Pattern of Residual Stress in Rail by FEM Analysis and Strain Gage Sectioning Technique

Final step of rail manufacturing is cold rolling straightening process and it hassignificant effects on mechanical properties, straightness, flatness and development of residualstresses. Measurement of residual stresses after straightening process is obligated by railmanufacturing standards. In the present investigation, an attempt has been made to evaluateresidual stresses after straightening process by finite element method and strain gage sectioningtechnique. The straightening process has been simulated here using the FE package ABAQUS. Allthe input data were extracted from experimental tests according to rail manufacturing standard andhomogenous and isotropic behavior of material were considered. Moreover, initial camber of therail was measured after hot rolling and cooling process. Obtained results of numerical calculationhas been validated by strain gage sectioning technique and compressive residual stresses in headand web and tension residual stress in foot of the rail has been observed. The roller arrangementused in this investigation could reduce the amount of residual stresses comparing with the previousresults. Furthermore, straightness of the rail after straightening was satisfactory.