of EMUs, the press-fit interface of wheel axles generates micron-scale reciprocating micro-slip under the coupling effect of rotating bending alternating load, wheel-rail impact load and random line vibration, inducing coupled damage of fretting wear and fretting fatigue. Different from conventional mechanical fatigue, the cumulative service load cycles of wheel axles can reach 108~109 in the ultra-high-cycle range. The fretting effect completely eliminates the traditional fatigue limit of steel materials, and concealed multi-source short cracks continuously initiate and propagate under low-stress and ultra-high-cycle conditions, which is extremely easy to cause sudden failure of wheel axles without obvious precursors. This paper systematically summarizes the interface zoning characteristics, macroscopic failure laws and microscopic damage evolution mechanisms of ultra-high-cycle fretting fatigue of press-fitted EMU wheel axles. The domestic and foreign research progress is reviewed from four dimensions including experimental characterization, numerical simulation, life prediction and anti-damage technology. Furthermore, the key scientific and engineering problems in current research, such as the wear-crack competition mechanism, scale effect, random load damage accumulation and early damage identification are deeply analyzed. Combined with the operation and maintenance requirements of high-speed trains, the future development directions of multi-scale mechanism research, load-adaptive life models, intelligent simulation and active protection technology are clarified. This study aims to improve the theoretical system of ultra-high-cycle fretting fatigue of high-speed wheel axles, and provide theoretical support and technical reference for structural optimization, assembly process upgrading, service damage evaluation and full-life-cycle safety operation and maintenance of EMU wheel axles.
Downloads
References
[1] Yang, G. X., & Xie, J. L. (2021). Research progress on fretting fatigue of interference fitted axles. Journal of Mechanical Engineering, 57(12), 1–13. [In Chinese]
[2] Zhu, T., Yang, G. W., & Xiao, S. N. (2022). Research on micro damage and crack initiation mechanism of railway interference fit axles. Tribology, 42(03), 421–430. [In Chinese]
[3] Liu, Y., Zhang, L., & Wang, W. J. (2023). Review on fretting fatigue damage of press fitted structure of high speed train wheel axles. Journal of the China Railway Society, 45(05), 36–45. [In Chinese]
[4] Hirakawa, K. (1997). Review of the fatigue of railway axles. Fatigue & Fracture of Engineering Materials & Structures, 20(12), 1611–1623.
[5] Zhang, Y., Liu, Y., & Wang, W. (2023). Experimental and numerical study on the multi site fretting fatigue crack initiation of press fitted axles. Fatigue & Fracture of Engineering Materials & Structures, 46(12), 2345–2358.
[6] Wang, C., Li, J. H., & Chen, Z. W. (2022). Research progress on microscopic damage mechanism of ultra high cycle fretting fatigue of metals. Materials Engineering, 50(08), 1–10. [In Chinese]
[7] State Administration for Market Regulation. (2017). TB/T 2368 2017, Technical specification for motor bogie axles. China Railway Press. [In Chinese]
[8] Zhang, M. X., & Zhao, Y. X. (2021). Ultra high cycle fatigue properties and failure mechanism of railway axle steel. Journal of Mechanical Strength, 43(04), 912–918. [In Chinese]
[9] Li, H., & Xiao, F. X. (2022). Numerical simulation of fretting behavior of high speed wheel axle interference fit interface. Computer Simulation, 39(07), 156–161. [In Chinese]
[10] Park, J., & Kim, J. (2024). Fretting Wear Simulation of Press fit Axles Using an Energy Based Wear Model. Journal of the Korean Society of Precision Engineering, 41(02), 112–119.
[11] Liu, Y., Wang, W. J., & Zhang, L. (2024). Multi scale analysis on subsurface micro crack initiation mechanism of EMU axle under ultra high cycle fretting fatigue. International Journal of Fatigue, 178, 107986.
[12] Chen, X., Yang, G. X., & Xie, J. L. (2023). Random load induced damage accumulation characteristics of press fit interface fretting fatigue for high speed train axles. Tribology International, 187, 108765.
[13] Zhang, H., Liu, Z., & Li, Y. (2024). Scale effect and equivalence conversion of fretting fatigue test for railway press fitted axle structures. Journal of Rail and Rapid Transit, 238(3), 289–301.
[14] Wang, Z., Zhang, Y., & Xiao, S. N. (2023). Competitive mechanism between fretting wear and short crack propagation of high speed wheel axles in ultra high cycle regime. Wear, 526–527, 204987.
[15] Niu, R., & Chen, Z. W. (2024). Nonlinear ultrasonic quantitative detection method for early micro damage of axle press fit interface. NDT & E International, 135, 102890.
[16] Hirakawa, K., & Matsumoto, T. (2022). Ultra high cycle fatigue behavior and fretting damage characteristics of high strength railway axle steel. Fatigue & Fracture of Engineering Materials & Structures, 45(8), 1123–1136.
[17] Li, J. H., & Wang, C. (2023). Research progress on surface strengthening technology for anti fretting fatigue of EMU wheel axles. Surface & Coatings Technology, 452, 129105.
[18] Zhao, Y. X., & Zhang, M. X. (2023). Modified S N model for ultra high cycle fretting fatigue life prediction of press fitted axle structures. International Journal of Mechanical Sciences, 245, 108092.
[19] Sun, B., & Xu, H. (2024). Dynamic simulation of interface wear evolution and stress redistribution of wheel axle interference fit under long term service. Finite Elements in Analysis and Design, 221, 103956.
[20] Kim, J., & Park, S. (2023). Influence of friction coefficient and assembly interference on fretting fatigue damage of press fit railway axles. Metals, 13(11), 1892.
[21] Yang, W., & Liu, Y. (2024). Full life cycle damage evolution law and failure prediction of EMU wheel axle ultra high cycle fretting fatigue. Journal of Mechanical Engineering, 60(2), 156–165. [In Chinese]
[22] Duan, H., & Wang, W. (2023). Experimental investigation on ultra high cycle fretting fatigue of full scale high speed train wheel sets. Engineering Failure Analysis, 152, 107589.
[23] Jiang, L., & Zhang, Q. (2024). Mechanical chemical coupling damage mechanism of fretting corrosion fatigue of wheel axle press fit interface. Corrosion Science, 228, 111768.
[24] Ma, X., & Li, P. (2023). Load sequence effect on variable amplitude ultra high cycle fretting fatigue damage of railway axles. Journal of Materials Science & Technology, 158, 168–179.
[25] Zhou, S., & Chen, Y. (2024). Research status and prospect of intelligent evaluation technology for residual life of in service EMU wheel axles. Journal of the China Railway Society, 46(1), 45–54. [In Chinese]
Downloads
Published
Issue
Section
License
Copyright (c) 2026 Academic Journal of Applied Sciences
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
