Rail grinding for the 21st century - taking a lead from the aerospace industry
Rail grinding for the 21st century - taking a lead from the aerospace industry
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DOI：
10.1177/0954409714527929
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发表时间：
2015-07-01
影响因子：
2
通讯作者：
Evans, Gareth
中科院分区：
文献类型：
--
作者：
Singleton, Roger;Marshall, Matthew B.;Evans, Gareth
钢轨打磨是Network Rail的关键维护活动。它是在夜间通过拥有轨道进行的，因此处理速度至关重要。提高钢轨打磨作业的金属去除率（MRR）是缩短该作业时间的一种方法。航空航天工业最近看到了磨削技术的进步，提高了MRR。这项工作的目的是评估他们的最佳做法及其在钢轨打磨作业中的应用。目前的网络铁路磨削作业包括预防性和纠正性的重新成型的轨头。在英国进行的大部分工作是预防性的重新配置，目前的列车速度从1英里/小时到10英里/小时。通过使用更先进的研磨技术，存在提高列车速度和提高该操作的生产率的机会。最相关的航空航天技术是高效深磨（HEDG）。这种方法使用：砂轮的高表面速度、超级磨料工具和高工件进给速率，以快速从切割区去除材料。通过应用研磨过程的功率要求（通过评估比研磨能）和切屑厚度理论来确定生产率的提高。还进行了计算机CAD/CAM建模，以评估改变研磨技术对轨道基础设施的潜在刨削和/或对示例轨道旁障碍物的干扰的影响。这项工作的结论是，确实存在提高研磨作业目前生产率的机会。理论上，利用HEDG技术可使列车速度增加100%（利用与当前设置相同的功率），以进行预防性重新配置。这就需要应用高表面速度的砂轮和超硬磨料技术。列车速度的进一步提高需要增加主轴功率。对于周边磨削设置和高的砂轮表面速度，磨削颗粒所经历的切屑厚度减小，这有利于砂轮磨损。HEDG技术在车轮周边切割的应用为CAD/CAM模拟提供了最佳条件，以避免钢轨刨削以及磨石与模拟轨道旁障碍物的任何潜在碰撞。
Rail grinding is a key maintenance activity for Network Rail. It is performed at night through possession of the track, so process speed is critical. Increasing the metal removal rate (MRR) of the rail grinding operations would be a way to improve the time taken for this operation. The aerospace industry has recently seen advances in grinding technologies that have increased MRR. This work was aimed at assessing their best practice and its application to rail grinding operations. Current Network Rail grinding operations include preventative and corrective re-profiling of the rail head. The majority of work performed in the UK is preventative re-profiling with current train speeds ranging from 1 to 10mile/h. Opportunities exist to increase train speed and improve the productivity of this operation through the use of more advanced grinding technologies. The most relevant aerospace technology is high efficiency deep grinding (HEDG). This approach uses: a high surface speed of the grinding wheel, superabrasive tooling, and high workpiece feed rates to remove material quickly from the cut-zone. Productivity improvements were identified by applying theory on power requirements (by assessing the specific grinding energy) and chip thickness of the grinding process. Computer CAD/CAM modelling was also performed to assess the effect of changing grinding techniques on potential gouging of the track infrastructure and/or interference with example trackside obstructions. The work concluded that opportunities do exist to improve the current productivity of grinding operations. Utilizing HEDG technology theoretically provides a 100% train speed increase (utilizing the same power available with the current setup) for preventative re-profiling. This requires the application of high surface speeds of the grinding wheel and superabrasive technology. Further increases in train speed require increased spindle power. The chip thickness experienced by grinding grains is reduced for a peripheral grinding setup and high wheel surface speeds that is beneficial for wheel wear. The application of HEDG technology cutting on the periphery of the wheel provided optimum conditions during CAD/CAM simulation to avoid rail gouging, and any potential collision of the grinding stone with modelled trackside obstructions.