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The aim of this paper is to develop means to predict accurately the residual stresses due to quenching process of an UIC60 rail. A three-dimensional nonlinear stress analysis model has been applied to estimate stress fields of an UIC60 rail in the quenching process. A cooling mechanism with water spray is simulated applying the elastic–plastic finite element analysis for the rail. The three-dimensional finite element analysis results of the studies presented in this paper are needed to describe the initial conditions for analyses of how the service conditions may act to change the as- manufactured stress field.
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