Rail Wheel Reprofiling With Controlled Deep Rolling Force
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Solution Overview
Problem
Existing methods for machining wheel running surfaces of rail vehicles do not ensure uniform boundary layer formation during deep rolling, resulting in reprofiled geometries with varying strength properties and potential changes to the original geometry.
Innovation Solution
Implementing a method where roller machining is performed under controlled force after reprofiling, allowing for defined rolling forces to be applied at specific points, enabling optimized surface homogeneity and geometry through successive measuring and machining steps, including the use of clamping units for flexible tool usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep rolling is performed without controlled force, then the process is simple and fast, but the surface homogeneity and strength properties vary
Solution Approach 1:
The patent applies controlled rolling forces with defined magnitude and distribution during the deep rolling process. By parameterizing the rolling force (magnitude, direction, and distribution), the process achieves uniform boundary layer formation and consistent strength properties across the wheel running surface, resolving the contradiction between simplicity and precision.
Solution Approach 2:
The patent incorporates successive measuring and machining steps where the surface geometry and properties are measured, and the rolling process is adjusted based on this feedback. This closed-loop approach ensures uniform boundary layer formation while maintaining process control, addressing the precision-complexity contradiction.
2Manufacturing precision
If multiple machining steps are performed to ensure uniform boundary layer, then surface quality improves, but processing time increases
Solution Approach 1:
The patent performs reprofiling and deep rolling in a predetermined sequence where the reprofiling prepares the surface geometry first, followed by controlled deep rolling that forms the boundary layer in one optimized pass. This preliminary preparation enables subsequent steps to be more efficient, reducing total processing time while ensuring boundary layer uniformity.
Solution Approach 2:
The patent implements successive measuring and machining steps that continue until the target geometry and surface properties are achieved. This continuous process ensures uniform boundary layer formation while optimizing the number of passes required, balancing precision and productivity.
3Manufacturing precision
If controlled rolling force is applied at defined points, then surface homogeneity improves, but device complexity increases
Solution Approach 1:
The patent employs a clamping unit that can alternatively receive different tools including turning tools and rolling tools. This multi-functional device reduces overall system complexity by consolidating multiple operations into a single versatile unit, while still enabling controlled rolling force application at defined points for surface homogeneity.
Solution Approach 2:
The clamping unit is designed to be positionally definable and adaptable, allowing it to accommodate different tool types and configurations based on the specific machining requirements. This dynamic adaptability reduces the need for multiple dedicated devices, lowering overall system complexity while maintaining manufacturing precision.
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 approach achieves a significantly homogenized surface finish with optimized geometry, improving surface quality and extending the service life of rail vehicle wheels by ensuring consistent strength properties across the reprofiled surface.
Implementation Method 1
The direct component contact area is plastically deformed while the adjacent contact area is elastically deformed
Implementation Method 2
introducing residual compressive stresses into the surfaces of rotation-symmetric objects
Implementation Method 3
the adjacent contact area is elastically deformed
Implementation Method 4
the work hardening of the wheel running surfaces achieves a finishing or reduction of the surface roughness, a hardening of the boundary layer
Implementation Method 5
suitable rolling elements are guided over the finished component surface under contact pressure
Implementation Method 6
with minor notches being leveled or the material in the plastically deformed volume is strengthened
Data Source
AI summary
A device for machining wheel running surfaces of a wheel for a rail vehicle includes a wheel machining machine having a machining tool for performing a re-profiling process on the wheel and a rolling tool for performing a rolling process on the wheel and applying a rolling force to the wheel. A clamping unit is alternatively used as a receptacle for the machining tool or for the rolling tool. A first drive motor drives a first feed axle to translate the clamping unit along a first axis. A second drive motor drives a second feed axle to translate the clamping unit along a second axis perpendicular to the first axis. A control module adjusts the rolling force by controlling torques of the first and second drive motors.