Design And Optimization Research Of The Milling Cutter For Rail Milling Train

After a long term of rolling, the deterioration of rail surface conditions and the accumulation of deformation of rail head will lead to bad wheel-rail contact conditions, shorting its service life and even endangering the running safety of the train. Rail milling train is a kind of new rail repair equipment. Compared with the traditional rail repair equipment, rail milling train has a lot of advantages, such as shorter prepare time, less environmental pollution, higher efficiency, lower operation cost, less operation restrictions, higher repair precision and better operation effect, etc. Rail milling trains are all adapted the way of milling first before grinding to repair the rail, and the milling part undertakes the vast majority of of rail machining capacity. So act as the operating components of milling part, the design quality of rail milling cutter will directly affect the repair precision of rail.The object of this thesis is the milling cutter used in repairing process for 60kg/m rail.The main research includes:1) Based on the national standards about 60 kg/m rail profile and its repair requirements, the theoretical profile of milling cutter was calculated by reversing and it was also fitted by circular blades and square blades. The intermediate coordinate system method was proposed to calculate the anchor points of the blade,by which the coordinate transformation between the blade coordinate and the milling cutter coordinate was realized;2) On the basis of cutting simulation research which studied the influence of technological parameters and Cutting tool geometry parameters on the chip size, the biggest size of chip was determined, and then calculated the size of milling cutter chip pocket by established chip pocket model;,which provide the basis for determine the scope of the number of sets of blades3) Based on the milling force formula, which proposed by Weilenamann, and the fitting of cutter profile, this article studied the influence of the class number and blade angle on the maximum milling force and stationary performance of milling cutter,by which the blade configuration of milling cutter was optimized;4) Additionally, in order to minimize structural compliance, the structural topological optimization of the body was carried out by the finite element methods.Compaired with the pre-optimized body,the one of optimized reduced27.51% in weight, and realize the goal of lightweight.After the above design and research,it is concluded that the milling cutter can not only meet the repair requirements, but also has a light and reasonable structure.