Rail Grinding Machine Overview
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What is one of the primary purposes of rail grinding?

  • To replace damaged rails
  • To increase the thickness of the rail
  • To optimize the rail's weight
  • To shift wheel contact away from defect areas (correct)

    • How does rail grinding contribute to reducing wear and tear?

  • By maintaining favorable steering of the wheels (correct)
  • By increasing the surface area of the rails
  • By aligning the rails perfectly with the wheels
  • By adding a protective coating to the rails

    • What effect does rail grinding have on rolling contact fatigue?

  • It completely prevents the formation of cracks.
  • It accelerates the development of fatigue cracks.
  • It helps control damage and removes initial cracks. (correct)
  • It eliminates the need for regular inspections.

    • What issue does rail grinding directly address regarding the rail's crown radius?

    <p>It restores the rail crown radius to reduce damage.</p> Signup and view all the answers

    What type of rail layer does grinding remove that is associated with crack formation?

    <p>Martensitic layer</p> Signup and view all the answers

    What is one consequence of misaligned welds that rail grinding seeks to mitigate?

    <p>Hunting on straight tracks</p> Signup and view all the answers

    Why is it undesirable for the rail radius to become flattened over time?

    <p>It increases the width of the contact band.</p> Signup and view all the answers

    What is a major benefit of removing corrugations from the rail top through grinding?

    <p>It enhances passenger comfort during travel.</p> Signup and view all the answers

    Which utility track vehicle has the highest wheel axle diameter?

    <p>UTV(PHOOLTAS) with mobile cranes</p> Signup and view all the answers

    Which of the following utility track vehicles has the lowest load capacity?

    <p>UTV(OEPL)</p> Signup and view all the answers

    What is the width of the UTV(BHEL)?

    <p>4115 mm</p> Signup and view all the answers

    Which vehicle has a wheel axle diameter of 915 mm?

    <p>All the vehicles</p> Signup and view all the answers

    What could be a possible utility of UTV(BEML) based on its features?

    <p>Heavy lifting operations</p> Signup and view all the answers

    What is the minimum distance that two curves must bifurcate in a compound curve?

    <p>1 m</p> Signup and view all the answers

    Which of the following columns is not required for GDMS Data?

    <p>Id</p> Signup and view all the answers

    What is the required data type for the 'Km' column?

    <p>Int</p> Signup and view all the answers

    How far apart should transition curves be from each other?

    <p>1 m</p> Signup and view all the answers

    Which data type is used for the 'Length' column in GDMS Data?

    <p>Float</p> Signup and view all the answers

    How should the user provide the name of the track line segment?

    <p>Letters, numbers, underscore, or dash</p> Signup and view all the answers

    What type of curve is described as being in a single straight line?

    <p>Single curve</p> Signup and view all the answers

    Which of the following is true about the 'End' column in GDMS Data?

    <p>It is not used</p> Signup and view all the answers

    For organizing track details, what is the sequence of data collection for UP and DN tracks?

    <p>In increasing km</p> Signup and view all the answers

    Which aspect is important for the 'Track' column in GDMS Data?

    <p>It is typically identified as UP, DN, SL, or numeric</p> Signup and view all the answers

    What is the primary purpose of identifying the contact band on the railhead?

    <p>To assess the damage on the rail surface</p> Signup and view all the answers

    Which characteristic indicates a good grinding finish on the rail?

    <p>Regular grind marks with silver finish</p> Signup and view all the answers

    What is the maximum surface roughness level allowed after rail grinding?

    <p>12 microns</p> Signup and view all the answers

    What does a Grind Quality Index (GQI) value of 100 indicate?

    <p>No deviation from the target profile</p> Signup and view all the answers

    What is the acceptable GQI value before and after grinding?

    <p>80</p> Signup and view all the answers

    Which factor indicates a bad grinding finish on the rail surface?

    <p>Blue colour at certain locations</p> Signup and view all the answers

    How is the efficacy of grinding assessed after a dye penetration test?

    <p>By the number and length of cracks</p> Signup and view all the answers

    What is the recommended facet width for rail grinding in the center of the rail?

    <p>10 mm</p> Signup and view all the answers

    What is the importance of measuring crown radius before and after grinding?

    <p>To evaluate grinding effectiveness</p> Signup and view all the answers

    What happens to the paint or chalk markers used to identify contact bands?

    <p>They manifest as a band-like formation</p> Signup and view all the answers

    What should be ensured before operating the crane?

    <p>The vehicle is stabilised and parking brakes are ON.</p> Signup and view all the answers

    What is the maximum wind speed in which the crane can be safely used?

    <p>50 kmph</p> Signup and view all the answers

    What should the operator ensure regarding the work area before crane operation?

    <p>No one is within the operating radius of the crane.</p> Signup and view all the answers

    What action should be taken if the crane must be left unattended with the boom extended?

    <p>Manoeuvre the load to ground and turn-off the vehicle.</p> Signup and view all the answers

    What should be avoided regarding the single point slinging?

    <p>It increases risk of bending and damage to rail surface.</p> Signup and view all the answers

    What should be done with support posts or foldable side walls after loading?

    <p>Lift them up or tie the rails with a chain to secure them.</p> Signup and view all the answers

    How should loading be conducted regarding weight distribution?

    <p>Loading should be uniformly distributed.</p> Signup and view all the answers

    What protective equipment should staff wear to minimize injury risk?

    <p>Protective gloves and industrial shoes.</p> Signup and view all the answers

    What is a requirement for the flat wagon used with the crane?

    <p>It should have a valid BPC for the movement.</p> Signup and view all the answers

    In what situation should care be taken while working with cranes near electric power cables?

    <p>When the machine is in operation.</p> Signup and view all the answers

    What is the load capacity of the railbound maintenance vehicle?

    <p>18.25t</p> Signup and view all the answers

    Which component is hydraulically operated in this railbound maintenance vehicle?

    <p>The jib crane</p> Signup and view all the answers

    What is the width measurement of the railbound maintenance vehicle?

    <p>3245 mm</p> Signup and view all the answers

    Which option describes the size of the wheel axle on this vehicle?

    <p>952 mm</p> Signup and view all the answers

    Which feature is provided to enhance operator comfort in the cabin?

    <p>Cushioned seat</p> Signup and view all the answers

    How does rail grinding impact the directional stability of trains?

    <p>It reduces hunting on straight tracks by ensuring proper wheel alignment.</p> Signup and view all the answers

    What consequence does rail grinding help avoid concerning the growth of defects in rail surfaces?

    <p>It shifts contact to areas with minimal wear, preventing further damage.</p> Signup and view all the answers

    Which of the following describes the issue with the white martensitic layer that rail grinding addresses?

    <p>It is prone to cracking due to its brittle nature.</p> Signup and view all the answers

    In what way does rail grinding aid in managing rolling contact fatigue?

    <p>It removes early-stage cracks before they worsen.</p> Signup and view all the answers

    What is a significant disadvantage if the rail crown radius flattens over time?

    <p>It leads to increased hunting and surface damage.</p> Signup and view all the answers

    How does rail grinding affect the hardness differences near welds?

    <p>It prevents dip formation caused by differential wear.</p> Signup and view all the answers

    What specific benefit does rail grinding provide concerning riding quality?

    <p>It removes corrugations and enhances smoothness.</p> Signup and view all the answers

    What characteristic of rail wheels does grinding aim to restore?

    <p>A rail crown radius that aligns with rail curvature.</p> Signup and view all the answers

    What is the primary function of the crane installed on the RBMV?

    <p>To lift and move P.Way materials and tools</p> Signup and view all the answers

    How many diesel engines are contained within the RBMV?

    <p>Two</p> Signup and view all the answers

    Which component is responsible for the power transmission in the RBMV?

    <p>Hydrodynamic power transmission systems</p> Signup and view all the answers

    What is the seating capacity in the staff cabin of the RBMV?

    <p>12 staff members</p> Signup and view all the answers

    What type of crane is installed on the RBMV?

    <p>A pillar jib crane with multi-stage extension</p> Signup and view all the answers

    What is the primary role of the drive cabin in the RBMV?

    <p>To drive the vehicle in either direction</p> Signup and view all the answers

    What model is the diesel engine used in RBMV?

    <p>Cummins model No. NTA855R</p> Signup and view all the answers

    What limits the attachment of another vehicle to the RBMV?

    <p>No BFR can be attached</p> Signup and view all the answers

    What arrangement is provided for materials in the RBMV?

    <p>Separate cabins for men and materials</p> Signup and view all the answers

    What is the purpose of preventive grinding in rail maintenance?

    <p>To prolong the lifespan of the rail by limiting metal removal</p> Signup and view all the answers

    What factor distinguishes corrective grinding from preventive grinding?

    <p>The total amount of metal removed during each cycle</p> Signup and view all the answers

    Why is preventive-gradual grinding adopted in Indian Railway rail maintenance?

    <p>To achieve a balance between preventive and corrective grinding strategies</p> Signup and view all the answers

    How do target rail profiles affect rail wheel interaction?

    <p>They are designed to minimize contact stresses during interactions</p> Signup and view all the answers

    What is a key characteristic of preventive grinding compared to corrective grinding?

    <p>It can be executed at lower speeds but with less metal removed</p> Signup and view all the answers

    What challenges might arise from implementing corrective grinding on Indian Railways?

    <p>It risks removing the head hardened layer, increasing wear</p> Signup and view all the answers

    In what way does the target rail profile differ between straight and curved tracks?

    <p>The profiles optimize for different patterns of wear and stress</p> Signup and view all the answers

    What is the significance of surface defects in the context of rail maintenance strategies?

    <p>They dictate the need for frequent preventive grinding to avoid severe issues</p> Signup and view all the answers

    What distinguishes emergency brakes from general braking systems in rolling stock?

    <p>Emergency brakes are automatically engaged while others are manual</p> Signup and view all the answers

    What should be checked to ensure the correctness of grinding patterns before starting the operation?

    <p>The patterns selected by the SSE/JE/TM</p> Signup and view all the answers

    Why is it imperative to synchronize the chainage of the track on the machine before starting?

    <p>To avoid misalignment during grinding</p> Signup and view all the answers

    What is the potential consequence of using GDMS suggested patterns if the direction of the curve is wrong?

    <p>Spoiling the surface profile</p> Signup and view all the answers

    What timing is recommended for taking the rail profile after grinding?

    <p>No later than 15 days after grinding</p> Signup and view all the answers

    Which action should be taken if the direction of the curve in GDMS software is not aligned with the ground?

    <p>Manually choose a different pattern</p> Signup and view all the answers

    What is notably assessed before and after grinding to ensure improvement?

    <p>The Grind Quality Index (GQI)</p> Signup and view all the answers

    What procedure should be followed for the buggies when starting grinding on a straight track?

    <p>They should be lowered only</p> Signup and view all the answers

    What must be ensured regarding alarms on the HMI of the machine during grinding operations?

    <p>They prompt immediate corrective actions</p> Signup and view all the answers

    What kind of tests should be conducted at the test sites within 10-15 days after grinding?

    <p>DPT tests and surface photographs</p> Signup and view all the answers

    What action is necessary if the SSE/JE/TM needs to change patterns on the curves?

    <p>Patterns must be changed promptly</p> Signup and view all the answers

    Study Notes

    Rail Grinding Machine (RGM)

    • Rail grinding re-profiles the railhead to optimize wheel-rail contact and improve their interaction.
    • Increased rail and wheel life are expected benefits, alongside reduced defect generation.
    • Indian Railways utilizes 72 stone grinders of the RGI Series, manufactured by Loram (USA).

    Purposes of Rail Grinding

    • Reduces contact stress and maintains proper wheel steering, minimizing wear and tear on rail and wheel surfaces.
    • Shifts wheel contact away from areas with surface defects, preventing further defect growth.
    • Avoids wheel contact with misaligned welds, reducing hunting on straight tracks and subsequent damage.
    • Controls damage from rolling contact fatigue by removing cracks in their early stages, hindering their development and reducing rail/weld failures.
    • Removes corrugations and other irregularities from the rail top, leading to improved riding quality.
    • Restores the rail crown radius, reducing hunting and damage caused by the flattening of the rail radius over time.
    • Removes the white martensitic layer on the rail top, which is brittle and contributes to crack formation.
    • Addresses dip formation near welds arising from the difference in hardness between the rail and the heat affected zone (HAZ).

    Process for Assessing Contact Band

    • Paint or chalk is applied to the rail surface and a freight train is allowed to pass over it.
    • The erased area creates a "band" where the wheels made contact.
    • This information, along with details of location, date, width of the contact band, and distance from the gauge face, are recorded both in writing and with a photograph.

    Dye Penetration Test

    • Conducted at the second portion of the test site to highlight damage, including cracks, on the rail surface.
    • Performed both before and after grinding.
    • Reduction in both number and length of cracks after grinding indicates the effectiveness of the grinding process.

    Monitoring Rail Surface Finish

    • The quality of the grinding is assessed by examining the rail surface finish after the process.
    • A good finish exhibits regular grind marks from the grinding stones (facets) with a silver finish.
    • Faulty finishes display irregular marks, skipping grinding at regular intervals, blue coloring on rails (blueing defect), or irregular facet widths.
    • Ideal facet width is approximately 10 mm in the center of the rail and 4 mm at the corners.

    Surface Roughness After Grinding

    • The rail surface should not be excessively rough after grinding.
    • Surface roughness levels should remain below 12 microns.

    Grind Quality Index (GQI)

    • Measures the effectiveness of grinding in achieving the target rail profile.
    • GQI 100 represents full achievement of the target profile.
    • Lower values indicate greater deviation from the target profile.
    • During operation, GDMS screen displays GQI for both rails before and after grinding.
    • Acceptable GQI is 80 and above.

    Crown Radius Measurement

    • Crown radius of the railhead is measured before and after grinding using a star gauge.

    Safety Precautions for Crane Operation

    • Ensure crane stabilization and engaged parking brakes before operation.
    • Avoid operating the crane in strong winds exceeding 50 km/h.
    • Maintain a clear view of the work area and confirm the absence of personnel within the crane's operating radius.
    • Continuously monitor the crane's stability during maneuvers.
    • Review the load to be lifted and the operating radius according to the Load Distance Diagram.
    • Exercise caution when working near electric power cables.
    • Never leave the machine unattended with the boom extended and load lifted from the ground. If unavoidable, lower the load to the ground and switch off the vehicle.
    • Preferably load/unload and handle materials from the cess side of the track. When handling materials between tracks, ensure proper track protection on the adjacent running track side.
    • Lock the crane movement to the infringing side during operation.
    • Avoid using single-point slinging to prevent bending and damage of the rail surface. Keep the overhang to a maximum of half the distance between lifting points.
    • Limit loading of rails and sleepers on Bulk Freight Railcars (BFR) in Utility Track Vehicles (UTVs) and Rail Borne Maintenance Vehicles (RBMVs) to 4 and 3 layers, respectively.
    • Maintain horizontal and straight orientation for rails during lifting and moving.
    • Secure rails by lifting support posts/foldable sidewalls or by chaining them after loading for safety before movement.
    • Distribute the load evenly to prevent eccentric loading.
    • Handle the crane with caution in electrified territories and station yards.
    • Prohibit staff from standing beneath suspended loads for safety.
    • Require staff to wear protective gloves and industrial shoes to minimize injury risk.

    Safety Precautions Specific to UTVs

    • A SSE/JE (P.Way) will act as a guard on the machine.
    • The guard and machine staff should be assigned to the BRN for safety when the machine moves towards the crane side with an attached BRN.
    • Ensure the flat wagon has a valid BPC for movement.

    GDMS Data Format

    • Column 1: Id - Text - Recommended: Row number in the file, aiding editing.
    • Column 2: LineSeg - Text - Required: User-provided name of the track line segment. Names consisting of letters, numbers, underscore, or dash.
    • Column 3: Region - Text - Required: Railroad Region.
    • Column 4: Division - Text - Required: Railroad Division.
    • Column 5: Sub Division - Text - Required: Railroad Subdivision.
    • Column 6: Track - Text - Required: Track Name (e.g., UP, DN, SL, 1, 2, 3, etc.)
    • Column 7: Start - Float - Not Used: Start Sta+Off of track segment.
    • Column 8: End - Float - Not Used: End Sta+Off of track segment.
    • Column 9: Km - Int - Required: Integer value specifying the kilometer location.
    • Column 10: StartM - Int - Not Used: Start Meter.
    • Column 11: Length - Float - Required: Length in meters of the specified kilometer.
    • Column 12: CurveNum - Text - Not Used: Curve names assigned by the program based on curve start point.
    • Column 13: ST - Sta+Off- Required: The first point of the curve.

    Utility Track Vehicle (UTV) and Rail Borne Maintenance Vehicle (RBMV) Dimensions

    • UTV (PHOOLTAS):
      • With mobile crane:
        • Length: 13170 mm
        • Width: 3950 mm
        • Wheel Axle DIA: 915 mm
        • Wheel Axle Load: 20.0 t
      • Without mobile crane:
        • Length: 13170 mm
        • Width: 3550 mm
        • Wheel Axle DIA: 915 mm
        • Wheel Axle Load: 20.0 mm
    • UTV (OEPL):
      • Length: 10270 mm
      • Width: 3830 mm
      • Wheel Axle DIA: 915 mm
      • Wheel Axle Load: 13.5 t
    • UTV (BEML):
      • Length: 12120 mm
      • Width: 3550 mm
      • Wheel Axle DIA: 915 mm
      • Wheel Axle Load: 15.0 t
    • UTV (BHEL):
      • Length: 9770 mm
      • Width: 4115 mm
      • Wheel Axle DIA: 1092 mm
      • Wheel Axle Load: 20.0 t
    • ** All dimensions are in mm.**

    Rail Grinding Machine (RGM)

    • Rail grinding re-profiles the railhead to optimize wheel-rail contact and improve interaction.
    • This increases rail and wheel life, while reducing defect generation.
    • Indian Railways uses 72 stone grinders from Loram, USA.

    Purposes of Rail Grinding

    • Reduces contact stresses and maintains favorable wheel steering.
    • Shifts wheel contact away from rail surface defects, preventing further growth.
    • Prevents wheel tread contact with misaligned welds, reducing hunting and damage.
    • Controls rolling contact fatigue damage and removes cracks in early stages, preventing further growth and failure.
    • Removes corrugations and irregularities, improving riding quality.
    • Restores rail crown radius, reducing damage caused by wheel flattening.
    • Removes the white martensitic layer on the rail top, which is brittle and prone to cracking.
    • Addresses dip formation near welds due to differential wear, which occurs because of the difference in hardness between the rail and the heat affected zone (HAZ).

    Grinding Strategy

    • Metal removal and grinding frequency are determined to control rolling contact fatigue.
    • Corrective grinding removes all corrugations and defects in a single cycle, achieving the target rail profile.
    • Preventive grinding is done early in defect generation, more frequently, with less metal removed per cycle.
    • Preventive-Gradual Grinding is the adopted strategy on Indian Railways, removing more metal than preventive grinding, but less than corrective grinding.
    • Aim is to achieve preventive grinding after 3-4 cycles.
    • Target rail profiles are designed to minimize contact stress during wheel-rail interaction.
    • Profiles vary for straight tracks, curved tracks, mild curves, sharp curves, high rails, and low rails.

    Rail Borne Maintenance Vehicle (RBMV)

    • Features include two driving cabins, cabins for men and material, a hydraulic crane, diesel engines, and hydrodynamic power transmission systems.
    • The crane is used for loading and unloading materials.
    • The vehicle has two diesel engines (Cummins NTA855R), each driving one bogie.
    • Two hydrodynamic power transmission systems are used for driving and grinding.
    • The vehicle is 22,270 mm long, 21,000 mm wide, and 14,783 mm high.
    • The maximum load capacity is 18.25 tonnes, with a width of 3,245 mm.

    Post Grinding Operations

    • Rail profile is measured within 15 days after grinding at test sites.
    • Dye Penetrant Test (DPT) is conducted within 10-15 days for defect detection, and a photograph is taken.
    • Surface photos are also taken within 10-15 days.
    • MINIPROF measurements and photographs are archived.

    Operating Procedures

    • Regularly check the motor performance through the HMI panel.
    • Prepare a chart in advance outlining the grinding patterns for the first pass.
    • Synchronize the chainage of the track and the machine before and during operation.
    • Ensure the SSE/JE/TM selects the correct grinding patterns.
    • Verify the grinding speed is accurate.
    • Monitor the SSE/JE/TM's motor sequencing during obstructions.
    • Verify the direction of the curve in the GDMS software matches field observations.
    • When the curve direction is incorrect, avoid using GDMS suggested patterns for the second and third passes and choose them manually.
    • Correct the GDMS data to prevent future issues.
    • Ensure prompt pattern changes by the SSE/JE/TM when entering or exiting curves.
    • Measure the GQI before and after grinding to assess improvements.
    • Learn how to use the GDMS software, including pattern and speed recommendations for curves.
    • Monitor the patterns in use in real-time.
    • Respond promptly to any alarms on the HMI.
    • Ensure that the buggies are lowered and raised on straight track only.

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    Related Documents

    Rail Grinding Machine Manual PDF

    Description

    Explore the essential functions and benefits of Rail Grinding Machines (RGM) in optimizing rail and wheel interactions. Understand how Indian Railways employs these machines to enhance the lifespan of railway components and improve riding quality. Learn about the purposes of rail grinding and its impact on rail maintenance.

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