• 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.
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