Manual Grinding of Rail Profile (Conventional Speed) Operation Instructions

I. Scope of application:

Rail wave wear, rail fat edge, saddle wear, weld convexity and fish scale pattern, as well as uneven top surface of fixed frog and movable heart rail, fat edge of point rail, fixed frog, movable heart rail, wing rail working edge and non-working edge of point rail, poor light band, and poor track dynamics caused by rail profile.

II. Standards and quality requirements

1. Working edge fat edge, weld depression, rail base material rail top surface depression, saddle wear, less than 0.3mm for lines with Vmax＞120km/h; less than 0.5mm for lines with Vmax≤120km/h.

2. Wave wear less than 0.2mm.

3. The light band is centered and straight, with a width of 20-30mm, and no continuous blue band. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕 󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

4. Use the rail profile detector to check the profile after operation, and use the rail profile analysis software to perform profile comparison and analysis to determine whether it meets the rail design profile requirements (the comprehensive evaluation reaches more than 70%). 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢 󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

III. Work flow chart Workload survey → Profile analysis, plan formulation → Preparation work → Grinding work

1. Workload survey, determine the grinding position. Select the corresponding observation point according to the existing rail status, use the rail profile detector or profile template to measure, and when using the profile template to measure, use a feeler gauge to measure according to the fit of the profile template. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬 󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟�According to 60N, CHN60 (determined according to the existing track type ) Comparative Analysis of Standard Silhouettes

2. Profile Analysis and Plan Development

2.1 When measuring with a rail profile detector, use rail profile analysis software to compare and analyze the standard profiles of 60N and CHN60 (determined based on the existing rail type). Develop a grinding plan to determine the grinding amount and number of passes. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘 󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

2.2 When using a profile template for measurement, use a feeler gauge to determine the amount of grinding and the number of grinding passes. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒

3. Prepare for the work and test run the grinding machine to ensure normal use. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣

IV. Grinding operation:

Carry out the contour grinding operation in the order of fattening the edge first, grinding the top, focusing on the outer contour, then the inner contour, eliminating the tip plastic, and removing the wing (see the attached figure) and the grinding plan. The machine operator must move at a uniform speed, observe the degree of spark flying, and control the grinding intensity. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣 󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

4.1 Use a rail milling machine to grind larger fat edges, and use a switch grinder to grind smaller fat edges. Grind the fat edges of both the non-working edge of the point rail and the working edge of the stock rail at the same time. 󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

4.2 Use a vertical grinder to perform profile grinding according to the grinding amount and number of passes specified in the grinding strategy. The inner part of the rail head (light band position) is not ground. Focus on grinding the non-working edge and then the working edge. When passing through harmful spaces in frogs, manual assistance is required to prevent the running wheels from deviating in harmful spaces. During the grinding process, use the profile template to measure and control the grinding amount. 󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

4.3 The fat edges of rail ends, fat edges of turnout wing rails, worn raised areas, and areas where the point rail and frog core cannot be reached by the grinder need to be ground and pried along with the tool. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢

V. Tools, Equipment, Machinery, and Materials

1. Tools: Special wrench for the grinder.

2. Instruments: Universal track ruler, rail profile tester, profile template, 1-meter ruler, and feeler gauge. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭

3.Machinery: track milling machine, switch grinding machine, vertical grinding machine, lithium-electric angle grinder, wind-powered snowplow. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒 󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗

4. Materials: rail milling machine cutter head, 125×65×20, 250×25×32, 125×6×22 grinding wheels. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙 󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

VI. Safety Risk Reminders

1. When starting or shutting down the grinder, the grinding wheel must not come close to the rail to avoid damaging the base material.

2. Properly wear labor protection equipment and pay attention to driving safety. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠆘󠆭󠆘󠇙󠆝

3. Before grinding, properly adjust the grinding wheel guard of the vertical grinder to avoid affecting the grinding quality and preventing the grinding wheel from breaking and flying and injuring people. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒

4. After grinding, clean the insulating joints and iron filings on the slide bed. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧

󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮5. Carry fire prevention and fire extinguishing equipment and pay attention to fire prevention. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙

󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮6. Track circuit sections and electrified sections require the cooperation of the electrical department to prevent damage or impact on their equipment during grinding. 󠄐󠄹󠅀󠄪󠄡󠄡󠄦󠄞󠄢󠄢󠄦󠄞󠄢󠄦󠄞󠄡󠄨󠄠󠄬󠅒󠅢󠄟󠄮󠄐󠅅󠄹󠄴󠄪󠄡󠄬󠅒󠅢󠄟󠄮󠄾󠅑󠅝󠅕󠄪󠄡󠄣 󠄢󠄧󠄩󠄡󠄩󠄧󠄩󠄧󠄩󠄬󠅒󠅢󠄟󠄮󠇘󠆭󠆘󠇙󠆝󠅵󠇗󠆭󠆁󠄐󠇗󠅹󠅸󠇖󠆍󠅳󠇖󠅹󠅰󠇖󠆌󠅹󠄬󠅒󠅢󠄟󠄮

Recommend the rail grinding machine link:  http://www.tiegongcn.com/rail-grinding-series/electric-rail-grinding-machine/eelctric-profile-rail-grinding-machine-motor.html

 

More Details , please contact me:

Alina Shen

Jinzhou Tiegong Railway Maintenance Machinery Co.,Ltd.

E-mail: jztg0115@163.com / alina@tiegong.net

M.P/Wechat/Whatsapp:+86-18341633378

Mobile: +86-15041639960

Web: https://www.tiegongcn.com