Assessment of rail grinding maintenance surface quality and damage propagation in subsequent loading cycles for premium rail grades

Rail samples were tested under various scenarios as part of a complete analysis of the rail grinding process. Two main group of tests were performed which assessed the following: 1) preventive and corrective maintenance on fresh rail samples and 2) post-grinding tribological performance of the ground samples. The results allowed further knowledge to be acquired with regards to the performance and effectiveness of the grinding process and its effect on the surface quality of the rail samples. Results indicated a correlation between White Etching Layer and the formation of cracks and defects. Additionally, the harder grades were found to retain larger quantities of White Etching Layer upon completion of the rolling/sliding testing due to the hardness gradient between the White Etching Layer and bulk material, promoting the formation of cracks

Post-field grinding evaluation of different rail grades in full-scale wheel/rail laboratory tests

Rail grinding is a maintenance task performed in the field to return it to profile and/or remove damage, however, it can affect the surface integrity of the rail. In this paper, the damage resistance of three different ground rails (R260, R350HT and R400HT) was evaluated. Rail samples were ground using the same parameters in a low-traffic line in the field. The rail metallurgy was then examined, and white etching layer (WEL) formation was evaluated. The resistance to wear and rolling contact fatigue (RCF) was studied in a Full-Scale Rig (FSR). Cracking was detected and, in some cases, WEL was found pressed into the pearlitic microstructure whereas in others the bonding between the WEL and the pearlite failed leading to delamination

A laboratory demonstration of rail grinding and analysis of running roughness and wear

Rail grinding has been widely used for rail maintenance to keep the performance of the rail track at satisfactory levels. However, there is a lack of knowledge on the relationship between different grinding parameters and the effect on the rails and the post-grinding evolution of roughness and wear. Rail undergoes significant levels of stress during grinding to remove any defects that appear during its life-cycle which can cause significant microstructural change. By developing a method of demonstrating rail grinding it will allow further investigation of the process and potentially the exploration of different grinding patterns. Moreover, an analysis of the roughness of wheel and rail is an input parameter in most modern simulation tools that could be associated with the coefficient of friction. This paper reports a laboratory demonstration of rail grinding followed by a series of tests to determine the wear of the rail and if there is a relationship between friction coefficient and roughness. The rail specimens that were ground have undergone a phase transformation and showed White Etching Layer (WEL) on the contact surface. This was found to initially act protectively for the rail disc reducing the wear rates, but then contributed to crack formation. No clear long-term correlation was identified between the coefficient of friction and roughness during the testing, however a relationship could be drawn when test periods were studied individually