Rail Reprofiling with Pulsating Forming to Smooth Milling Corrugation
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Solution Overview
Problem
Existing methods for reprofiling rail tracks result in significant noise pollution due to milling corrugations, which are difficult to eliminate and require lengthy machining times, often involving hazardous grinding processes that produce dust and increase environmental and health risks.
Innovation Solution
A method involving a machining vehicle equipped with a machining unit containing a first machining aggregate with a rotationally driven chip-removing milling wheel and a second machining aggregate for plastic deformation of corrugation crests, applying a pulsating forming force to reduce and modify surface corrugation without continuous tool contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding or sliding grinding stones are used to eliminate milling corrugations, then surface smoothness is improved, but machining time increases and dust is generated
Solution Approach 1:
The patent replaces the traditional mechanical grinding process with a hydraulic pressing process. Instead of using rotating grinding stones that mechanically remove material through abrasion, the invention uses a hydraulically actuated pressing device that applies controlled pressure to the rail surface. This substitution eliminates dust generation while maintaining surface smoothness and reducing machining time, as the hydraulic system can quickly apply and release pressure without the inertia associated with rotating grinding equipment.
Solution Approach 2:
The patent employs a hydraulic pressing device with a hydraulically actuated piston to apply pressure to the rail surface. The hydraulic system allows for precise control of the pressing force and duration, enabling efficient elimination of milling corrugations. The hydraulic fluid transmission provides smooth, controlled pressure application that effectively smooths the surface without the dust and time losses associated with traditional grinding methods.
2Object-affected harmful factors
If belt grinders or face milling cutters are used to remove milling corrugations, then noise pollution is reduced, but machining time increases
Solution Approach 1:
The patent replaces rotational grinding or milling systems with a direct hydraulic pressing mechanism. This substitution eliminates the noise generated by high-speed rotating belts or cutters while achieving the same surface smoothing effect. The hydraulic pressing device operates quietly through fluid pressure transmission, and its rapid actuation cycle maintains efficiency without the time-consuming continuous contact of traditional grinding methods.
3Productivity
If continuous contact of machining tool with running surface is used, then material removal is efficient, but surface hardening is reduced
Solution Approach 1:
The patent implements periodic pressing cycles where the hydraulic piston applies pressure to the rail surface in repeated cycles. Each cycle consists of a pressing phase that eliminates corrugations and a release phase that allows the material to recover and harden. This periodic action maintains high productivity through continuous cycling while enabling surface hardening during the release intervals, solving the contradiction between efficient material removal and surface strengthening.
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
This method achieves shorter machining times, reduces noise pollution, avoids dust and environmental hazards, and results in surface hardening and longer rail service life, while allowing for precise reprofiling and adaptation to different operating conditions.
Implementation Method 1
at least the corrugation crests are plastically deformed and leveled
Implementation Method 2
a pulsating forming force is applied to the running surface to be machined
Implementation Method 3
the rail surface is shot peened, at least in the region of the running surface
Implementation Method 4
with an Almen value which satisfies the formula A=B×Z2+C
Implementation Method 5
impact forces are applied intermittently, a plurality of hammer tools being mounted in a common tool carrier
Implementation Method 6
device for compacting and consolidating rail parts
Data Source
AI summary
In a reprofiling method of a rail (2) of a laid rail track (1) during a travel movement of a machining vehicle (13) along a rail track (1) in a section of its running surface (10) located on the rail head (5), a machining unit (14) includes a first and a second machining aggregate (16, 20). In a first machining step, material is removed in a milling process. In this process, a surface corrugation with corrugation crests (18) and corrugation troughs (19) is formed. In the second machining step, the surface corrugation is reduced by plastic deformation of the corrugation crests (18) by at least one forming force (21) directed towards the running surface (10) to be machined and applied in a pulsating manner.