In the maintenance and repair of heavy-haul railways, rail grinding is a very important task. Why is rail grinding necessary? This is because the service life of rails is directly related to rolling contact fatigue cracks and rail wear. Fatigue cracks affect the running state of wheels and rails, increase maintenance costs, shorten the service life of rails, and even cause rail breaks. Rail wear, especially the side wear of the upper rail on curves, can lead to rapid rail damage.

To slow down the development of rolling contact fatigue and wear damage between rails and wheels and extend the service life of rails, modern rail maintenance and repair technologies must be adopted. 現在, rail grinding (フライス加工) technology is widely used by heavy-haul railways around the world as the main means to alleviate rolling contact fatigue and wear damage of rails.

簡単に言うと, after a period of use, rails will develop problems such as side wear, wave wear, hidden rail defects, rail cracks, rail flanges, and scratches, losing their standard “私” 形. All these are signs of rail “illness”, which disrupts the optimal rail profile, alters the wheel-rail contact state, increases wheel-rail noise, accelerates the deterioration of vehicle and track components, and exacerbates the further spread of rail damage.

After the rail wears down, it can no longer maintain its optimal profile. The cure for this is to perform a kind of “surgical operation” on the rail-rail grinding. Rail grinding essentially involves cutting the surface of the rail to remove defects and restore it to its optimal profile.

The more severe the rail damage, the greater the amount of cutting required, the larger the workload, the greater the difficulty, and the shorter the rail’s lifespan. したがって, corrective grinding and restorative grinding are like “treating diseases”, while the best approach is to prevent the rail from “falling ill”, つまり, to carry out regular preventive grinding to eliminate damage in its nascent stage. The reason why preventive grinding is good is that it does not require a large amount of rail cutting, generally controlled within 0.1 to 0.2mm. こちらです, it can extend the rail’s lifespan without a large amount of cutting, making it the most economical and effective method.

Rail grinding operations are divided into four categories:

(1) Corrective grinding, also known as restorative grinding, with each grinding amount ranging from 0.5 to 4.6mm;

(2) Transitional grinding, which aims to transform the corrective grinding system into a preventive or periodic grinding system;

(3) Preventive grinding or periodic grinding, which only requires the removal of a small amount of metal, 0.2 to 0.3mm, and is the most economical and effective;

(4) Special grinding to achieve a specific rail cross-section shape and a smooth rail contact surface. To achieve the best quality of rail grinding, the grinding method is usually determined based on multiple factors such as the line grade of the operation section, transportation capacity, target rail cross-section, pre-grinding rail condition, grinding cycle, and block time.

According to the maintenance and repair practices of heavy-haul railway lines in various countries around the world, among the four types of grinding operations, preventive grinding has the highest cost-effectiveness. Nowadays, preventive rail grinding technology has become an indispensable part of heavy-haul railway line maintenance and repair. According to statistical data, in Canada, the use of rail grinding technology can extend the lifespan of rails in curved sections by 2.2 times and in straight sections by 3 に 4 回; in the United States, experiments have shown that preventive grinding technology reduces the annual rail damage rate by 65% compared to corrective grinding; in Australia, the use of preventive grinding technology can extend the rail lifespan by 50% に 58%.

Regular preventive grinding of rails can extend their lifespan by 5 に 8 年, 列車の運行を改善する, 乗客の快適性を維持する, ハンティングモーションを減らす, 低ノイズ, エネルギー消費を削減する, 機関車のコンポーネントと線路のメンテナンスコストを削減します。, 経済的および社会的利益の両方をもたらす. 研究によると、レールの微小亀裂は 0.2mm を超えない, 予防研削はレールの劣化の加速を止める最良の時期です.

レールの研磨方法は主に3種類あります: スライディングシュー研磨, 砥石研削, フライス研削.

スライディングシュー研削は、レールに砥石を押し当て、前後に動かすことでレールの表層を削り取ります。. この研削方法では、レール頭部を縦方向にのみ研削できます。, レールのプロファイルを調整できません, そして投票率を削ることができない. さらに, it is relatively slow and is gradually being phased out. Grinding wheel grinding typically uses a high-speed rotating grinding wheel driven by an electric motor or hydraulic motor to grind the rail. This is an active grinding method and is currently the main grinding method. Milling grinding is a new type of rail profile restoration operation mode. The milling cutters are installed on the radial surface of the milling wheel, and each milling section has several milling cutters. There are several milling sections in one rotation of the milling wheel, and all the milling cutters together form the required rail head profile.

On railways, the rail head rolling surface is usually ground by grinding machines or grinding cars to eliminate surface irregularities and surface defects of the rail, thereby restoring the rail head profile to its original design shape, slowing down the further development of surface defects, improving the smoothness of the rail surface, and achieving the goals of enhancing passenger comfort, reducing wheel-rail noise, and extending the rail’s lifespan. In addition to small-scale rail grinding tools, the major large-scale rail grinding equipment currently available in China mainly includes the GMC-96x rail grinding train, the CMC-20 rail grinding car (switch grinding car), the GMC-96b rail grinding train, and the PGM-48 rail grinding train etc. Each type of equipment has its unique capabilities and advantages.

サプライヤー

洛陽豊洋重工業株式会社, 株式会社, 1998年に設立された鉄道鋳造部品のメーカーです. 当社の工場面積は72,600㎡です。, 以上の 300 従業員, 32 技術者, 含む 5 シニアエンジニア, 11 アシスタントエンジニア, そして 16 技術者. 弊社の生産能力は 30,000 年間トン. 現在, 私たちは主に鋳物を生産しています, 機械加工, 機関車の組立て, 鉄道車両, 高速鉄道, 鉱山機械, 風力, 等.
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