Crane Wheel / Crane Rail Interface

Testing of Material Wear Properties

History of Wheel / Rail InterfaceMaterials and Heat Treatment

No test data available for Hard Wheel / Soft Rail CombinationInformation almost all anecdotalApplication successes and failures

Many variables to considerCrane OperationRunway and Building ConditionWheels and Rails

Sizes, Materials, Heat TreatmentsUsers concerned about switching to Hard Wheel

Initial belief is the Hard Wheel may act like a tool and cut into the soft rail

Wheel - Rail Interface

Sub-Surface Shear – Leads to Spalling

Sub-Surface Shear Leads to Spalling

High Surface Stress at Impact – Leads to

Flange Breakage

CONTACT STRESS - LEADS TO

ADHESIVE WEAR

Adhesive Wear on FlangesNon-Lubricated Metal-to-Metal Contact

Adhesive Wear on FlangesNon-Lubricated Metal-to-Metal Contact

200

300

400

500

600

700

800

Bri

ne

ll H

ard

ne

ss

Hard Wheel Test Sample

581 BHN(56 HRc)

Soft Wheel Test Sample

280 BHN

Hardened Wheel578 - 690 BHN(56 - 62 HRc)Hardened Wheel

420 - 481 BHN(45 - 50 HRc)

Rim Toughened Wheel

321 - 363 BHN

Cast Wheel250 - 300 BHN

Wheel Test Samplesv. Wheel Hardness

Materials AISI 1055, 1070, 4140Rim Toughened based on ASTM A504 Class C

Rail Test Samplesv. Rail Hardness

200

250

300

350

400

450

Bri

ne

ll H

ard

ne

ss

Soft RailTest Sample

285 BHN

Control Cooled Rail

248 - 320 BHN

Head Hardened Rail321 - 388 BHN

Material based on ASTM A759Carbon 0.67% - 0.84%

The Battelle InstituteInformation on Test Laboratory

Technology Development for Industry and GovernmentBased in Columbus, Ohio

7,500 Research Scientists and EngineersEuro 1 Billion Annually in Revenue for ResearchServes over 2000 Companies and Government Agencies50-100 Patents / yearOperates 4 National Laboratories

Material Test Parameters

Pressure = 13.8 MPa Stroke Length = 28 mm Cycle = 2 Strokes Speed = 25 mm/sec Delay Between Stroke = 4.9 sec Room Temperature Air Blown to Clear Debris

BattelleTest Rig

Wheel Wear

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Cycles

Wea

r D

epth

(m

m)

Soft Wheelv.

Soft Rail

Hard Wheelv.

Soft Rail

Rail Wear

0.00

0.50

1.00

1.50

2.00

2.50

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Cycles

Wea

r D

epth

(m

m)

Soft Wheelv.

Soft Rail

Hard Wheelv.

Soft Rail

Material Test Samples after 10,000 Cycles

Hard Wheel Material

Soft Rail Material

Soft Wheel Material

Soft Rail Material

Wear Depth Test Results10,000 Cycles

Worst combination for wear is Soft Wheel – Soft RailBest combination for wear is Hard Wheel – Soft Rail

2.118

0.068

1.158

0.0530.00

0.50

1.00

1.50

2.00

2.50

Soft Rail-Soft Wheel Soft Rail-Hard Wheel

We

ar

De

pth

(m

m)

Rail Wear Wheel Wear

Crane Wheel / Crane Rail Interface

Testing of Material Wear Properties

Thanks for your attention!