The recent increase of train speed and frequency determines a rise of the loads transmitted to the superstructure. Therefore, railway components might experience service loads that have not considered at the design stage. Moreover, wear and backlash modification between components of a mechanical system might be able to modify the internal boundary conditions of the assembly. According to damage tolerance philosophy, an initial flaw is assumed to exist in the fatigue critical location of a structural component, and the analysis of the crack propagation life for such component needs accurate Stress Intensity Factor (SIF) evaluations. In this study, the effects of the boundary conditions on the crack propagation life have been evaluated for a semi-elliptical surface crack having semi-axes a and c and growing from the root of a shoulder fillet notch in a round bar loaded in bending. Two cases have been analyzed: - the shoulder is free from external forces; - the shoulder is in contact with an adjacent generic body. At first, the SIF distribution has been calculated with the Virtual Crack Closure Technique, considering or not the nonlinear effect induced by the contact forces arising from the interaction between the shoulder and the neighboring component. Successively, in both the above cases a two-parameters propagation law has been utilized to predict the evolution of both crack shape and crack depth when a cyclic bending load is applied to the rod. For this purpose, different values of the Stress Concentration Factor at the root of the fillet, and of the initial aspect ratio of the crack front, were considered in the calculations. It is found that the aspect ratio evolves to a unique asymptote, taking or not into account the non-linearity introduced by the contact at the shoulder, and this value depends on the notch severity. The ratio between the dimensionless SIFs obtained with and without the unilateral constraint at the shoulder, β cs / β fs , does not depend on the relative crack depth and crack shape. Also, the effect of the notch severity on the dimensionless SIF appears to be evident only for the portion of the crack front in the vicinity of the free surface.

Thermal track buckling is probably the major problem due to the advent of continuous welded rail track. In fact, when the rails temperature rises over a critical value, the track can buckle, suddenly or progressively, in the lateral plane. Both poor ballast conditions and large lateral alignment defects are the principal causes of such phenomenon. In a previous paper, a parametric finite element model for thermal track buckling simulation was presented and validated by comparison with analytical results of the literature. In this study, the finite element model has been further validated by comparison with analytical and numerical results obtained by three other authors. Moreover, to take into account the effect on the buckling temperatures of the vertical loads due to train passes, the tie-ballast lateral resistance has been modified along the track, taking into account the vertical reaction forces distribution induced by axle loads. A sensitivity analysis has been carried out both for tangent and curved track, considering two values of the alignment defect amplitude, and different values of the parameters that characterize actual railway vehicles. It is found that the conditions to trigger progressive buckling (△ T max ≈ △ T min ) are attained with small values of the truck center distance, and in a more accentuated manner in the presence of high values of the lateral alignment defect. △ T max and △ T min increase with axle spacing, and this increase is more pronounced for low values of the truck center spacing. △ T max and △ T min also increase with curve radius, but decrease for increasing values of the misalignment defect amplitude. In explosive buckling conditions (△ T max ≠ △ T min ), there is a limit value of the truck center distance above which the vertical load has no more effects, and the results of the static thermal buckling are found.

The lateral stability of the continuous welded rail (CWR) depends on a number of parameters which contribute to the progressive loss of the initial alignment of the track and its consequent predisposition to deform sideways, gradually or sharply, with serious risks for the safety both of passengers and operators. Different types of initial lateral defect, in terms of shape and size, are introduced by many authors in their own numerical and analytical model, but essentially all of them can be traced back — except for small “personalizations” — to the model proposed by Andrew Kish, who hypothesized the existence of a misalignment defect having the shape of a sine curve extended for half-wavelength, characterized by amplitude and wavelength values typical of the USA railroads. Moreover, all previous studies focused their attention on the introduction, in a geometrically perfect railway track, of a single defect confined in a zone of finite dimensions and having a rather simple geometry which qualitatively approximates the real defect, with the aim of simplifying the calculation of the buckling temperatures of the track associated with such geometry. In this paper, it was preliminarily analyzed the way the defect introduced in the track affects the critical temperature values. It started with a defect created artificially, applying to a geometrically perfect track and in the absence of thermal loads, a lateral displacement in the central transversal section of the track, and calculating, with the hypothesis of linear elastic behavior, the resulting deformed shape, which was assumed, after zeroing the corresponding stress field, as the input geometry for the subsequent buckling calculation. The deformed shape so obtained, being a Zimmermann deformed shape type, has no geometrical discontinuities near the defect and interprets in a natural way the defected geometry of the track, due to the dependence of its configuration on the flexural stiffness of the entire track in the lateral plane. Afterwards, modeling was carried out taking into account the real behavior of the track after the loss of its rectilinear configuration: the defect was created simulating the response of the track to a momentary lateral load — resulting, e.g., from train passages — which succeeded to cause a permanent displacement resulting from the elastic-plastic response of the track. The deformed shape of the track obtained in this way was used as the input geometry for the calculation of the buckling temperatures, once without resetting the stress field induced in the structure by the loading–unloading hysteresis cycle, and then considering the track free from internal stresses. The results show that both the numerical model that contemplate the defect introduced “plastically”, and that where the track is free from internal stresses, lead to more conservative results against the risk of thermal buckling in railway tracks made with CWR. A better approximation of the realistic representation of a generic defected railway track was pursued considering an indefinite number of defects distributed along the track, where each defect was characterized by different amplitude and wavelength values. The obtained results show that the presence of multiple defects further reduces the safety factor against the thermal track buckling phenomenon. The paper ends with the proposal of an evaluation criterion that takes into account the effects of multiple alignment defects on the critical buckling temperatures in continuous welded rail tracks.

From the advent of high-speed (HS) railways and with increasing traffic-induced loads transmitted to the superstructure, maintenance costs due to track geometry degradation have become a crucial problem for researchers and railway administrations. Moreover, the operations of ballast renewal, track tamping, and track re-alignment, that are indispensable to guarantee a good track geometry, have dramatic effects on the tie-ballast lateral resistance, which in turn reduce the track flexural strength in the lateral plane and increase the proneness of railway tracks made of continuous welded rails (CWR) to experience either progressive lateral shift of the track panel or thermal track buckling phenomena. To restore proper values of the tie-ballast lateral resistance, railway technicians either impose a speed reduction or compact the ballast bed mechanically by mean of the dynamic track stabilizing machines. Recently, elastic elements in railway tracks are receiving more and more attention due to their ability to reduce track geometry degradation and to attenuate noise and vibrations. Under Tie Pads, or Under Sleeper Pads (USP), guarantee better homogenization of the track vertical stiffness and have received more attention due to their ability to reduce maintenance costs. Most published studies focused their attention to USPs’ attitude to improve track performances in terms of dynamic impact force mitigation and track quality improvement; however, with few exceptions, no available literature exists on lateral resistance of ballasted track with USP, and some question still remains whether or not the lateral resistance is improved by USP. In this study, the experimental results of about 40 lateral resistance tests carried out in situ are reported and discussed. The tests were performed with the Discrete Cut Panel Pull Test (DCPPT) technique on three type of concrete ties, with and without USP; each type of tie and the related track conditions (ballast thickness, subgrade thickness and composition, shoulder width, ballast wall, etc.) were representative of specific track conditions, namely traditional tracks, high-speed lines and gallery. The tests were carried out in loaded and unloaded track conditions, in compacted and just-laid track conditions. In compacted ballast conditions the peak lateral resistance due to USPs can increase up to 20% — depending on the material used — and this variation is almost constant in the bedding modulus range considered in this study, which was quite well representative of typical static bedding modulus values of actual USPs. Even higher advantages seem to be achievable with softer USPs in weak or just-tamped ballast conditions.