A rail repair disc cutter with blade air cooling device and damping

Abstract

The application discloses a rail repair disc milling cutter with a blade air cooling device and damping resistance, which comprises a connecting flange plate, an integral cutter and a gas guide pipe, the connecting flange plate is fixed to the main shaft of a rail milling and grinding vehicle milling unit through bolts, the center of the integral cutter is provided with a clamping groove, a plurality of direct-current gas flow channels are arranged in the integral cutter and are communicated with the clamping groove, one end of the gas guide pipe is embedded in the clamping groove, and the other end of the gas guide pipe is connected with a gas storage unit of the rail milling and grinding vehicle, a plurality of deep grooves are formed in the integral cutter, and a damping resistance is arranged in each deep groove. Compared with the prior art, the rail repair disc milling cutter is provided with a nozzle type gas micro flow channel at each blade, so that each cutting edge can be air-cooled during cutting work, the temperature of the blade during cutting is reduced, the wear of the milling blade during machining is reduced, the probability of residual stress generated on the machined surface of the rail is reduced, and the impact on the integral cutter is reduced.

Description

Technical Field

[0001] This invention relates to the field of cutting tool machining technology, and in particular to a rail repair disc milling cutter with blade air cooling device and vibration damping. Background Technology

[0002] As a critical foundational component of the railway transportation network, the performance of rails directly impacts the stability and safety of train operations. The ever-increasing demand for rail transit leads to higher dynamic axle loads, train speeds, and traffic volumes, placing greater demands on the load-bearing capacity of rails. Under harsh and complex service conditions, rails are more prone to surface damage and defects during dynamic contact with wheels, such as railhead defects, corrugation, spalling, hidden damage, fatigue cracks, and pitting. These surface damages and defects can lead to rail failure and even derailment of high-speed trains. Therefore, it is essential to use online rail repair disc milling cutters for milling-grinding repair to periodically remove surface defects and restore the rail to its normal profile. During heavy-load milling, the difficult-to-machine nature of rail materials, the huge feed per tooth, the enormous cutting forces and periodic impacts generated during cutting, and the large amount of cutting heat cause severe wear and even chipping of the disc milling cutter inserts. This results in residual stress on the machined surface, reducing the rail's service performance and decreasing the repair efficiency of the disc milling cutter. Therefore, there is an urgent need for a rail repair disc milling cutter with blade air cooling and vibration reduction functions, which can effectively reduce the impact and vibration on the cutter head and blades during actual machining, while reducing the scrap rate of the blades, extending the service life of the blades, and improving the efficiency of milling repair.

[0003] Currently, there are some relatively mature devices for disc milling cutters used in online rail repair. For example, patent application CN201420222616.9 discloses a contour-following combination milling cutter for railway rail repair. Addressing the technical problems of existing railway rail maintenance and shaping equipment, such as low repair efficiency and inability to repair large burrs or flash on the rail top working surface, which prolongs rail repair time and increases repair costs, this invention provides a contour-following combination milling cutter for railway rail repair, enabling the rail top working surface to be shaped in one pass, thus improving the efficiency of rail repair operations. Another example is patent application CN201720314918.2, which discloses a forming disc milling cutter suitable for rail milling machines. Compared to ordinary disc milling cutters, it features an insert at a certain angle to the outer contour of the rail to remove severely burred edges. Furthermore, it incorporates finite element simulation based on a chip model to design a novel chip-receiving groove for the disc milling cutter. For example, the invention patent with patent application number CN201821586144.X discloses a milling cutter disc for milling steel rails. It designs a structure that can acquire milling status information of the milling cutter disc during the milling process and monitor the milling cutter disc, thereby preventing possible processing failures of the milling cutter disc and stopping processing in time.

[0004] However, existing technologies do not consider improving the harsh cutting conditions of disc milling cutters, resulting in short insert life during actual machining. This necessitates frequent pauses for insert replacement, reducing the efficiency of rail profile repair. Furthermore, frequent wear of inserts at various locations diminishes the effectiveness of rail profile repair. Summary of the Invention

[0005] This invention relates to a disc milling cutter for rail repair equipped with a blade air-cooling device and vibration damping. The purpose is to cool the blade during the cutting process, reduce the impact of cutting heat on the blade, and effectively reduce the impact and vibration on the cutter head and blade during actual machining. This reduces the wear rate of the blade, increases the service life of the blade, and also reduces the probability of residual stress on the machined surface, thus extending the service life of the blade and improving the efficiency of milling repair.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] According to one aspect of the present invention, a rail repair disc milling cutter with blade air cooling device and vibration damping is provided, comprising a connecting flange, an integral cutter head, and an air guide pipe. The connecting flange is fixedly connected to the integral cutter head and is fixedly connected to the spindle of the rail milling turning unit by bolts. The integral cutter head has a groove at its center and several direct current gas channels are provided inside the integral cutter head, all of which are connected to the groove. One end of the air guide pipe is embedded in the groove, and the other end is connected to the air storage unit of the rail milling turning vehicle. A fixing flange is fixedly provided on the end face of the integral cutter head on the side where the air guide pipe is provided, for pressing the integral cutter head and the air guide pipe together. Several deep grooves are formed around the fixing flange on this end face, each deep groove is evenly distributed at equal intervals, and each deep groove is provided with a nano-vibration damper. A damping cover plate is provided outside the deep groove to form a sealed space to protect the nano-vibration damper.

[0008] In the above technical solution, the overall cutter head further includes a central hub and a plurality of cutter holders evenly spaced in the circumferential direction. Each cutter holder is provided with a chip groove, each cutter holder is provided with a cutter slot, and each cutter slot is fixedly connected with a profiled blade assembly.

[0009] Furthermore, the profile blade group includes straight blades, arc blades, and edge-cleaning blades, wherein the arc blades and edge-cleaning blades in the profile blade group are fitted together to form the rail gauge angle profile.

[0010] Furthermore, the air guide tube is provided with several air vents, which correspond to the direct current gas flow channels. An annular air channel is provided inside the overall cutter head, and each direct current gas flow channel is connected to the annular air channel. Each cutter holder is provided with a nozzle-type gas microchannel, one end of which faces the cutting edge of the blade in the profile blade assembly, and the other end is connected to an auxiliary air channel, which is connected to the annular air channel.

[0011] Furthermore, a sealing ring is provided at the connection between the slot of the integral cutter head and the air guide pipe.

[0012] Furthermore, each of the aforementioned nano-vibration dampers includes a primary nano-vibration damper and a secondary nano-vibration damper. The mounting surface of the primary nano-vibration damper is perpendicular to the direction of the main cutting force on the straight insert and is used to absorb the tangential vibration of the disc milling cutter. The secondary nano-vibration damper is mounted at an angle of ° to the primary nano-vibration damper and is used to absorb the axial impact vibration of the disc milling cutter at the same frequency.

[0013] Furthermore, each of the secondary sonic dampers includes a secondary heavy metal damper, a guide post, and an elastic element. The guide posts are respectively disposed on the inner and outer sides of the secondary heavy metal damper. Each guide post is fixedly connected to one end of the elastic element, and the other end of the elastic element is fixedly connected to the end face of the corresponding secondary heavy metal damper. The guide post of the secondary heavy metal damper extends out of the damping cover plate and is threadedly connected to the damping cover plate. The side of the secondary heavy metal damper is provided with a groove for installing the primary sonic damper.

[0014] Furthermore, each of the main dampers includes a cover plate and a heavy metal damper. The heavy metal damper extends into the side groove of the secondary heavy metal damper. Elastic elements are fixedly connected to both end faces of the heavy metal damper. The other ends of the two elastic elements abut against the inner wall of the step of the side groove of the secondary heavy metal damper and the cover plate, respectively. The cover plate is fixedly connected to the secondary heavy metal damper by threads.

[0015] Furthermore, the elastic force of the elastic element in the main sonic damper is similar to the sum of the elastic forces of the corresponding secondary sonic damper elastic element.

[0016] Furthermore, a damping partition is fixedly connected to the damping cover plate, and a number of threaded holes penetrate the damping cover plate and the damping partition plate. The number of threaded holes in the damping cover plate is the same as the number of guide posts on the side of the outer end face of the overall cutter head in the secondary damping system. After the damping cover plate is installed, the guide posts and the threaded holes are threadedly engaged.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0018] This invention utilizes uniformly distributed nano-vibration dampers on the overall cutter head to absorb the impact vibrations of the disc milling cutter at various locations during machining, achieving localized vibration absorption. Pre-adjusting each nano-vibration damper allows for synchronized vibration reduction, lowering the impact on the disc milling cutter and reducing cutting instability caused by cutting vibrations. Furthermore, by incorporating gas flow channels within the overall cutter head, particularly nozzle-type micro-channels at each cutting edge, each cutting edge receives air cooling during cutting, reducing cutting edge temperature and wear, effectively extending cutting edge life during actual machining, and decreasing the probability of residual stress on the machined rail surface. It also enables rapid cutting edge cooling even when cutting fluid is prohibited. Attached Figure Description

[0019] Figure 1 This is an exploded perspective view of the overall structure of the disc milling cutter of the present invention;

[0020] Figure 2 This is a gas flow path diagram of the disc milling cutter of the present invention;

[0021] Figure 3 This is a schematic cross-sectional view of the gas flow channel in this invention;

[0022] Figure 4 This is an enlarged schematic diagram of the tool holder in this invention;

[0023] Figure 5 This is a schematic diagram of the air duct structure in this invention;

[0024] Figure 6 This is a schematic diagram of the disc milling cutter of the present invention from another perspective (the air guide tube is not shown in the figure);

[0025] Figure 7 For the present invention Figure 6 The diagram shown illustrates the operation of a disc milling cutter without a damper.

[0026] Figure 8 For the present invention Figure 6 The diagram shows a part of the damping cover plate removed by a disc milling cutter.

[0027] Figure 9 This is a schematic diagram of the installation of the nano-damping in this invention;

[0028] Figure 10 This is a schematic diagram of a nano-damping structure in this invention;

[0029] Figure 11 This is a schematic diagram showing the direction of the cutting force.

[0030] Figure 12 This is a schematic diagram of one structure of the fixed flange in this invention;

[0031] Figure 13 This is a schematic diagram of one structure of the connecting flange in this invention;

[0032] In the diagram: 1. Connecting flange; 2. Integral cutter head; 3. Profiled blade assembly; 4. Air guide pipe; 5. Fixed flange; 201. Direct flow gas channel; 202. Nozzle-type gas microchannel; 203. Annular air channel; 205. Auxiliary pipe; 206. Sonic damping; 207. Damping cover plate; 301. Straight blade; 302. Arc-shaped blade; 303. Edge cleaning blade; 401. Sealing ring; 402. Vent hole; 2061. Main sonic damping; 2062. Damping partition; 2063. Secondary sonic damping; 2064. Elastic element; 2065. Secondary heavy metal damping body; 2066. Guide column; 2067. Cover plate; 2068. Heavy metal damping body. Detailed Implementation

[0033] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0034] The purpose of this invention is to address the existing problems mentioned in the background section by providing a rail repair disc milling cutter with blade air cooling device and vibration damping, such as... Figure 1 , 5 As shown, it includes a connecting flange 1, an integral cutter head 2, and an air guide pipe 4. The connecting flange 1 and the integral cutter head 2 can be fixedly connected using studs, such as... Figure 7 As shown, the connecting flange 1 is fixedly connected to the spindle of the rail milling and turning unit by bolts, and the integral cutter head 2 has a groove in the center, as shown. Figure 2 , 3 As shown, the integral cutter head 2 has nine DC gas flow channels 201 inside, all of which are connected to the slots. One end of the air guide pipe 4 is embedded in the slot of the integral cutter head 2, and the other end is connected to the air storage unit of the rail milling car. The integral cutter head 2 has a fixed flange 5 on one side of the air guide pipe (e.g., Figure 12 As shown in the diagram, the fixed flange 5 has countersunk holes. Bolts are used to pass through these countersunk holes to fix the fixed flange 5 to the integral cutter head 2, and to press the air guide pipe 4 into the groove. (As shown in the diagram) Figure 6 and 7As shown, several deep grooves are formed around the fixed flange on the end face of the integral cutter head 2. Each deep groove is evenly distributed at equal intervals. In the example shown, the interval is 60°. Each deep groove is provided with a nano-vibration damper 206. A damping cover plate 207 is provided outside the deep groove and is fixed to the end face of the integral cutter head 2 with bolts to form a sealed space to protect the nano-vibration damper 206.

[0035] The integral cutter head 2 includes several uniformly spaced cutter holders in the circumferential direction. Each cutter holder is provided with a chip groove to accommodate the chips generated during cutting and to prevent the chips from affecting the surface of the steel rail. Each cutter holder is provided with a cutter groove, and a profiled blade assembly 3 is fixedly connected to each cutter groove.

[0036] like Figure 4 As shown, the profile blade group 3 includes a straight blade 301, an arc blade 302, and a burr removal blade 303. The arc blade 302 and the burr removal blade 303 in the profile blade group 3 are fitted together to form the rail gauge angle profile, which can more completely remove the burrs generated during the rail cutting process.

[0037] The air guide pipe 4 is provided with nine vent holes, corresponding to the direct current gas flow channel 201, for connecting the airflow pipe inside the air guide pipe with the direct current gas flow channel 201, such as... Figure 2 , 3 As shown in Figure 4

[0038] Each of the aforementioned tool holders is equipped with a nozzle-type gas microchannel 202. One end of the nozzle-type gas microchannel 202 faces the cutting edge of the blade in the profile blade assembly, and the other end is connected to an auxiliary air channel 205. The auxiliary air channel 205 is connected to an annular air channel 203, allowing airflow to flow from the gas storage unit of the rail milling machine into the annular air channel 203 through the direct gas channel 201, then be diverted to the auxiliary air channel 205, and finally precisely diverted to the cutting edge of each blade through the nozzle-type gas microchannel 202. This effectively cools the blades of the profile blade assembly, reduces the temperature of the machining contact surface, and reduces residual stress on the rail surface. In addition, an O-ring seal, i.e., a sealing ring 401, is provided at the connection between the slot of the integral tool holder 2 and the air guide pipe 4 (e.g., Figure 5 To prevent gas leakage, the air passages in the overall cutter head should be staggered from the deep groove positions to avoid intersections.

[0039] like Figures 8-11As shown, each of the aforementioned nano-vibration dampers 206 includes a main nano-vibration damper 2061 and a secondary nano-vibration damper 2063. The mounting surface of the main nano-vibration damper 2061 is perpendicular to the direction of the main cutting force on the straight blade. In this embodiment, the cutting edge of the straight blade makes a 9° angle with the axial direction of the integral cutter head 2. The mounting surface of the main nano-vibration damper 2061 makes a 9° angle with the axial direction of the integral cutter head 2. The mounting direction of the main nano-vibration damper is the same as the direction of the main cutting force on the integral cutter head 2. The mounting angle of the secondary nano-vibration damper 2063 with the main nano-vibration damper 2061 is 90°.

[0040] Each of the sub-damping elements 2063 includes a sub-heavy metal damping body 2065, a guide post 2066, and an elastic element 2064. The guide posts are respectively disposed on both sides of the sub-heavy metal damping body. In this embodiment, there are three guide posts at one end near the inside of the deep groove, and three grooves are provided on the corresponding mounting surface in the deep groove, which correspond to the guide posts near the inside of the deep groove, so as to facilitate positioning and fixing during installation. There are two guide posts at the other end. The number of guide posts at both ends can also be set to other numbers, as long as it is convenient for installation and processing.

[0041] Each of the five guide posts is equipped with an elastic element 2064. One end of the elastic element 2064 is fixedly connected to the guide post, and the other end is fixedly connected to the end face of the corresponding secondary heavy metal damping body 2065. In addition, the guide post near the end face of the overall cutter head 4 and the secondary heavy metal damping body can be connected by threads or kept at a certain distance. The secondary heavy metal damping body has a groove on its side. The damping cover plate 207 is fixedly connected to a damping partition plate 2062 and has two threaded holes that penetrate the damping cover plate 207 and the damping partition plate 2062. Each threaded hole of the damping cover plate 207 is used to install and adjust the two guide posts of the secondary sonic damper 2063 near the end face of the overall cutter head. Before the overall cutter head 2 is used, the sonic damping needs to be adjusted. At this time, the guide post in the threaded hole of the damping cover plate can be rotated with a screwdriver to control the distance between the end face of the guide post and the end face of the secondary heavy metal damping body, thereby controlling the tension of the elastic element to achieve adjustment.

[0042] Each of the main dampers 2061 includes a cover plate 2067 and a heavy metal damper 2068. The heavy metal damper 2068 extends into the side groove of the secondary heavy metal damper 2065. Elastic elements 2064 are fixedly connected to both end faces of the heavy metal damper, and the two elastic elements 2064 abut against the inner wall of the stepped side groove of the cover plate and the secondary heavy metal damper, respectively. The cover plate is threaded onto the secondary heavy metal damper, pressing the heavy metal damper into the side groove of the secondary heavy metal damper. Before the entire device is installed, the cover plate is rotated using an adjustable torque wrench to adjust the deformation of the elastic elements 2064 to adjust the elastic force, thereby achieving the predetermined torque and completing the pre-adjustment.

[0043] The elastic force of the elastic unit in the main sonic damper 2061 is similar to the sum of the elastic forces of the corresponding secondary sonic damper 2063 elastic unit. The heavy metal damper and the secondary heavy metal damper can be made of tungsten steel. The counterweight has a large mass and can absorb greater vibration impact in the same space.

[0044] Specifically, before the overall cutter head is put into operation and before installation, the cover plate of the main sonic damper is rotated using an adjustable torque wrench until the predetermined torque is reached, thus completing the pre-adjustment of the main sonic damper. Then, the two guide posts are passed through the threaded holes of the damping cover plate 207 and screwed into the secondary heavy metal damping body. The two guide posts are then adjusted using an adjustable torque screwdriver, with the predetermined torque being half of the pre-adjusted torque of the main sonic damper. After pre-adjustment, the sonic damper 206 is fixed in the deep groove using the damping cover plate 207. The overall cutter head is then put into operation. First, use a screwdriver to rotate the guide post in the threaded hole of the damping cover plate to control the distance between the end face of the guide post and the end face of the secondary heavy metal damping body for further adjustment. This can be demonstrated by tapping the overall cutter head 2. When the tapping sound stops quickly after tapping the cutter body, it indicates that the anti-vibration damping has taken effect. Then, fix the main shaft of the rail milling turning unit to the connecting flange with bolts, and then connect the air duct to the air storage unit of the rail milling turning car. Finally, place it on the rail. When the main shaft of the rail milling turning unit works, it drives the overall cutter head 2. After the disc 2 rotates, the integral cutter head works and cuts on the rail. Straight inserts are used to process the smoother curved sections of the rail profile, while arc-shaped inserts are used to process the curved sections with the greatest curvature of the rail profile. At the same time, the air storage unit of the rail milling carriage continuously supplies air to the air guide pipe. The airflow can flow from the air storage unit of the rail milling carriage into the annular air passage 203 through the direct gas flow channel 201, then be split into the auxiliary pipe 205, and finally be precisely split into the cutting edge of each insert through the nozzle-type gas micro-channel 202. This ensures that there is always air blowing from each nozzle-type gas micro-channel 202 onto the cutting edge of the insert in the profile insert group, so that the cutting edge and the rail in contact during cutting are cooled down, reducing the wear rate of the milling inserts during processing, effectively extending the life of the inserts during actual processing, and reducing the probability of residual stress on the processed surface of the rail. When the integral cutter head is subjected to vibration and impact, the main sonic damper absorbs the tangential vibration of the integral cutter head, and the secondary sonic damper absorbs the vibration of the integral cutter head in the left and right directions along the spindle, thereby reducing the impact on the integral cutter head.

[0045] The above specific embodiments are used to explain and illustrate the present invention, but not to limit the present invention. Any modifications and changes made to the present invention within the spirit and scope of the claims shall fall within the protection scope of the present invention.

Claims

1. A rail repair disc milling cutter with blade air-cooling device and vibration damping, characterized in that, The device includes a connecting flange (1), an integral cutter head (2), and a gas guide pipe (4). The connecting flange (1) is fixedly connected to the integral cutter head (2). The connecting flange (1) is fixedly connected to the spindle of the rail milling turning unit by bolts. The integral cutter head has a slot in the center. The integral cutter head (2) has several direct current gas channels (201) inside, all of which are connected to the slot. One end of the gas guide pipe (4) is embedded in the slot, and the other end is connected to the gas storage unit of the rail milling turning vehicle. A fixed flange (5) is fixedly installed on the end face of the integral cutter head (2) on the side where the gas guide pipe (4) is installed, which is used to press the integral cutter head (2) and the gas guide pipe (4). Several deep grooves are opened around the fixed flange on this end face. Each deep groove is evenly distributed at equal intervals. Each deep groove is provided with a nano-vibration damper (206). A damping cover plate (207) is provided outside the deep groove to form a closed space to protect the nano-vibration damper (206). The integral cutter head (2) includes a central hub and several cutter holders evenly spaced in the circumferential direction. Each cutter holder is provided with a chip groove, and each cutter holder is provided with a cutter groove. Each cutter groove is fixedly connected with a profile blade group (3). The profile blade group (3) includes a straight blade (301), an arc blade (302), and a cleaning edge blade (303). The arc blade (302) and the cleaning edge blade (303) in the profile blade group (3) are fitted together to form the rail gauge angle profile. Each of the aforementioned nano-vibration dampers (206) includes a main nano-vibration damper (2061) and a secondary nano-vibration damper (2063). The mounting surface of the main nano-vibration damper (2061) is perpendicular to the direction of the main cutting force on the straight insert and is used to absorb the tangential vibration of the disc milling cutter. The secondary nano-vibration damper (2063) is mounted at a 90° angle to the main nano-vibration damper (2061) and is used to absorb the axial impact vibration of the disc milling cutter at the same frequency. Each of the sub-sub ... Each of the main sonic dampers (2061) includes a cover plate (2067) and a heavy metal damper (2068). The heavy metal damper (2068) extends into the side groove of the secondary heavy metal damper (2065). Elastic elements (2064) are fixedly connected to the end faces of the two ends of the heavy metal damper. The other ends of the two elastic elements (2064) abut against the inner wall of the step of the side groove of the secondary heavy metal damper and the cover plate, respectively. The cover plate is fixedly connected to the secondary heavy metal damper by threads.

2. The rail repair disc milling cutter with blade air-cooling device and vibration damping as described in claim 1, characterized in that, The air guide tube (4) is provided with a plurality of air holes (402), the air holes corresponding to the direct current gas flow channel (201), and an annular air channel (203) is provided in the overall cutter head (2), each of the direct current gas flow channels (201) is connected to the annular air channel (203); each of the cutter holders is provided with a nozzle-type gas microchannel (202), one end of the nozzle-type gas microchannel (202) faces the cutting edge of the blade in the profile blade group, and the other end is connected to an auxiliary pipe (205), the auxiliary pipe (205) is connected to the annular air channel (203).

3. The rail repair disc milling cutter with blade air-cooling device and vibration damping as described in claim 1, characterized in that, A sealing ring (401) is provided at the connection between the slot of the integral cutter head (2) and the air guide pipe (4).

4. A rail repair disc milling cutter with blade air-cooling device and vibration damping as described in claim 1, characterized in that, The elastic force of the elastic element in the main sonic damper (2061) is similar to the sum of the elastic forces of the corresponding secondary sonic damper (2063).

5. A rail repair disc milling cutter with blade air-cooling device and vibration damping as described in claim 1, characterized in that, The damping cover plate (207) is fixedly connected to a damping partition plate (2062), and has several threaded holes that penetrate the damping cover plate (207) and the damping partition plate (2062). The number of threaded holes in the damping cover plate (207) is the same as the number of guide posts in the secondary damping damper (2063) near the outer end face of the overall cutter head (2). After the damping cover plate (207) is installed, the guide posts and the threaded holes are threaded together.

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