Experimental and simulation research on residual stress for abrasive belt rail grinding

Zhao, Chaoyue; Li, Jianyong; Fan, Wengang; Liu, Yueming; Wang, Wenxi

doi:10.1007/s00170-020-05664-5

Cited by 31 publications

(14 citation statements)

References 25 publications

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“…The contact wheel consists of a hub and a rubber layer wrapped around the hub. The force is applied to the contact wheel in the grinding process and the particles of abrasive belt slides on the rail surface to achieve material cutting and removal [20,21]. To complete the repair of rail surface, several grinding units are arranged in the direction of the rail extension to achieve enveloping grinding of the rail.…”

Section: Contact Analysis In Rail Grinding With Abrasive Beltmentioning

confidence: 99%

Static Contact Modelling and Analysis for Rail Grinding with Abrasive Belt

Liu¹,

Fan²,

Zhang³

et al. 2022

Int. j. simul. model.

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Rail grinding with abrasive belt is increasingly applied in daily rail maintenance due to its high efficiency and high quality. The contact between rail and abrasive belt largely determines grinding efficiency and grinding quality, but the influences of grinding process and contact wheel's parameters on the contact behaviour are obscure. To explore the influences, a finite element model of the wheelrail contact was established. The simulation results showed that the grinding angle significantly affected the shape of contact spot. The contact spot gradually became narrower as the grinding angle increased. Similarly, the reduction of the contact wheel radius significantly increased the contact stress. But when the ratio of the thickness of rubber layer to wheel radius increased above 60 %, it had little effect on the size of contact spot and maximum contact stress. This study provides the basis for the selection of grinding process and contact wheel's parameters. In the actual grinding process, grinding process and contact wheel should be selected according to grinding requirements.

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Section: Contact Analysis In Rail Grinding With Abrasive Beltmentioning

confidence: 99%

Static Contact Modelling and Analysis for Rail Grinding with Abrasive Belt

Liu¹,

Fan²,

Zhang³

et al. 2022

Int. j. simul. model.

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“…Cheng et al 5 studied the residual stress of the surface after drilling under different cutting parameters and processing features and proposed a machining‐induced surface residual stress prediction method based on Gaussian process regression while verifying the performance using other machine learning algorithms. Zhao et al 6 performed the effects of the grinding process parameters on the residual stress on the rail surface and performed a finite element analysis with thermal and mechanical coupling for single and multiple abrasive scratches. Zou et al 7 carried out the effect of normal pressure and grinding speed on residual stress and concluded that the residual compressive stresses formed in the machined surface layer are mainly due to low‐frequency vibrations at the grinding interface.…”

Section: Introductionmentioning

confidence: 99%

“…Combining the above single grain force model and the dynamic effective grain number N d Δ , the total normal grinding force F N Δ and the tangential grinding force F T Δ for the different grain geometrical characteristics can be derived using Equations ( 2), ( 4), (6), and (8).…”

mentioning

confidence: 99%

A prediction model of residual stress for belt‐grinding blade based on geometrical characteristic and progressive wear of abrasive grains

Wang

Lai

et al. 2022

Numerical Meth Engineering

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The formation mechanism of residual stress on the machined surface of belt grinding is sophisticated, and residual stress is an important factor affecting the fatigue life of aero‐engine blades. In this study, a prediction model of residual stress in a belt grinding blade is proposed with the geometrical characteristics and progressive wear of the grains as the research topic. By extracting the morphological features of abrasive belt, the residual stress based on different geometrical characteristics of grains (pyramidal, hexahedral, spherical, and conical belts) were investigated, and the optimal grain geometry was determined to be a uniformly arranged positive quadrilateral cone. Accordingly, a grinding experiment with a pyramidal belt was conducted to obtain an experienced model of the grain wear height. A numerical simulation model of the grain wear evolution under four wear states (no abrasion, early abrasion, middle abrasion, and late abrasion) was developed. Additionally, more detailed progressive wear of the abrasive grains was also applied to grind the entire profile of the complex curved blade. The residual stress on the blade surface was mainly compressive, and the surface stress values were distributed between −385 and −117 MPa with the service life of the pyramidal abrasive belt.

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“…Rail grinding technology plays an important role in railway maintenance [1][2][3]. Due to the rapid development of China's railways, diverse efficient and intelligent rail grinding technologies and devices have been developed [4]. Rail grinding vehicles with abrasive belt have the advantages of lightweight, flexibility, integration, energy conservation, and environmental protection.…”

Section: Introductionmentioning

confidence: 99%

DMA2022：Vibration control of the rail grinding vehicle with abrasive belt based on structural optimization and lightweight design

Fan

Zhang

et al. 2022

Preprint

Self Cite

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As a new grinding and maintenance technology, rail belt grinding shows significant advantages in many applications. The dynamic characteristics of the rail belt grinding vehicle largely determines its grinding performance and service life. In order to explore the vibration control method of the rail grinding vehicle with abrasive belt, the vibration response changes in structural optimization and lightweight design are respectively analyzed through transient response and random vibration simulations in this paper. Firstly, the transient response simulation analysis of the rail grinding vehicle with abrasive belt is carried out under operating conditions and non-operating conditions. Secondly, the vibration control of the grinding vehicle is implemented by setting vibration isolation elements, optimizing the structure, and increasing damping. Thirdly, in order to further explore the dynamic characteristics of the rail grinding vehicle, the random vibration simulation analysis of the grinding vehicle is carried out under the condition of the horizontal irregularity of the American AAR6 track. Finally, by replacing the Q235 steel frame material with 7075 aluminum alloy and LA43M magnesium alloy, both vibration control and lightweight design can be achieved simultaneously. The results of transient dynamic response analysis show that the acceleration of most positions in the two working conditions exceeds the standard value in GB/T 17426-1998 standard. By optimizing the structure of the grinding vehicle in three ways, the average vibration acceleration of the whole car is reduced by about 55.1% from 15.6 m/s 2 to 7.0 m/s 2 . The results of random vibration analysis show that the grinding vehicle with Q235 steel frame does not meet the safety conditions of . By changing frame material, the maximum vibration stress of the vehicle can be reduced from 240.7 Mpa to 160.0 Mpa and the weight of the grinding vehicle is reduced by about 21.7% from 1500 Kg to 1175 Kg. The modal analysis results indicate that the vibration control of the grinding vehicle can be realized by optimizing the structure and replacing the materials with lower stiffness under the premise of ensuring the overall strength. The study provides the basis for the development of lightweight, diversified and efficient rail grinding equipment.

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Experimental and simulation research on residual stress for abrasive belt rail grinding

Cited by 31 publications

References 25 publications

Static Contact Modelling and Analysis for Rail Grinding with Abrasive Belt

Static Contact Modelling and Analysis for Rail Grinding with Abrasive Belt

A prediction model of residual stress for belt‐grinding blade based on geometrical characteristic and progressive wear of abrasive grains

DMA2022：Vibration control of the rail grinding vehicle with abrasive belt based on structural optimization and lightweight design

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