Evaluating the impact of rail surface roughness post-grinding: An experimental and elastoplastic modelling approach

Grinding is regularly conducted on railway tracks to prevent crack propagation and surface deterioration. However, grinding can introduce roughness on rail surfaces, potentially leading to stress and strain concentration that increase the likelihood of crack initiation. This paper proposes the utilization of surface roughness obtained by replicating the ground rail surface to assess its impact on train wheel-rail interactions. A novel approach which integrates the replicated roughness into an elastoplastic contact model, allows for a detailed assessment of its effects on contact pressure, and residual strain and stress distributions. The findings highlight the importance of considering surface roughness in predictive maintenance planning for railway infrastructure, as it can significantly influence the structural integrity and long-term performance of the track system. • Novel approach replicates rail profile roughness in situ and integrates it into an elastoplastic contact model. • Replication campaigns show a significant reduction in rail roughness parameters due to wear and plastic deformation. • Roughness integration into the model shows a substantial increase in contact pressure and stress concentrations. • Grinding-induced roughness causes concentrated residual plastic strains and stresses near the rail surface, exceeding 400 %.