面向钢轨目标廓形的多砂带磨削作业打磨模式
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摘要
基于砂带打磨钢轨时的接触状态,在单条砂带磨削角度给定的前提下,推导单条砂带磨削在钢轨横向截面上的材料去除深度,建立单条砂带材料去除的廓形模型和面积模型。为在多砂带联合磨削下包络形成钢轨目标廓形,在给定首条砂带的磨削角度后,根据当前钢轨表面的剩余高度并以打磨量最大为原则设定其他砂带的磨削角度,结合工艺参数生成钢轨养护时的多砂带联合磨削作业打磨模式。以打磨质量指数评价打磨质量,确定打磨次数,评价多砂带联合磨削作业打磨模式的打磨质量。结果表明:在砂带磨削工艺参数一定时,砂带的磨削能力与钢轨表面的曲率半径相关;以最大打磨深度对应的角度进行砂带布局的打磨模式能够很好地满足钢轨目标廓形的磨削需求。
Based on the contact state of grinding rail with abrasive belt and under the given grinding angle of single abrasive belt, the material removal depth of single abrasive belt grinding on rail transverse section was deduced, and a profile model and an area model for material removal from a single abrasive belt were established. To achieve the target profile of rail under the combined grinding of multi-abrasive belts, after the grinding angle of the first abrasive belt was given, the grinding angles of other abrasive belts were set according to the remaining height of rail surface and the principle of maximum grinding quantity. The grinding mode of multi-abrasive belt combined operation for rail maintenance was generated by combining process parameters. The grinding quality index was used to assess rail grinding quality and determine the number of grinding times, and to evaluate the grinding quality of multi-abrasive belt combined grinding mode. Result show that, when the process parameters of abrasive belt grinding are constant, the grinding ability of abrasive belt is related to the curvature radius of rail surface. The grinding mode of abrasive belt layout with the angle corresponding to the maximum grinding depth can well meet the requirements for rail target profile.
Based on the contact state of grinding rail with abrasive belt and under the given grinding angle of single abrasive belt, the material removal depth of single abrasive belt grinding on rail transverse section was deduced, and a profile model and an area model for material removal from a single abrasive belt were established. To achieve the target profile of rail under the combined grinding of multi-abrasive belts, after the grinding angle of the first abrasive belt was given, the grinding angles of other abrasive belts were set according to the remaining height of rail surface and the principle of maximum grinding quantity. The grinding mode of multi-abrasive belt combined operation for rail maintenance was generated by combining process parameters. The grinding quality index was used to assess rail grinding quality and determine the number of grinding times, and to evaluate the grinding quality of multi-abrasive belt combined grinding mode. Result show that, when the process parameters of abrasive belt grinding are constant, the grinding ability of abrasive belt is related to the curvature radius of rail surface. The grinding mode of abrasive belt layout with the angle corresponding to the maximum grinding depth can well meet the requirements for rail target profile.
引文
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[2] SATOH Yukio,IWAFUCHI Kengo.Effect of Rail Grinding on Rolling Contact Fatigue in Railway Rail Used in Conventional Line in Japan[J].Wear,2008,265(9):1342-1348.
[3] 周清跃,田常海,张银花,等.高速铁路钢轨打磨关键技术研究[J].中国铁道科学,2012,33(2):66-70.(ZHOU Qingyue,TIAN Changhai,ZHANG Yinhua,et al.Research on Key Rail Grinding Technology of High-Speed Railway[J].China Railway Science,2012,33(2):66-70.in Chinese)
[4] 顾凯凯,王文健,郭俊,等.钢轨—磨石相互作用的摩擦学模拟试验研究[J].摩擦学学报,2015,32(2):154-159.(GU Kaikai,WANG Wenjian,GUO Jun,et al.Tribological Simulation Experiment of Interactions between Rail and Grinding Stone[J].Tribology,2015,32(2):154-159.in Chinese)
[5] LIN Qiang,GUO Jun,WANG Hengyu,et al.Optimal Design of Rail Grinding Patterns Based on a Rail Grinding Target Profile[J].Proceedings of the Institution of Mechanical Engineers,Part F:Journal of Rail & Rapid Transit,2016,232(2):560-571.
[6] HILLS D A,NOWELL D,SACKFIELD A.Mechanics of Elastic Contacts[M].Oxford:Butterworth-Heinemann Ltd.,1993.
[7] GREENWOOD J A.Analysis of Elliptical Hertzian Contacts[J].Tribology International,1997,30(3):235-237.
[8] WANG Y J,HUANG Y,CHEN Y X,et al.Model of an Abrasive Belt Grinding Surface Removal Contour and Its Application[J].The International Journal of Advanced Manufacturing Technology,2016,82(9/10/11/12):2113-2122.
[9] ANTOINE J F,VISA C,SAUVEY C,et al.Approximate Analytical Model for Hertzian Elliptical Contact Problems[J].Journal of Tribology,2006,128:660-664.
[10] 吴建强,黄云.船用螺旋桨叶片四坐标砂带磨削的研究[J].机械科学与技术,2011,30(8):1226-1229.(WU Jianqiang,HUANG Yun,Analysis of Four-Axis Belt Grinding of Marine Propeller Blades[J].Mechanical Science and Technology,2011,30(8):1226-1229.in Chinese)
[11] 任娟娟,赵华卫,欧阳明.高速铁路钢轨打磨对轮轨接触关系的影响[J].华中科技大学学报:自然科学版,2016,44(4):95-100.(REN Juanjuan,ZHAO Huawei,OUYANG Ming.Influence of Rail Grinding on Wheel-Rail Contact Relationship for High-Speed Railway[J].Journal of Huazhong University of Science and Technology:Natural Science,2016,44(4):95-100.in Chinese)