Contact Mechanism of Rail Grinding with Open-Structured Abrasive Belt Based on Pressure Grinding Plate

The current research of abrasive belt grinding rail mainly focuses on the contact mechanism and structural design.Compared with the closed structure abrasive belt grinding,open-structured abrasive belt grinding has excellent performance in dynamic stability,consistency of grinding quality,extension of grinding mileage and improvement of working efficiency.However,in the contact structure design,the open-structured abrasive belt grinding rail using a profiling pressure grinding plate and the closed structure abrasive belt using the contact wheel are different,and the contact mechanisms of the two are different.In this paper,based on the conformal contact and Hertz theory,the contact mechanism of the pressure grinding plate,abrasive belt and rail is analyzed.Through finite element simulation and static pressure experiment,the contact behavior of pressure grinding plate,abrasive belt and rail under single concentrated force,uniform force and multiple concentrated force was studied,and the distribution characteristics of contact stress on rail surface were observed.The results show that under the same external load,there are three contact areas under the three loading modes.The outer contour of the middle contact area is rectangular,and the inner contour is elliptical.In the contact area at both ends,the stress is extremely small under a single concentrated force,the internal stress is drop-shaped under a uniform force,and the internal stress under multiple concentration forces is elliptical.Compared with the three,the maximum stress is the smallest and the stress distribution is more uniform under multiple concentrated forces.Therefore,the multiple concentrated forces is the best grinding pressure loading mode.The research provides support for the application of rail grinding with open-structured abrasive belt based on pressure grinding plate,such as contact mechanism and grinding pressure mode selection.

A prediction method of rail grinding profile using non-uniform rational B-spline curves and Kriging model

Non-uniform rational B-spline(NURBS)curves are combined with the Kriging model to present a prediction method of the rail grinding profile for a grinding train.As a worn rail profile is a free-form curve,the parameterized model of a rail profile is constructed by using the cubic NURBS curve.Taking the removed area of the rail profile cross-section by grinding as the calculation index of the grinding amount,the grinding amount calculation model of a grinding wheel is established based on the area integral formula of the cubic NURBS curve.To predict the grinding amount of a grinding wheel in different modes,a Kriging model of the grinding amount is constructed,taking the travel speed of a grinding train,the grinding angle and grinding pressure of a grinding wheel as the variables,and considering the grinding amount of a grinding wheel as the response.On this basis,the prediction method of the rail grinding profile is presented based on the order-forming mechanisms.The effectiveness of this method is verified based on a practical application.

Modelling of dynamic contact length in rail grinding process

Rails endure frequent dynamic loads from the passing trains for supporting trains and guiding wheels. The accumulated stress concentrations will cause the plastic deformation of rail towards generating corruga- tions, contact fatigue cracks and also other defects, resulting in more dangerous status even the derailment risks. So the rail grinding technology has been invented with rotating grinding stones pressed on the rail with defects removal. Such rail grinding works are directed by experiences rather than scientifically guidance, lacking of flexible and scientific operating methods. With grinding control unit holding the grinding stones, the rail grinding process has the characteristics not only the surface grinding but also the running railway vehicles. First of all, it＇s important to analyze the contact length between the grinding stone and the rail, because the contact length is a critical parameter to measure the grinding capabilities of stones. Moreover, it＇s needed to build up models of railway vehicle unit bonded with the grinding stone to represent the rail grinding car. Therefore the theoretical model for contact length is developed based on the geometrical analysis. And the calculating models are improved considering the grinding car＇s dynamic behaviors during the grinding process. Eventually, results are obtained based on the models by taking both the operation parameters and the structure parameters into the calculation, which are suitable for revealing the process of rail grinding by combining the grinding mechanism and the railway vehicle systems.

Multi-Objective Optimization of Rail Pre-Grinding Profile in Straight Line for High Speed Railway

In order to modify the rail pre-grinding profile smoothly,non-uniform rational B-spline(NURBS)curve with weight factors is used to establish a parameterized model of the profile.A wheel-rail contact stochastic finite element model(FEM) is constructed by the Latin hypercube sampling method and 3 D elasto-plastic FEM,in which the wheelset's lateral displacement quantity is regarded as a random variable.The maximum values of nodal accumulated contact stress(NACS) and nodal mean contact stress(NMCS) in different pre-grinding profiles with differential weight factors are calculated and taken as the training samples to establish two Kriging models.A multi-objective optimization model of pre-grinding profile is established,in which the objective functions are the NACS and NMCS Kriging models.The optimum weight factors are sought using a non-dominated sorting genetic algorithm II(NSGA-II),and the corresponding optimum pre-grinding profile is obtained.The contact stress calculation before and after optimization indicates that the maximum values of NACS and NMCS decline significantly.