【摘要】：鋼軌因車輛的頻繁行駛而產(chǎn)生的磨耗與損傷嚴(yán)重影響了行車的平穩(wěn)性與安全性,需要采用鋼軌打磨車進(jìn)行在線打磨修復(fù)。由于打磨經(jīng)驗(yàn)及工藝機(jī)理的缺乏,作業(yè)過程中難以保證打磨的效率及質(zhì)量,甚至發(fā)生過度磨削、損傷鋼軌的嚴(yán)重事故。軌道交通的快速發(fā)展使得這一問題越來越突出。為此,本文結(jié)合鋼軌打磨車的作業(yè)特點(diǎn),建立鋼軌打磨車磨削性能與工藝參數(shù)之間的理論模型,探討鋼軌打磨的工藝規(guī)律,為鋼軌打磨作業(yè)及打磨裝備的研發(fā)提供理論支撐。明確鋼軌打磨參數(shù)對鋼軌廓型變化的影響規(guī)律是設(shè)定打磨關(guān)鍵參數(shù)、實(shí)現(xiàn)目標(biāo)廓型的重要依據(jù)。因此,首先基于作業(yè)形式建立打磨砂輪與鋼軌的空間幾何模型,分別探討不同砂輪擺角與磨削深度對鋼軌廓型、磨削面積及打磨面寬度的影響規(guī)律。其次,進(jìn)一步分析由多個打磨砂輪構(gòu)成的打磨模式對鋼軌廓型變化的影響。最終,利用上述規(guī)律實(shí)現(xiàn)所需打磨模式的設(shè)定：依據(jù)砂輪數(shù)目、鋼軌目標(biāo)廓型及待磨廓型以確定砂輪的磨削位置、擺角及對應(yīng)的磨削深度。上述分析得到不同打磨參數(shù)對鋼軌的影響規(guī)律并確定打磨模式的設(shè)定準(zhǔn)則,而為了接近砂輪真實(shí)的磨削狀態(tài),須構(gòu)造具備穩(wěn)定磨削層的砂輪模型以實(shí)現(xiàn)對打磨過程的描述。具體的,以磨削層球體磨粒截圓面積和的方差作為磨削層均勻度的判斷準(zhǔn)則,將等間距分布的球體磨�？臻g模型進(jìn)行多次振動達(dá)到磨削層空間穩(wěn)定狀態(tài)；選取具有代表性的磨削層作為打磨砂輪的磨削表面,并將其表面磨粒的形狀與位姿進(jìn)行隨機(jī)變換以構(gòu)建能夠提供穩(wěn)定切削角的表面磨粒,最終生成打磨砂輪磨削表面形貌�；谀チ？臻g分布所獲得的砂輪表面形貌生成是進(jìn)行磨削性能分析、獲得被磨鋼軌數(shù)據(jù)的重要基礎(chǔ)。首先,結(jié)合打磨砂輪特點(diǎn)及打磨車行車條件可獲得磨粒與鋼軌的接觸線長度及切削軌跡分布等磨削要素隨切削速度的變化規(guī)律。其次,基于.磨粒切削鋼軌的幾何與受力模型建立磨粒對鋼軌表面的三維切削模型并獲得被磨鋼軌的形貌變化,得到打磨砂輪設(shè)定功率與磨粒名義切削深度、砂輪磨削深度的對應(yīng)關(guān)系。最后,利用鋼軌打磨試驗(yàn)臺驗(yàn)證上述規(guī)律的有效性,包括單個砂輪設(shè)定功率與磨削深度的關(guān)系驗(yàn)證以及多個砂輪順序打磨鋼軌的效果驗(yàn)證。鋼軌打磨車的打磨作業(yè)是在行駛狀態(tài)下完成的。其所具備的軌道車輛特性將影響打磨砂輪與鋼軌的磨削接觸關(guān)系,改變打磨砂輪的磨削位置或磨削深度,進(jìn)而影響磨削結(jié)果。為此,首先建立鋼軌打磨車的垂向動態(tài)模型,分析鋼軌打磨車行駛狀態(tài)對打磨砂輪垂向位移的影響。其次,建立鋼軌打磨車三維模型以分析其行駛狀態(tài)所引起的輪對橫移現(xiàn)象,并獲得不同的輪對橫移量在橫向及垂向上對打磨砂輪磨削位置的影響。最終,獲得鋼軌打磨車行駛狀態(tài)對砂輪磨削的影響規(guī)律并對相應(yīng)的磨削模型進(jìn)行修正,以更加貼近實(shí)際的鋼軌打磨作業(yè)狀態(tài)。
[Abstract]:The wear and damage of rail caused by the frequent driving of the vehicle seriously affect the stability and safety of the train. It is necessary to use the rail grinding car for on-line grinding and repair. Due to the lack of grinding experience and the process mechanism, it is difficult to ensure the efficiency and quality of the grinding in the process of operation, even over grinding, and the serious damage to the rail is damaged. Therefore, the rapid development of rail traffic makes this problem more and more outstanding. Therefore, this paper, combining the working characteristics of the rail grinding car, establishes the theoretical model between the grinding performance and the technological parameters of the rail grinding car, discusses the technological rules of the rail grinding, and provides the theoretical support for the rail grinding operation and the research and development of the grinding equipment. The influence of grinding parameters on the change of rail profile is an important basis for setting the key parameters of grinding and realizing the profile of the target. Therefore, the geometric model of the grinding wheel and rail is established based on the operation form, and the influence of the angle and depth of the grinding wheel on the rail profile, the grinding area and the width of the grinding surface is discussed respectively. Further analysis is made on the influence of the grinding mode composed of multiple grinding wheels on the change of rail profile. Finally, the required grinding mode is set by the above rules: the grinding position of the grinding wheel, the swing angle and the corresponding grinding depth are determined on the basis of the number of grinding wheels, the target profile of the rail and the shape of the grinding profile. The rule of the influence of the parameters on the rail and the setting criterion of the grinding mode is determined. In order to close the grinding state of the grinding wheel, a model of grinding wheel with stable grinding layer must be constructed to describe the grinding process. The distributed spherical abrasive space model is used for multiple vibration to achieve the stability of the grinding layer, and the representative grinding layer is selected as the grinding surface of the grinding wheel, and the shape and position of the surface abrasive particles are randomly transformed to build the surface grinding grain which can provide the stable cutting angle and finally produce the grinding surface of the grinding wheel. The surface morphology of the grinding wheel based on the spatial distribution of abrasive particles is an important basis for grinding the grinding rail data. First, the length of the contact line of the abrasive and rail and the distribution of the cutting trajectory with the cutting speed can be obtained by the characteristics of grinding wheel and the driving condition of the grinding vehicle. Secondly, based on the geometry and stress model of the abrasive cutting rail, the three-dimensional cutting model of the abrasive grain on the rail surface is established and the change of the shape of the worn rail is obtained. The corresponding relationship between the nominal cutting depth of the grinding wheel and the grinding depth of the grinding wheel and the grinding depth of the grinding wheel is obtained. Finally, the effectiveness of the above rules is verified by the rail grinding test bench. It includes the verification of the relationship between the set power of a single grinding wheel and the grinding depth and the verification of the effect of multiple grinding wheels in the order of grinding the rail. The grinding operation of the rail grinding car is completed under the running state. The characteristics of the rail vehicle will affect the grinding contact between grinding wheel and rail, and change the grinding position or grinding of the grinding wheel. For this reason, the vertical dynamic model of the rail grinding vehicle is first established, and the influence of the running state of the rail grinding wheel on the vertical displacement of the grinding wheel is analyzed. Secondly, the three dimensional model of the rail grinding car is established to analyze the shift of the wheel set caused by the running state, and the transversal displacement of different wheelset is obtained. And the effect of vertical grinding wheel on grinding wheel grinding wheel. Finally, the influence law of the running state of the rail grinding wheel on grinding wheel grinding is obtained and the corresponding grinding model is corrected so as to be closer to the actual working state of the rail grinding.
【學(xué)位授予單位】：北京交通大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2015
【分類號】：U216.65;TG580.6

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