After a long operating period of the rail the radius of the running edge may change or seamy formations may occur. The following method is employed for deburring and re-profiling the rail edges: The edges are ground with rotating cylindrical grinding wheels and the wheel spindles can be inclined up to 60º. For deburring purpose a fixed angle setting is adequate. For reprofiling several passes with an angle difference of approx. 15º are necessary, depending on the accuracy of the radius required (Fig. B).

Corrugation grinding Rate/h Grinding wheel

In rail metres consumption/h

Corrugation depth up to 0.0787" 984’ approx. 10

Corrugation depth up to 0.0157" 492’ approx. 12

The present price per grinding wheel (3.94"x4.33"xM20left) is approx. US$26.00. Per working shift (5 to 8 h) 1 dust filter mats must be replaced. The price per filter mat is approx. US$20.00

Re-profiling Rate/h Grinding wheel

In rail metres consumption/h

Re-profiling of the running edge 984’ approx. 10

Corrugation grinding spindle 1 ea. every 250 h Unit price approx. US$2,500.00

Gas pressure 1 ea. every 500 h Unit price approx. US$ 100.00

Although all maintenance task specified in the maintenance table can be performed by authorized personnel, we recommend having a factory check carried out every 1000 h by our own personnel.

CORRUGATION GRINDING MACHINE

The Corrugation Grinding Machine AT 1002 K60 has been specially designed for use on "T" and Girder rails. Its compact size and exceptionally easy handling ensure economical application whether under normal service conditions or with LRV operating intervals of under five minutes. Maximum on- and off-tracking time is 30 seconds. The machine is raised and driven sideways from the track by electric power. The machine is designed for one-man operation and can be employed on "T" and Girder rails. Crossings and switches as well as tight curves (R > 10 m) can also be ground. The track width is infinitely adjustable from 38.5" – 59.1".

The Corrugation Grinding Machine AT 1002 K60 is designed on the one hand for grinding middle and short pitch corrugation (Fig. A), and on the other for deburring and re-profiling of the gauge-side edge and the field-side edge of "T" and Girder rails (Fig. B).

Short pitch corrugation consists of small ridges which form on the traction head of the rail causing noise and wear in the rolling stock. For corrugation grinding the traction head is ground with two rotating cylindrical grinding wheels arranged in succession (Fig. A). One of two grinding passes is made per operation, depending on the corrugation depth. By adjusting the vertical axes of the grinding wheels, the traction head can be re-profiled in multi-facets mode. The difference in grinding angle and the number of single operations depends on the rail shape or on customer requirements (usually 4-5 operations).

After a long operating period of the rail, the radius of the gauge-side edge may change or seam formations may occur. The following method is employed for deburring and re-profiling the rail edges. The edges are ground with rotating cylindrical grinding wheels and the wheel spindles can be inclined up to 60º. For deburring purposes a fixed angle setting is adequate. For re-profiling several passes with an angle difference of approximately 15º are necessary, depending on the accuracy of the radius required (Fig. B).

With corrugation depths up to 0.0118" and an average of 6 passes, it is possible to finish-grind 574’ to 656’ of rail per hour.

The feed rate of the machine is approximately 82’ to 131’/minute.

In operation the machine can surmount gradients of up to 6%.

The machine is supplied via cable with three-phase current (standard 3 x 400 V). Normally, this is supplied from a sound-dampened diesel generator which should have an output of at least 25 KVA. The cable can be up to 656’. The generator is usually permanently mounted on a small truck (approximately 4 ton capacity). This vehicle is equipped with a lifting platform of 1.1 ton load capacity for transporting the corrugation grinding machine.

The machine is raised to two electric elevating motors on two solid-tire wheels arranged in the gravity axis. These wheels are driven by geared motors, enabling the machine to be rapidly driven off sideways away from the danger zone. For this purpose an appropriate cross-way must be provided in the open track.

Cylindrical cup-type grinding wheels are used, with diameters ranging from 3.5" to 4.3" and heights of 3.5" to 4.7". The mounting hole is 0.87". The product from WEGUSTA, Düsseldorf, has proved highly satisfactory (dia. 39.4" x 43.3" x 0.87"). With two cylindrical grinding wheels, it is possible to finish-grind a rail length of approximately 263’.

Maintenance of the machine is confined to daily cleaning and greasing of a few bearings. A yearly overhaul is recommended if the machine is in daily use.

Wearing parts include spindle nuts, roller bearings in the grinding spindles as well as V-belts and possibly V-belt pulleys. These are commonly available standard parts.

The repair service is assured at all times by Railquip, Inc. Guarantee covers one year in accordance with the manufacturer’s terms and conditions.

The three functions are carried out manually with a hand wheel provided for each function.

Dimensions: Track widths 38.6" to 59.1"

Length 63"

Width Track width +15.7"

Height 51.2"

Weight: 1,433 lbs.

Grinding spindle drives: Three-phase motor 15 kW, 400 V / 60 Hz

Speeds: Motor 3000 rpm

Cyl. grinding wheels: 6000 rpm

Feed drive: 2 geared motors 0.25 / 0.35 kW

In- and off-tracking device: 2 geared motors 0.25 kW

Work lighting: 2 spot lights 24 V

Electrical connection: 5 pole plug