面向钢轨修复的不同槽型接触轮砂带打磨接触行为及材料去除特性

Contact Behavior and Material Removal Characteristics of Abrasive Belt Grinding of Contact Wheels with Different Slotted for Rail Rehabilitation

为掌握不同槽型接触轮砂带对钢轨打磨接触行为及材料去除特性的影响规律,基于橡胶接触特性,建立X齿型、锯齿型和人字型3种典型接触轮砂带打磨仿真模型,模拟分析不同槽型特征对接触轮-钢轨静态接触行为和动态冲击应力的影响机制;通过钢轨砂带打磨试验,对比研究3种槽型接触轮的材料去除特性。结果表明:3种槽型接触轮与钢轨的接触区域整体均呈椭圆形态,符合赫兹接触理论,内部接触形态则随槽型特征呈现为块状分布;接触区域应力分布总体符合弹性半空间接触理论,但在接触块边缘会出现应力集中;X齿型接触轮和人字型接触轮因齿尖和齿槽结构的存在而具有较高的材料去除能力,同等打磨条件下X齿型接触轮较平型接触轮的材料去除能力提高了79%;顺磨条件下的材料去除能力高于逆磨,以X齿型接触轮为例,顺磨比逆磨的材料去除能力提高了22.7%;X齿型和人字型接触轮砂带打磨的噪声、振动、粗糙度、平均电流均较高,锯齿型接触轮具有较低的振动、粗糙度及平均电流,平型轮则具有较低的噪声和电流。

In order to comprehend the influence laws of different groove types contact wheels on the contact behavior and material removal characteristics of rail grinding using abrasive belt,a simulation model for Xtooth,serrated and herringbone contact wheels,based on rubber contact characteristics,was established.Then,the simulation and analysis of the influence mechanism of different groove characteristics on the static contact behavior and dynamic impact stresses between the contact wheel and the rail was carried out.Finally,rail belt grinding tests were conducted to comparatively study the material removal characteristics of the three types of grooved contact wheels.The results indicate the following:the contact area between the contact wheel and the rail adopts an elliptical shape,congruent with the principles of Hertzian contact theory.The internal contact morphology displays a block distribution pattern,directly corresponding to the groove type.The stress distribution within the contact area adheres to the tenets of the elastic half-space contact theory,though noteworthy stress concentration is observed at the edge of the contact block.The dynamic interplay among groove structures results in higher material removal capacity for X-tooth and herringbone wheels,attributed to the tooth tips and groove structures.Under the same grinding conditions,the material removal capacity of Xtooth contact wheels was 79%higher than that of flat contact wheels.On the other hand,the material removal capacity is higher under smooth grinding conditions than that of reverse grinding.Taking X-tooth contact wheel as an example,the material removal capacity of smooth grinding is 22.7%higher than that of reverse grinding.Regarding other characteristic parameters,X-tooth and herringbone contact wheels show elevated levels of noise,vibration,roughness,and average current.In contrast,serrated contact wheels exhibit lower levels of noise,vibration,roughness,and average current,whereas flat wheels demonstrate lower noise and current levels.