The Link Between the Rail Wear Rate and Rolling Contact Fatigue

Abstract

Railway infrastructure is a cornerstone of sustainable transportation, providing an energy-efficient and low-carbon alternative to road and air travel. At the heart of this system lies the rail, a high-value asset whose operational reliability and longevity are fundamental to safe and efficient train operations. Yet rails are subject to inevitable degradation, primarily wear and rolling contact fatigue (RCF). These degradation mechanisms are interdependent and often competitive: while moderate wear can delay or even suppress fatigue crack initiation, excessive wear undermines rail strength and shortens service life. Conversely, insufficient wear promotes RCF, particularly under modern high-traction rolling stock. This dissertation analyses the wear and RCF on the Belgium railway network, considering key factors including curve radius, annual traffic tonnage, steel grades and rail grinding, and explores how preventive maintenance strategies, most notably grinding, can be optimized by maintaining a dynamic balance between wear and RCF so as to extend rail life, reduce life-cycle costs, and sustain safe railway operations.