Abstract Abrasive material and hardness of grinding wheel are two important factors affecting the grinding efficiency and quality. In this study, two kinds of abrasive grains (i.e., zirconium corundum (ZA) and brown fused alumina (BA)) were used to produce eight grinding wheels, among which five with different contents of abrasive grains and four with different hardness levels. Rail grinding experiments were conducted to investigate their grinding efficiency (grinding amount of rail), grinding quality (including surface roughness, surface burn, white etching layer (WEL), and residual stress), and wear types of grinding wheels. The results show that ZA grinding wheel produced larger grinding amount, higher surface roughness, but lower level of surface burn, thinner WEL, and smaller parallel residual stress than BA grinding wheel. With the increase in grinding wheel hardness, the surface roughness and residual stress of ground rail showed decrease trends, but the thickness of WEL increased. The wear type of ZA grains was macro-fracture and the wear type of BA grains was attrition wear. With the increase in grinding wheel hardness, the wear type was changed from grain pullout wear to macro-fracture. Based on the analysis of results, the appropriate grinding wheel was recommended that can improve the grinding process and reduce the grinding cost.

中文翻译：

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磨料和砂轮硬度对钢轨磨削行为的影响

摘要 砂轮的磨料和硬度是影响磨削效率和质量的两个重要因素。在这项研究中，两种磨粒（即锆刚玉（ZA）和棕刚玉（BA））被用来生产八个砂轮，其中五种磨粒含量不同，四种不同硬度等级。进行钢轨磨削实验，研究其磨削效率（钢轨磨削量）、磨削质量（包括表面粗糙度、表面烧伤、白色蚀刻层（WEL）和残余应力）和砂轮磨损类型。结果表明，与BA砂轮相比，ZA砂轮的磨削量更大，表面粗糙度更高，但表面烧伤程度更低，WEL更薄，平行残余应力更小。随着砂轮硬度的增加，地轨的表面粗糙度和残余应力呈下降趋势，但WEL的厚度增加。ZA晶粒的磨损类型为宏观断裂，BA晶粒的磨损类型为摩擦磨损。随着砂轮硬度的增加，磨损类型由晶粒拉拔磨损转变为宏观断裂磨损。根据结果​​分析，推荐合适的砂轮，以改善磨削工艺，降低磨削成本。磨损类型由晶粒拉拔磨损转变为宏观断裂磨损。根据结果​​分析，推荐合适的砂轮，以改善磨削工艺，降低磨削成本。磨损类型由晶粒拉拔磨损转变为宏观断裂磨损。根据结果​​分析，推荐合适的砂轮，以改善磨削工艺，降低磨削成本。