Research on Time-varying Contact Behavior and Simulation for Waved Rail Surface Grinding by Abrasive Belt

doi:10.3901/JME.2018.04.087

Abstract

Abstract: Due to the complex and varied load impact, the longitudinal rail surface tends to form the wavy irregularity with certain length and amplitude, resulting that the equivalent curvature of rail surface and normal contact stress of the contact area in the process of grinding operation change dynamically. For this purpose, the basic contact characteristic for the waved rail surface grinding by abrasive belt is analyzed. Based on the Hertz contact theory, the macro time-varying contact theory model involved with time, grinding pressure, feed speed, diameter and rubber layer thickness of contact wheel is built, by which the more practical contact area form and stress distribution at any time are revealed. The theory and finite element simulation comparison analysis for the three typical different moments (close to the peak of wave, the trough of wave and the horizontal position respectively) is implemented. Results show that the theoretical calculation data and the simulation data agree well, which verifies correctness and validity of the proposed theory model.

Key words: abrasive belt, contact, rail grinding, simulation

CLC Number:

TG742

FAN Wengang, CHENG Jifa, LÜ Hongbin, LI Jianyong, SONG Xiaoyang. Research on Time-varying Contact Behavior and Simulation for Waved Rail Surface Grinding by Abrasive Belt[J]. Journal of Mechanical Engineering, 2018, 54(4): 87-92.

References

[1] 金学松, 杜星, 郭俊, 等. 钢轨打磨技术研究进展[J]. 西南交通大学学报, 2010, 45(1):1-11. JIN Xuesong, DU Xing, GUO Jun, et al. State of arts of research on rail grinding[J]. Journal of Southwest Jiaotong University, 2010, 45(1):1-11.
[2] 刘月明, 李建勇, 蔡永林, 等. 钢轨打磨技术现状和发展趋势[J]. 中国铁道科学, 2014, 35(4):29-37. LIU Yueming, LI Jianyong, CAI Yonglin, et al. Current state and development trend of rail grinding technology[J]. China Railway Science, 2014, 35(4):29-37.
[3] ZHI S, ZAREMBSKI A M, LI J Y, et al. Towards a better understanding of the rail grinding mechanism[C]//ASME 2013 Rail Transportation Division Fall Technical Conference, Altoona:American Society of Mechanical Engineers, Rail Transportation Division RTD, 2013:15-17.
[4] 智少丹, 李建勇, 樊文刚, 等. 钢轨打磨接触线模型研究[J]. 铁道学报, 2013, 35(10):94-99. ZHI Shaodan, LI Jianyong, FAN Wengang, et al. Research on contact line model for rail grinding[J]. Journal of the China Railway Society, 2013, 35(10):94-99.
[5] 郭战伟. 基于轮轨蠕滑最小化的钢轨打磨研究[J]. 中国铁道科学, 2011, 32(6):9-15. GUO Zhanwei. Study of rail grinding based on wheel rail creep minimization[J]. China Railway Science, 2011, 32(6):9-15.
[6] ZHANG X, KUHLENKOTTER B, KNEUPNER K. An efficient method for solving the Signorini problem in the simulation of free-form surfaces produced by belt grinding[J]. International Journal of Machine Tools & Manufacture, 2005, 45(6):641-648.
[7] ZHANG X, KNEUPNER K, KUHLENKOTTER B. A new force distribution calculation model for high-quality production processes[J]. International Journal of Advanced Manufacturing Technology, 2005, 27(7):726-732.
[8] REN X, KUHLENKOTTER B, MULLER H. Simulation and verification of belt grinding with industrial robots[J]. International Journal of Machine Tools & Manufacture, 2006, 46(7-8):708-716.
[9] REN X, CABARAVDIC M, ZHANG X, et al. A local process model for simulation of robotic belt grinding[J]. International Journal of Machine Tools & Manufacture, 2007, 47(6):962-970.
[10] 刘斐, 王伟, 王雷, 等. 接触轮变形对机器人砂带磨削深度的影响[J]. 机械工程学报, 2017, 53(5):86-92. LIU Fei, WANG Wei, WANG Lei, et al. Effect of contact wheel's deformation on cutting depth for robotic belt grinding[J]. Journal of Mechanical Engineering, 2017, 53(5):86-92.
[11] KHELLOUKI A, RECH J, ZAHOUANI H. The effect of abrasive grain's wear and contact conditions on surface texture in belt finishing[J]. Wear, 2007, 263(1-6):81-87.
[12] KHELLOUKI A, RECH J, ZAHOUANI H. Influence of the belt-finishing process on the surface texture obtained by hard turning[J]. Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture, 2007, 221(7):1129-1137.
[13] 黄云, 黄智. 现代砂带磨削技术及工程应用[M]. 重庆:重庆大学出版社, 2009. HUANG Yun, HUANG Zhi. Modern abrasive belt grinding technology and engineering application[M]. Chongqing:Chongqing University Press, 2009.
[14] 吴昌林, 丁和艳, 陈义. 材料去除深度与磨粒的关系建模方法研究[J]. 中国机械工程, 2011, 22(3):300-304. WU Changlin, DING Heyan, CHEN Yi. Research on modeling method of relation between abrasive grain and material removal depth[J]. China Mechanical Engineering, 2011, 22(3):300-304.
[15] 赵燕涛. 自由曲面变压力砂带磨削相关技术的研究[D]. 沈阳:东北大学, 2014. ZHAO Yantao. Research on the related technology of variable pressure belt grinding on free——form surface[D]. Shenyang:Northeastern University, 2014.
[16] WANG Y J, HUANG Y, CHEN Y X, et al. Model of an abrasive belt grinding surface removal contour and its application[J]. International Journal of Advanced Manufacturing Technology, 2016, 82(9-12):2113-2122.
[17] 王荣全. 面向钢轨打磨的砂带磨削过程建模与实验研究[D]. 北京:北京交通大学, 2016. WANG Rongquan. The modeling and experimental research of belt-grinding process in rail[D]. Beijing:Beijing Jiaotong University, 2016.