Vibration Control of the Rail Grinding Vehicle with Abrasive Belt Based on Structural Optimization and Lightweight Design

Abstract As a new grinding and maintenance technology, rail belt grinding shows significant advantages in many applications. The dynamic characteristics of the rail belt grinding vehicle largely determines its grinding performance and service life. In order to explore the vibration control method of the rail grinding vehicle with abrasive belt, the vibration response changes in structural optimization and lightweight design are respectively analyzed through transient response and random vibration simulations in this paper. Firstly, the transient response simulation analysis of the rail grinding vehicle with abrasive belt is carried out under operating conditions and non-operating conditions. Secondly, the vibration control of the grinding vehicle is implemented by setting vibration isolation elements, optimizing the structure, and increasing damping. Thirdly, in order to further explore the dynamic characteristics of the rail grinding vehicle, the random vibration simulation analysis of the grinding vehicle is carried out under the condition of the horizontal irregularity of the American AAR6 track. Finally, by replacing the Q235 steel frame material with 7075 aluminum alloy and LA43M magnesium alloy, both vibration control and lightweight design can be achieved simultaneously. The results of transient dynamic response analysis show that the acceleration of most positions in the two working conditions exceeds the standard value in GB/T 17426-1998 standard. By optimizing the structure of the grinding vehicle in three ways, the average vibration acceleration of the whole car is reduced by about 55.1% from 15.6 m/s2 to 7.0 m/s2. The results of random vibration analysis show that the grinding vehicle with Q235 steel frame does not meet the safety conditions of $$3\sigma$$ 3 σ . By changing frame material, the maximum vibration stress of the vehicle can be reduced from 240.7 MPa to 160.0 MPa and the weight of the grinding vehicle is reduced by about 21.7% from 1500 kg to 1175 kg. The modal analysis results indicate that the vibration control of the grinding vehicle can be realized by optimizing the structure and replacing the materials with lower stiffness under the premise of ensuring the overall strength. The study provides the basis for the development of lightweight, diversified and efficient rail grinding equipment.