Investigating the effects of contact pressure on rail material abrasive belt grinding performance

  • He Zhe
  • Li Jianyong
  • Liu Yueming
  • Nie Meng
  • Fan Wengang
ORIGINAL ARTICLE

Abstract

This paper presents an experimental investigation into the effects of various contact pressures on the abrasive belt grinding performance of rail material. The contact relations between the contact wheel covered with elastic rubber and the head surface of the rail are first analytically discussed as they relate to the pressure distribution. The contact pressure, which is proposed as the control variable in grinding experiments instead of the loaded force, apparently indicates a highly accurate contact state. Accordingly, contact pressure was chosen as a variable parameter for abrasive belt grinding experiments on an Mn-steel rail workpiece. The results of the experiment, including material removal rate, grinding ratio, surface roughness, hardness, chip size, and chip elements, are discussed in detail. Elevated contact pressure exerted a positive influence on material removal rate in the experiments, and the surface hardness of the ground rail surface increased as contact pressure increased. Conversely, grinding ratio decreased with increasing contact pressure. The size of chips also increased as contact pressure increased, as did the oxygen content in the chips—this may indicate that Fe3O4 and Fe2O3 content in the chips also increased as contact pressure increased.

Keywords

Contact pressure Abrasive belt grinding Rail grinding Grinding performance 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Cannon DF, Edel K-O, Grassie SL, Sawley K (2003) Rail defects: an overview. Fatigue Fract Eng Mater Struct 26(10):865–886CrossRefGoogle Scholar
  2. 2.
    Oostermeijer KH (2008) Review on short pitch rail corrugation studies. Wear 265(9–10):1231–1237CrossRefGoogle Scholar
  3. 3.
    Steenbergen M (2016) Rolling contact fatigue in relation to rail grinding. Wear 356–357:110–121CrossRefGoogle Scholar
  4. 4.
    Zarembski AM (2008) Grinding as part of rail management strategy. Railw Track Struct 104(6):55–58Google Scholar
  5. 5.
    Zarembski AM (2005) The art and science of rail grinding. Simmons-Boardman Books, Inc 1–7Google Scholar
  6. 6.
    Reddy V, Chattopadhyay G, Larsson-Kråik PO (2004) Technical vs. economic decisions: a case study on preventive rail grinding. The Seventh Asia-Pacific Division Meeting of the International Foundation of Production Research 30(7):1–7Google Scholar
  7. 7.
    Uhlmann E, Lypovka P, Hochschild L, Schröer N (2016) Influence of rail grinding process parameters on rail surface roughness and surface layer hardness. Wear 366–367:287–293CrossRefGoogle Scholar
  8. 8.
    Gu KK, Lin Q, Wang WJ, Wang HY, Guo J, Liu QY, Zhu MH (2015) Analysis on the effects of rotational speed of grinding stone on removal behavior of rail material. Wear 342–343:52–59CrossRefGoogle Scholar
  9. 9.
    Zhong ZW, Venkatesh VC (2009) Recent developments in grinding of advanced materials. Int J Adv Manuf Technol 41(5):468–480CrossRefGoogle Scholar
  10. 10.
    Zhi SD, Li JY, Fan WG, Shen HK, Wang H (2013) Research on contact line model for rail grinding. J China Railw Soc 35(10):94–99Google Scholar
  11. 11.
    Grzesik W, Rech J, Żak K (2015) High-precision finishing hard steel surfaces using cutting, abrasive and burnishing operations. Procedia Manuf 1:619–627CrossRefGoogle Scholar
  12. 12.
    Zhu DH, Luo SY, Yang L, Chen W, Yan SJ, Ding H (2015) On energetic assessment of cutting mechanisms in robot-assisted belt grinding of titanium alloys. Tribol Int 90:55–59CrossRefGoogle Scholar
  13. 13.
    Liu YM, Li JY, Cai YL, Nie M (2014) Current state and development trend of rail grinding technology. China Railw Sci 35(4):29–37Google Scholar
  14. 14.
    Zhi SD, Li JY, Zarembski AM (2014) Modelling of dynamic contact length in rail grinding process. Front Mech Eng 9(3):242–248CrossRefGoogle Scholar
  15. 15.
    Carlson GA Jr (1985) Overview of abrasive belt grinding. Tool Prod 51(25):70–74Google Scholar
  16. 16.
    Antoine JF, Visa C, Sauvey C, Abba G (2006) Approximate analytical model for hertzian elliptical contact problems. J Tribol 128(3):660–664CrossRefGoogle Scholar
  17. 17.
    Wang YJ, Huang Y, Chen YX, Yang ZS (2015) Model of an abrasive belt grinding surface removal contour and its application. Int J Adv Manuf Technol 82(9):2113–2122Google Scholar
  18. 18.
    Wang WX, Li JY, Fan WG, Song XY, Wang LF (2016) Characteristic quantitative evaluation and stochastic modeling of surface topography for zirconia alumina abrasive belt. Int J Adv Manuf Technol 1–11Google Scholar
  19. 19.
    Jourani A, Hagège B, Bouvier S, Bigerelle M, Zahouani H (2013) Influence of abrasive grain geometry on friction coefficient and wear rate in belt finishing. Tribol Int 59:30–37CrossRefGoogle Scholar
  20. 20.
    Xie Y, Williams JA (1996) The prediction of friction and wear when a soft surface slides against a harder rough surface. Wear 196(1–2):21–34CrossRefGoogle Scholar
  21. 21.
    Grzesik W, Rech J, Żak K (2015) Characterization of surface textures generated on hardened steel parts in high-precision machining operations. Int J Adv Manuf Technol 78(9–12):2049–2056CrossRefGoogle Scholar
  22. 22.
    Wang YZ, Hou LW, Lan Z, Zhang GL (2016) Precision grinding technology for complex surface of aero face-gear. Int J Adv Manuf Technol 86(5–8):1263–1272CrossRefGoogle Scholar
  23. 23.
    Liu YM, Warkentin A, Bauer R, Gong YD (2013) Investigation of different grain shapes and dressing to predict surface roughness in grinding using kinematic simulations. Precis Eng 37(3):758–764CrossRefGoogle Scholar
  24. 24.
    Liu MH, Zhang K, Xiu SC (2017) Mechanism investigation of hardening layer hardness uniformity based on grind-hardening process. Int J Adv Manuf Technol 88(9–12):3185–3194CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2017

Authors and Affiliations

  • He Zhe
    • 1
  • Li Jianyong
    • 1
    • 2
  • Liu Yueming
    • 1
    • 2
  • Nie Meng
    • 1
    • 2
  • Fan Wengang
    • 1
    • 2
  1. 1.School of Mechanical, Electronic and Control EngineeringBeijing Jiaotong UniversityBeijingChina
  2. 2.Key Laboratory of Vehicle Advanced Manufacturing, Measuring and Control TechnologyMinistry of EducationBeijingChina

Personalised recommendations