An efficient 3D elastic-plastic finite element (FE) model was developed to simulate the evolution of contact mechanics under wheel-rail cyclic rolling contact and to predict rolling contact fatigue (RCF). A periodic crack nest derived from rail corrugation was selected as a representative case to investigate contact stresses and accumulated plastic strain on corrugated rails, with emphasis on the effects of corrugation geometric gradients. An incremental multiaxial fatigue-damage criterion was used to predict fatigue accumulation and crack initiation, followed by 3D oblique crack propagation simulation to elucidate corrugation-induced RCF formation. The FE results show that the maximum accumulated plastic strain shifts from the crest to the upslope, promoting localized ratchetting, accelerated fatigue damage, and dominant crack formation. Crack interaction and coalescence during cyclic rolling contact drive material shelling and crack nest development. These observations and simulations demonstrate the reliability of the developed FE model for predicting RCF.
