Feasibility study of a vision system for on-line monitoring of rolling contact fatigue tests

Wear and Rolling Contact Fatigue (RCF) tests on wheel/rail specimens are important to develop wheels of new materials for improved lifetime and performance, able to operate in harsh environments and at high rolling speeds. We have studied the feasibility of a novel non-invasive all-optical system, based on a high-speed video camera and two laser illumination sources, which is able to continuously monitor the dynamics of the specimens used to test wheel and rail materials, in a laboratory test bench. Surface micro- and macrotopography are monitored using blob analysis and 3D laser triangulation respectively. Blob analysis yields to good discrimination among the specimens, in terms of wear induced surface damage; the 3D measurement, which is characterized by a resolution of 0.033 mm, is able to monitor RCF effects. The system is described with the aid of end-cycle specimens, as well as of intermediate specimens, prior to its installation in the test bench for rolling contact tests.