This study aims to analyze the rolling contact fatigue susceptible to residual stresses caused by the contact between the wheel and rail and its manufacturing process. For this purpose, a rail available in Iran railway is used with an exact prole geometry. The location of maximum stress caused by the contact of wheel/rail for rail proles can be calculated by a three-dimensional elastic-plastic nite element model. Then, in order to estimate the stress distribution in the rail manufacturing process, a thermal analysis with a nite element method will be performed. Afterward, the results of the performed stress analysis will be used as inputs for three-dimensional crack growth and rail fatigue life estimation model to calculate the stress intensity factors and fatigue life according to a set of parameters related to the boundary element method. Finally, three-dimensional nite element analysis results obtained show good agreement with those achieved in eld measurements.

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