Impact of journal bending on the failure of axle bearings in railroad passenger cars

Abstract

This research presents a systematic methodology to analyze the failure mechanism of cylindrical roller bearings of railroad passenger cars. Initially, a finite element model is developed to calculate the journal bending and internal contact load distribution, considering multi-interfacial contact parameters. Then, non-Hertzian contact theory is applied to prove the rollers’ abnormal contact behaviors, including load-distribution and displacement. Subsequently, a grease lubrication model is developed to study bearings lubrication under different operating conditions. Additionally, an exact service life model from ISO standards is used to evaluate the effect of journal bending. Finally, a system failure mechanism can be summarized and validated in the experiments, also helpful for axle box system bearings design and assembly.