Key Takeaways & Executive Findings
- •• A coupled mechanical model of the grinding wheel/rail based on contact mechanics is established and embedded into a multi-rigid buggy dynamic model, enabling accurate analysis of grinding force dynamics. • Convex rail irregularities cause significant vibration in the grinding wheel, primarily transmitted between the wheel and frame, with minimal effect on the wheelset. • For long-wave corrugation, the grinding effect correlates with the phase angle of the wheelset, highlighting the importance of phase alignment in grinding operations. • The findings provide a theoretical basis for optimizing grinding patterns and improving grinding quality and efficiency in subway rail maintenance.
Abstract
During the grinding train operation process, the grinding force between the grinding wheel and the rail is critical in ensuring the grinding quality and efficiency. The coupling vibration among the frame, the grinding wheels, and the wheelsets will seriously affect the stability of the grinding force. In this paper, the coupled mechanical model of the grinding wheel/rail is established based on the contact mechanics theory, which is embedded as a sub-model into the dynamic model of the multi-rigid buggy. The interaction among the frame, the grinding wheels and the wheelsets is analysed by setting the convex irregularity on the rail. The grinding effect is evaluated in combination with the subway’s long wave corrugation grinding conditions. The results show that when the grinding buggy passes the convex irregularity, the vibration excited by the wheelset system has a significant impact on the dynamic behavior of the grinding wheels. The vibration of the grinding wheel is mainly transmitted between the grinding wheel and the frame, less affecting the wheelset. For the long wave corrugation of the subway, the grinding effect of the grinding wheel has a certain correlation with the phase angle of the wheelset through the corrugation. The research results provide an important reference for the setting of the grinding pattern.
1. Introduction
With the increase in the operation of urban subways, the rolling contact fatigue and wear between wheels and rails have significantly deteriorated the rail structure. The grinding trains can repair rail defects such as corrugation, fatigue cracks, etc. [1]. Moreover, the grinding operation can effectively improve the safety and stability of vehicles and prolong the service life of the rail [2–5]. Currently, China doesn’t have a fully developed grinding train system, and the relevant theoretical research lags behind [6, 7].
The research on grinding technology primarily focuses on rail profile optimization and grinding train dynamics. The appropriate rail grinding profile can effectively reduce wheel-rail wear speed. In the literature [8–12], a non-linear algorithm is used to optimize the rail profile to reduce wheel-rail contact stress, contact fatigue, and rail wear speed. The optimized grinding profile also achieved the expected results in practice. However, the target profile is completed by the grinding train; the train dynamics performance will directly affect the final profile of the rail. The grinding train dynamics mainly focus on the dynamics of the vehicle system; few scholars consider the coupling effect between the grinding wheel and rail, and the contact force between the grinding wheel and rail is also considered a concentrated force in the vehicle system dynamics. Wang et al. [13] optimized the primary positioning stiffness of the grinding buggy without considering the force between the grinding wheel and the rail. Zhang et al. [14] established the mechanical model of the grinding wheel employing grinding theory, and the effects of rail irregularity, grinding speed, and rail corrugation on the fluctuation of grinding force are analyzed by the dynamic model of the grinding buggy. Zhi et al. [15] established the grinding wheel force model based on the grinding mechanism of abrasive particles, discussed the relationship between cutting depth and motor output power, and analyzed the grinding effect of rail. The research was unable to analyze the mechanical properties in the contact zone between the grinding wheel and the rail, and therefore, the grinding effect could not be accurately assessed.
The contact mechanics theory is suitable for solving the stress distribution in the contact spot. At present, the grinding force has already been studied employing the contact mechanics theory in rail belt grinding. Wang et al. [16] regarded the contact state between the rail and the abrasive belt as the contact between two free surfaces, and calculated the shape, area, and contact force distribution in the contact zone. He et al. [17] ...
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Tao Liu, Dabin Cui, Xinyi Li, Zhanghong Liu, Li Li (2025). Research on the Coupling Force between the Grinding Wheel and Rail in Grinding Train System. Chinese Journal of Mechanical Engineering. https://doi.org/10.1186/s10033-025-01328-1
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Frequently Asked Questions
What is the main contribution of this paper?
The paper establishes a coupled mechanical model of the grinding wheel/rail based on contact mechanics, embedded into a multi-rigid buggy dynamic model, to analyze the coupling force and its effects on grinding quality and efficiency.
How does the grinding wheel/rail coupling force affect grinding quality?
The coupling force stability is critical for grinding quality. Vibrations from the wheelset and frame can cause fluctuations in the grinding force, leading to uneven material removal and reduced grinding effectiveness.
What is the significance of the phase angle in long-wave corrugation grinding?
The study found that the grinding effect correlates with the phase angle of the wheelset relative to the corrugation, indicating that aligning the grinding wheel's motion with the corrugation phase can improve grinding outcomes.
How does this research contribute to rail maintenance?
The findings provide a theoretical basis for optimizing grinding patterns and improving the design of grinding trains, ultimately enhancing rail repair efficiency and prolonging rail service life.
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