Experimental Investigation on Comprehensive Performance Comparison for Rail Grinding Using Abrasive Belt and Abrasive Wheel

doi:10.3969/j.issn.1004-132X.2022.17.014

Abstract

Abstract: Based on the self-developed lithium battery-driven rail abrasive belt and abrasive wheel grinding machine， the 60N rail profile was used as the experimental objects to comprehensively compare the performance of the new rail belt grinding technology and the traditional grinding wheel grinding technology. The results show that when the grinding pressure is in the range of 45 to 75 N， the material removal rate of abrasive belt grinding is about 15 to 30 times that of abrasive wheel grinding， while when the pressure is increased to 90 N， the material removal rate of abrasive belt grinding is as high as 102 times that of abrasive wheel grinding. The vibration acceleration， noise and energy consumption of abrasive belt grinding are less than that of abrasive wheel grinding. The abrasive belt grinding chips are banded， while the abrasive wheel grinding chips are molten at high temperature. At the same time， when the grinding pressure is increased to 105 N， the rail surface will turn blue after grinding， but the abrasive belt grinding will not. In addition， the lateral surface roughness of abrasive belt grinding is greater than that of abrasive wheel grinding， up to 8 μm， which meets the maximum 10 μm required by Chinese railway rail maintenance. To sum up， rail abrasive belt grinding technology is significantly superior to traditional abrasive wheel grinding technology in material removal rate， vibration， noise， energy consumption and temperature， etc. It is expected to be one of the effective methods to solve serious rail diseases in engineering practices.

Key words: rail grinding, abrasive belt, abrasive wheel, material removal, vibration, energy consumption

摘要： 基于自主研发的锂电驱动钢轨砂带打磨机和砂轮打磨机，以60N型钢轨廓形作为实验对象，全面对比了新型钢轨砂带打磨技术和传统砂轮打磨技术的性能。结果表明：当打磨压力在45～75 N范围内时，砂带打磨的材料去除率约为砂轮打磨的15～30倍，而当压力增大到90 N时，砂带打磨的材料去除率高达砂轮打磨的102倍；砂带打磨的振动加速度、噪声和能耗均小于砂轮打磨；砂带打磨切屑为带状，而砂轮打磨则表现为高温熔融状，同时当打磨压力增大到105 N时，砂轮打磨后钢轨表面会出现发蓝现象，而砂带打磨不会；此外，砂带打磨的横向表面粗糙度大于砂轮打磨，最高可达8 μm，但满足中国铁路钢轨养护要求的最大值10 μm。综上，钢轨砂带打磨技术在材料去除率、振动、噪声、能耗和温度等方面显著优于传统砂轮打磨技术，预期将成为工程实际中解决钢轨严重病害问题的有效方法之一。

关键词: 钢轨打磨, 砂带, 砂轮, 材料去除, 振动, 能耗

CLC Number:

TG580.6

WU Zhiwei, FAN Wengang, WANG Qian, LIU Yi, MA Tengfei, . Experimental Investigation on Comprehensive Performance Comparison for Rail Grinding Using Abrasive Belt and Abrasive Wheel[J]. China Mechanical Engineering, 2022, 33(17): 2125-2132.

吴志伟, 樊文刚, 王谦, 刘弋, 马腾飞, . 钢轨砂带打磨与砂轮打磨综合性能对比实验研究[J]. 中国机械工程, 2022, 33(17): 2125-2132.

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