Research on Processing Parameter Optimization of Rail Repair by Abrasive Waterjet

doi:10.3969/j.issn.1004-132X.2025.05.025

Abstract

Abstract: In order to improve the efficiency and repair quality of abrasive waterjet repairing rails and reduce energy loss， the orthogonal experiments on abrasive waterjet repairing rails were carried out on Chinas U71Mn 60 kg/m heavy rail， based on central composite design（CCD） response surface method. The repair quality regression model of rails was established， the influences of each processing parameter on the repair quality was studied. The results show that the nozzle feed rate has the more significant effect on the profiles， the surface roughnesses of cutting ground zones and the surface roughnesses of deformation ground zones than that of waterjet pressure. And two sets of processing parameter optimization combinations are obtained under different applicable conditions， one focuses on the repair quality， the other focuses on efficiency of repairing. It is found that the errors of the predicted values and the experimental values of the profiles， the surface roughnesses of the cutting ground zones and the surface roughnesses of the deformation ground zones are less than 6%， and the average error is less than 4%. It is proved that the model may effectively predict the surface roughnesses of the cutting surfaces， which lays a theoretical foundation for the practical applications of abrasive waterjet repairing rails.

Key words: abrasive waterjet, rail repair, parameter optimization, response surface method

摘要： 为提高磨料水射流修复钢轨的效率及修复质量并降低能量损耗，对我国U71Mn 60 kg/m重轨开展了磨料水射流修复钢轨正交试验，基于中心复合设计（CCD）响应曲面法建立了钢轨修复质量回归模型，探究了各工艺参数对修复质量的影响。研究结果表明，喷嘴进给速度较水射流压力对截面轮廓度、切割磨削区表面粗糙度和变形磨削区表面粗糙度的影响更显著；得到了侧重于修复质量以及侧重于修复效率的两套不同适用条件下的工艺参数优化组合，通过试验验证发现，截面轮廓度、切割磨削区表面粗糙度和变形磨削区表面粗糙度的预测值与试验值的误差均小于6%，平均误差小于4%，证明该模型可有效预测切割面的表面粗糙度，为磨料水射流修复钢轨实际应用奠定了理论基础。

关键词: 磨料水射流, 钢轨修复, 参数优化, 响应曲面法

CLC Number:

U216

ZHENG Yan. Research on Processing Parameter Optimization of Rail Repair by Abrasive Waterjet[J]. China Mechanical Engineering, 2025, 36(05): 1132-1141.

郑燕. 磨料水射流修复钢轨工艺参数优化研究[J]. 中国机械工程, 2025, 36(05): 1132-1141.

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