Accounting Method for Residual Technological Stresses in Modeling the Stress-Deformed State of a Railway Wheel Disk. Report 1

The work is devoted to the development of a method for accounting residual technological stresses in wheel disks, which will provide both the versatility of the approach and the accuracy of calculations. The analysis of stresses in the wheel disk from the action of assembly (interference between the hub and the axle) and operational loads is carried out based on the results of finite element modeling. Adequacy verification of the used model was made by comparing the calculated information with the experimental data of JSC “VNIIZHT”. The analysis of calculated and experimental values of radial stresses was carried out for the most loaded (critical) zones of the disk during operation—the zones of its interface with the rim and the hub. It was found that by setting the interference fit value to be greater than the actual one, it is possible to obtain the formation of additional stresses in the wheel, which, with a sufficient degree of accuracy, reflect the effect of residual technological stresses on its stress–strain state. On the example of calculating a wheel with a flat-conical disk (GOST 10791–2011), it is shown that an increase in the interference fit value by 60% (from 0.25 to 0.4 mm per diameter) makes it possible to adequately predict the magnitude of stresses in the most critical disk elements. The maximum relative deviations of the calculated values of radial stresses from the experimental ones, both along the outer and inner sides of the wheel, do not exceed 14%. Despite the simplicity of implementation, the proposed method provides an increase in the accuracy of predicting the strength characteristics of wheels, as well as the possibility of using it for various standard wheel sizes.