The Influence of Braking Heat and Thermal Expansion on Tread Crack of Railway Wheels

Combining with the wheel–rail rolling contact models and extended finite element method (XFEM), this study systematically analyses the influence of wheel thermal expansion induced by braking thermal load on the tread cracking behavior of railway freight trains during the emergency braking process. Unlike the well-documented effect of material softening at elevated temperatures, the key contribution of this work lies in identifying and elucidating the dominant role of thermally induced geometrical changes in the contact conditions. The results demonstrate that wheel thermal expansion significantly alters the shape of the contact spot and the stress distribution, thereby reconstructing the mechanical driving force at the crack tip. Specifically, thermal expansion effectively suppresses Mode I cracking. Although it slightly reduces the magnitude of ΔKII, the primary and critical outcome is a distinct shift in the location of the maximum ΔKII from the deep interior of the crack to its superficial outer tip, driven by the altered contact geometry. This shift intensifies the crack propagation trend along the length direction near the surface. Therefore, although the nominal contact stress decreases when considering braking heat, the risk of surface-initiated damage increases, which needs to be paid attention to during operations and maintenance.