Abstract
A Belgrospi rail defect originating from short-pitch corrugation was observed on the low rail of a metro track with small radius curves in China. To investigate its formation mechanism, a 3D elastic–plastic finite element (FE) model was developed to simulate the material mechanical responses in corrugated rail subjected to cyclic rolling contact. The FE model incorporates wheel substructure reduction, rail shadow elements and periodic boundary conditions to efficiently simulate the wheel–rail cyclic rolling contact, and employs an improved non-linear kinematic hardening law to accurately capture rail cyclic deformation and ratchetting behavior. An analysis of the distribution and evolution of accumulated plastic strain on corrugated rail surface under varying contact conditions was conducted, investigating the correlation with the corrugation geometry and its role in Belgrospi formation. The results indicate that corrugated rails exhibit significant residual stress and accumulated plastic strain, while smooth rails do not. When the wheel cyclic rolling over short-pitch corrugation under higher creepage and higher coefficient of friction, the maximum accumulated plastic strain gradually shifts from the crest and stabilizes near the middle of the upslope. Under these conditions, the accumulated plastic strain continues to increase with the number of rolling cycles, forming ratchetting strain. The ratchetting strain rate is also highest near the middle of the upslope, where the estimated fatigue life is shortest, contributing to the formation of Belgrospi.
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3D elastic--plastic finite element analysis of Belgrospi rail defect induced by short-pitch corrugation on metro | Authorea try { document.documentElement.classList.add('js'); } catch (e) { } var _gaq = _gaq || []; _gaq.push(['_setAccount', 'G-8VDV14Y67G']); _gaq.push(['_trackPageview']); (function() { var ga = document.createElement('script'); ga.type = 'text/javascript'; ga.async = true; ga.src = ('https:' == document.location.protocol ? 'https://ssl' : 'http://www') + '.google-analytics.com/ga.js'; var s = document.getElementsByTagName('script')[0]; s.parentNode.insertBefore(ga, s); })(); Skip to main content Preprints Collections Wiley Open Research IET Open Research Ecological Society of Japan All Collections About About Authorea FAQs Contact Us Quick Search anywhere Search for preprint articles, keywords, etc. Search Search ADVANCED SEARCH SCROLL This is a preprint and has not been peer reviewed. Data may be preliminary. 21 October 2025 V1 Latest version Share on 3D elastic--plastic finite element analysis of Belgrospi rail defect induced by short-pitch corrugation on metro Authors : Zhijun Zhou 0009-0008-8902-0142 , Chenyu Yang , Gongquan Tao , and Zefeng Wen [email protected] Authors Info & Affiliations https://doi.org/10.22541/au.176102848.85780946/v1 136 views 97 downloads Contents Abstract Supplementary Material Information & Authors Metrics & Citations View Options References Figures Tables Media Share Abstract A Belgrospi rail defect originating from short-pitch corrugation was observed on the low rail of a metro track with small radius curves in China. To investigate its formation mechanism, a 3D elastic–plastic finite element (FE) model was developed to simulate the material mechanical responses in corrugated rail subjected to cyclic rolling contact. The FE model incorporates wheel substructure reduction, rail shadow elements and periodic boundary conditions to efficiently simulate the wheel–rail cyclic rolling contact, and employs an improved non-linear kinematic hardening law to accurately capture rail cyclic deformation and ratchetting behavior. An analysis of the distribution and evolution of accumulated plastic strain on corrugated rail surface under varying contact conditions was conducted, investigating the correlation with the corrugation geometry and its role in Belgrospi formation. The results indicate that corrugated rails exhibit significant residual stress and accumulated plastic strain, while smooth rails do not. When the wheel cyclic rolling over short-pitch corrugation under higher creepage and higher coefficient of friction, the maximum accumulated plastic strain gradually shifts from the crest and stabilizes near the middle of the upslope. Under these conditions, the accumulated plastic strain continues to increase with the number of rolling cycles, forming ratchetting strain. The ratchetting strain rate is also highest near the middle of the upslope, where the estimated fatigue life is shortest, contributing to the formation of Belgrospi. Supplementary Material File (zhouzj_manuscript.docx) Download 6.52 MB Information & Authors Information Version history V1 Version 1 21 October 2025 Copyright This work is licensed under a Non Exclusive No Reuse License. Keywords 3-d finite element analysis cyclic constitutive equation cyclic deformation rolling contact fatigue (rcf) wheel rail Authors Affiliations Zhijun Zhou 0009-0008-8902-0142 Southwest Jiaotong University State Key Laboratory of Rail Transit Vehicle System View all articles by this author Chenyu Yang Southwest Jiaotong University State Key Laboratory of Rail Transit Vehicle System View all articles by this author Gongquan Tao Southwest Jiaotong University State Key Laboratory of Rail Transit Vehicle System View all articles by this author Zefeng Wen [email protected] Southwest Jiaotong University State Key Laboratory of Rail Transit Vehicle System View all articles by this author Metrics & Citations Metrics Article Usage 136 views 97 downloads .FvxKWukQNSOunydq8rnd { width: 100px; } Citations Download citation Zhijun Zhou, Chenyu Yang, Gongquan Tao, et al. 3D elastic--plastic finite element analysis of Belgrospi rail defect induced by short-pitch corrugation on metro. 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