Microscopic contact pressure and material removal modeling in rail grinding using abrasive belt

2020 ◽  
Vol 235 (1-2) ◽  
pp. 3-12
Author(s):  
Wengang Fan ◽  
Wenxi Wang ◽  
Junda Wang ◽  
Xinle Zhang ◽  
Chang Qian ◽  
...  
Keyword(s):  
Surface Topography ◽  
Contact Pressure ◽  
Material Removal ◽  
Normal Load ◽  
Great Influence ◽  
Theoretical Models ◽  
Contact Behavior ◽  
Abrasive Belt ◽  
Grinding Method ◽  
Rail Grinding

Recently, the emerging rail grinding method using abrasive belt has been proposed to efficiently achieve the required geometric profile and the surface quality of the railhead. Although the abrasive features indeed have a great influence on this rail grinding process, the surface topography of abrasive belt regarding grits at the microscopic scale is neglected. In this article, a microscopic contact pressure model was developed to reveal the contact behavior of every active grit based on the digital representation of the surface topography of abrasive belt. Then a numerical model of material removal quantity was also established based on the consideration of the characteristics of abrasive grits and their interactions. Finally, the series of finite element simulations and grinding tests were successively implemented. The normal load and the surface topography of abrasive belt significantly affected the microscopic contact behavior of grits, thus confirming the proposed theoretical models of microscopic contact pressure and material removal quantity.

Influencing Mechanism of Rubber Wheel on Contact Pressure and Metal Removal in Corrugated Rail Grinding by Abrasive Belt

2018 ◽  
Vol 140 (12) ◽  
Author(s):  
Wengang Fan ◽  
Yueming Liu ◽  
Xiaoyang Song ◽  
Jifa Cheng ◽  
Jianyong Li
Keyword(s):  
Contact Pressure ◽  
Metal Removal ◽  
Removal Rate ◽  
Boundary Curve ◽  
Theoretical Models ◽  
Belt Grinding ◽  
Railway Network ◽  
Abrasive Belt ◽  
Influencing Mechanism ◽  
Rail Grinding

Rail grinding has been widely recognized as an essential measure in routine maintenance of railway network in the world. Compared with other technologies, the emerging abrasive belt grinding process for direct rail maintenance rather than limited polishing finish has shown the convincing potential to improve metal removal rate and surface quality. However, the influencing mechanism of the rubber wheel on contact pressure and metal removal for the corrugated rails is yet unknown. This paper develops a contact pressure model to obtain the boundary curve and the stress distribution of the contact zone between the rubber wheel with concave peripheral surface and the rail surface with corrugation. Based on this, the metal removal model is subsequently established through the abrasive processing theory. Finite element (FE) simulations and grinding tests are finally implemented. Results confirm the above-mentioned theoretical models of contact pressure and metal removal and show the significant influences of the rubber wheel's feature on contact pressure and metal removal.

scholarly journals Contact Model And Simulation Analysis of Rail Grinding With Open-Structured Abrasive Belt Based On Pressing Plate

2021 ◽  
Author(s):  
Chang Qian ◽  
Zhiwei Wu ◽  
Guangyou Hou ◽  
Wengang Fan
Keyword(s):  
Theoretical Model ◽  
Contact Stress ◽  
High Speed ◽  
Contact Model ◽  
Concentrated Force ◽  
Rail Corrugation ◽  
Abrasive Belt ◽  
Grinding Method ◽  
Rail Grinding ◽  
Working Length

Abstract Recently, the emerging rail grinding method with open-structured abrasive belt based on pressing plate which adopts full contour copying grinding method to extend the working length of abrasive belt and is more suitable for preventative grinding and maintenance of rail corrugation in high-speed railway has been proposed. The essence of its grinding process is the complex nonlinear interaction among the pressing plate, abrasive belt and rail. The research on the contact mechanism of the rail grinding method with open-structured abrasive belt based on pressing plate is still very lacking, which limits the practical application of the emering rail grinding method to a certain extent. In this paper, a theoretical model of the contact between pressing plate, abrasive belt and rail is established. The contact area morphology and contact stress distribution were obtained, and validity of the theoretical model was verified by finite element simulation. At the same time, the distribution characteristics of contact stress under single concentrated force, uniform force and multiple concentrated force were studied based on the contact model. It is concluded that the multiple concentrated force is the optimal loading method, and the contact stress is more uniform, which is more conducive to repair the standard contour of rail.

scholarly journals Investigation of Material Removal and Surface Topography Formation in Vibratory Finishing

Procedia CIRP ◽  
2014 ◽  
Vol 14 ◽  
pp. 25-30 ◽  
Author(s):  
Eckart Uhlmann ◽  
Arne Dethlefs ◽  
Alexander Eulitz
Keyword(s):  
Surface Topography ◽  
Material Removal ◽  
Vibratory Finishing

The role of surface topography and normal load in the initiation of ratchetting-peak friction, seizure, scuffing, and elastic shakedown

2021 ◽  
pp. 1-12
Author(s):  
Vimal Edachery ◽  
V. Swamybabu ◽  
Gurupatham Anand ◽  
Paramasamy Manikandan ◽  
Satish V. Kailas
Keyword(s):  
Steady State ◽  
Surface Topography ◽  
Sliding Wear ◽  
Friction And Wear ◽  
Critical Parameter ◽  
Normal Load ◽  
Sliding Direction ◽  
Elastic Shakedown ◽  
Lubrication Conditions

Abstract Surface topography is a critical parameter that can influence friction and wear in engineering applications. In this work, the influence of surface topography directionality on seizure and scuffing initiation during tribological interactions is explored. For this, unidirectional sliding wear experiments were carried out in immersed lubrication conditions for various normal loads. The tribological interactions were studied using EN31-60 HRC flats and SAE52100-60HRC pins in a sphere on flat configuration. The results show that, in some cases, the sliding interactions in the initial cycles lead to a high friction coefficient of up to ∼0.68 in lubricated conditions, which was termed as ‘peak friction’, and this was accompanied by scuffing. The existence of peak friction was found to be dependent on surface topography directionality, especially when the directionality in topography was parallel to the sliding direction. Continuous ratchetting was found to be the cause of peak friction which was accompanied by seizure and scuffing. When the topography directionality was perpendicular or independent of sliding direction, elastic shakedown occurred at earlier cycles and prevented peak friction initiation, scuffing and also facilitated for higher steady-state friction values.

Microstructural and Tribological Characterization of API X52 Dual-Phase Steel

2021 ◽  
Author(s):  
Gamri Hamza ◽  
Allaoui Omar ◽  
Zidelmel Sami
Keyword(s):  
Mechanical Properties ◽  
Dual Phase Steel ◽  
Volume Fraction ◽  
Wear Behavior ◽  
Normal Load ◽  
Great Influence ◽  
Dual Phase ◽  
Martensite Volume Fraction ◽  
Direct Quenching ◽  
Disc Configuration

Abstract The effect of the morphology and the martensite volume fraction on the microhardness, the tensile, the friction and the wear behavior of API X52 dual phase (DP) steel has been investigated. Three different heat treatments were used to develop dual phase steel with different morphologies and with different amounts of martensite: Intermediate Quenching Treatment/Water (IQ); Step Quenching Treatment (SQ) and direct quenching (DQ). Tribological tests are conducted on DP steels using a ball-on-disc configuration under normal load of 5 N and at a sliding speed of 4 cm/s were used to study the friction and wear behavior of treated samples. Results show that the ferrite–martensite morphology has a great influence on the mechanical properties of dual phase steel. The steel subjected to (IQ) treatment attain superior mechanical properties compared to the SQ and the DQ treatments. On the other hand, it is also found that the friction coefficient and the wear rate (volume loss) decrease when the hardness and the martensite volume fraction increase. The steel with fine fibrous martensite provide good wear resistance.

Experiment and Surface Roughness Prediction Model for Ti-6Al-4V in Abrasive Belt Grinding

2016 ◽  
Vol 1136 ◽  
pp. 42-47 ◽  
Author(s):  
Ya Xiong Chen ◽  
Yun Huang ◽  
Gui Jian Xiao ◽  
Gui Lin Chen ◽  
Zhi Wu Liu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Great Influence ◽  
Grinding Force ◽  
Work Piece ◽  
Belt Grinding ◽  
Abrasive Belt ◽  
Belt Speed ◽  
Feeding Speed

In abrasive belt grinding, abrasive belt granularity, abrasive belt speed,feeding speed and grinding force have a great influence on the surface roughness. In order to predicate the surface roughness of Ti-6Al-4V,a response surface methodology are used to build the model to predict surface roughness,and the influence of various parameters on surface roughness was analysed. The research shows that with the abrasive belt granularity and abrasive belt speed increasing,the work piece surface roughness decreases;with the grinding force and feeding speed increasing,the work piece surface roughness increases. Through the test,the response surface methodology with high prediction accuracy,provides a theoretical basis for the reasonable selection of abrasive belt grinding parameters.

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