Rail Profile Milling with Fluid-Adjusted Cutting Plates
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Solution Overview
Problem
Existing rail milling technologies face challenges in achieving high accuracy and preventing corrugation patterns, requiring post-machining steps due to limitations in cutting edge alignment and material removal precision.
Innovation Solution
A mobile device with a milling body and adjustable cutting plates that can be deflected radially or axially using a pressure transmission fluid, allowing for precise positioning and fixation without mechanical changes, enabling accurate milling of rail profiles with deviations less than 1/100 mm and avoiding post-machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If peripheral milling with cutting edges distributed over the periphery of the milling body is used to increase machining speed, then productivity is improved, but manufacturing precision deteriorates due to corrugated surface and increasing distance between material removing devices
Solution Approach 1:
The milling body is segmented into multiple cutting plates arranged in axial groups, with each cutting plate having multiple cutting edges. This segmentation allows for optimized material removal while maintaining surface quality by distributing cutting actions across multiple discrete elements rather than relying on a single peripheral arrangement.
Solution Approach 2:
Different axial groups of cutting plates are positioned at specific radial distances from the axis of rotation, creating local variations in cutting geometry. This allows each axial group to perform optimized cutting functions, with cutting edges in different axial groups removing material at different rates and positions, thereby preventing corrugation patterns while maintaining high productivity.
2Manufacturing precision
If cutting plates are fixed rigidly to achieve high manufacturing precision, then manufacturing precision is improved, but adaptability deteriorates due to inability to adjust for different rail profiles and wear conditions
Solution Approach 1:
The cutting plates are mounted on adjustable supports that allow dynamic repositioning of cutting edges in the radial direction. This dynamic adjustment capability enables the milling device to adapt to different rail profiles and wear conditions while maintaining precise cutting edge alignment during operation, resolving the contradiction between rigidity and adaptability.
Solution Approach 2:
The radial position of cutting edges can be changed by adjusting the supports, allowing modification of cutting parameters without changing the fundamental milling mechanism. This parameter adjustment capability provides versatility for different rail conditions while maintaining the precision benefits of rigid cutting plate construction during actual milling operations.
3Manufacturing precision
If multiple passes are used in rail planning to achieve high manufacturing precision, then manufacturing precision is improved, but productivity deteriorates due to relatively long machining time
Solution Approach 1:
Multiple cutting edges on each cutting plate and multiple axial groups are configured to perform preliminary material removal actions simultaneously during a single pass. This preliminary action approach removes the need for multiple sequential passes required in traditional planning, thereby achieving high profile accuracy while significantly reducing total machining time.
Solution Approach 2:
The milling device maintains continuous cutting action across multiple axial groups and cutting edges simultaneously, eliminating the intermittent stopping and starting characteristic of multi-pass planning operations. This continuous useful action achieves both high precision through comprehensive material removal and high productivity by eliminating idle time between passes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves high accuracy in rail milling, maintaining the advantages of milling such as high material removal capacity and low heat generation while preventing corrugation patterns, allowing for precise adjustment of cutting depth and reducing material input into the track.
Implementation Method 1
The adjusting means (8) is configured to be movable and/or deformable by a pressure transmission fluid
Data Source
AI summary
A device for milling a profile of a rail track intended for rail-bound vehicles includes at least one milling body that is capable of being driven in a rotationally movable manner about an axis of rotation, and a plurality of cutting plates attached to the at least one milling body. At least some of the cutting plates are capable of being pretensioned non-positively for fixing in a respective receiver by at least one clamping body against an abutment as a stop. The at least some of the cutting plates are capable of being deflected in the respective receiver in a radial and/or axial direction by an adjusting means and are capable of being fixed in an adjusted position by the clamping body. The adjusting means is configured to be movable and/or deformable by a pressure transmission fluid.