Determination of permissible defect size for solid axles loaded under fully-reversed rotating bending

The aim of the present work was to develop a guideline for approving the railway axles made of C35 steel and containing surface and/or in-body defects after manufacturing. First, several through and part-through circular cracks were modeled on the surface and in the body of the axle at its critical cross-section. Then, the permissible size of such cracks was determined by using the fracture mechanics. To verify the validity of the guideline, the theoretical result for the semi-circular surface crack was compared with the allowable size prescribed by the international railway standard. A very good agreement was found to exist between the predicted and the standard values.