Abele, Eberhard ; Turan, Emrah ; Falk, Florian ; Tamuzkhah, Ehsan ; Khodabakhshi, Shahrokh ; Gares, Makrem (2016):
High Speed Rail Milling – New Approach to increase the productivity and process quality in maintenance of rails.
13th High Speed Machining Conference 2016, Metz (France), October 4th – 5th, 2016, [Conference or Workshop Item]

Abstract

As the growing rail freight traffic and the passenger transport accelerate the formation of rail wear the maintenance of the rail network is necessary. In this context the high speed rail milling enables the realization of a reduced processing time for the maintenance and optimized surface quality. In this paper, the cutting forces, the chip formation and the surface quality are investigated for different cutting edge geometries under variation of the process parameters. It has been found out that the cutting forces can be reduced by choosing a positive rake angle and decreasing the feed per tooth whereby the cutting speed does not have a significant influence on the cutting forces. The surface roughness measurements have shown that the surface quality diminishes with increasing feed per tooth. However, there are no significant differences between the surface roughness values of the rail surfaces produced by the tool with the negative and the positive rake angle. Chip investigations revealed a formation of adiabatic shear bands (ASB) between adjoined saw-tooth shaped chip segments. An increase in cutting speed causes a reduction of the width of ASB’s whilst the shear band angle also decreases.

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