CC BY
42A.S.Limarev, M.Y.Ushakov, I.Y.Mezin
Nosov Magnitogorsk State Technical University
REVIEW OF THE MAIN REQUIREMENTS FOR PERFORMANCE AND QUALITY CHARACTERISTICS OF THE RAILWAY BOLTING
Abstract. The article discusses the requirements for rail rail bonding. The intermediate bonders are designed for secure connections to the rail base of the rails and provide the electrical insulation of rails in areas with self-locking and electric traction. Presented variety of designs of rail bonders used on the territory of Russia. The prospects for development of rail bonds production at JSC "MMK-METIZ".
Keywords: rail fasteners, railroad, terminal, anchorage bond, the terminal bolt bond List the keywords.
Intorduction
Since the middle of the XIX century the railway transport has become one of the main methods of delivery of goods and people. One of the main reasons for the popularity of rail transport is its reliability and safety. Road safety depends on all elements of the system, one of which is the upper structure of railway track.
Upper way serves to guide the rolling movement, the perception of force effects from the wheels and transfer them to the bottom structure. Upper way is a complex structure, including a ballast bed, sleepers, rails, rail fasteners, turnouts, blind intersection, bridge and switch ties. The connection of rails and sleepers called rail grid. When laying the rails and sleepers on the ballast, sleepers deepened in the ballast layer, which is placed on the main floor subgrade. The thickness of the ballast and the distance between the sleepers should be such that the pressure on the roadbed does not exceed the value of providing its elastic precipitate disappears after removal of the load.
Operating requirements
The intermediate rail fasteners are designed for reliable connection rails with rail base (sleepers, beams, monolithic base and so on.) And provide electrical insulation of rails in areas with self-locking and electric traction. Such bonds shall meet the following requirements [1, 8-11].
• Stability gauge. The requirement to ensure the stability of the track width is important and obviously it is directly related to traffic safety provision of conditions to prevent wheel failure.
• Press rails to the ground, excluding separation and theft of rails. Violation of requirements for ensuring the adequacy of the pressing rails to the base leads to isolation from the rail sleepers when installing or disassembling the way, and when, lifting of during straightening work. This is due to rotting wooden sleepers, the destruction of plugs, insufficient strength and corrosion of the binding on concrete foundations.
Rail movement causes a change in their stress-strain state, which may cause the emission path when the temperature rises and the gap junctions when it is lowered. Rail movement the path leads to a shift and skew sleepers, rail pads loss. Dealing with the consequences of Rail movement is associated with the implementation of complex and time-consuming adjustment work on gaps and discharge of thermal stresses in the rail lashes. Therefore, to ensure the quality of construction of railway track is necessary to satisfy the following conditions.
• Optimum conditions for operation temperature of the rails. The requirement for optimization of temperature operation rails also related to the size of the pressing forces to the base. Delete the temperature de-formation of the rails is very difficult, because it causes complication of construction way more expensive rail fasteners.
• Carrying out the adjustment of the height of the rails and the track gauge, replacement parts fasteners without interruptions in the movement of trains. Carrying position adjustment rails adjustment is particularly important in the concrete rail base and in the wintertime. In conditions of high congestion in the train path residual deformations accumulate quickly, it is a violation of the provisions of the rail project. Bearing path with tamping techniques in complex organizations re-
quire interruptions in the movement of trains, so the use of shims for the carriage way is very appropriate. In the winter in areas swelling use of shims is the only way to fix the way the level and profile. Bonds concrete sleepers must be capable of adjusting the position of the rails at a height of 10-20 mm.
• Mechanized cleaning and maintenance bonds nodes. Under current conditions, the assembly and disassembly of rail grid is conducted on the bases with production lines. Therefore, there was the requirement that the mechanization of work on the assembly and disassembly of bonds nodes. Mechanization of work on changing the rails, the replacement of worn-out elements fasteners, adjusting the tension binding with the current content path will significantly improve the quality of the railway track.
• Rational spatial elasticity and vibration fasteners nodes.
Ensuring rational spatial elastic rail fastening is extremely necessary in order to process the elastic dynamic effects of the wheels rolling on the rails, put out high-frequency vibration, frustrating the way and especially its bolting, as well as to create equal firmness rail base.
For use in continuous welded rail fastening assembly should create tension binding providing resistance per unit length longitudinal movement of the rail is not less than 25 kN/m. On the path of the link in order to prevent theft of the rails is necessary that the longitudinal displacement resistance per unit length is not less than 15 kN/m.
• Electrical isolation from the rail base. In areas with a self-locking fastening for concrete sleepers must ensure electrical isolation of the rails from the sleepers with a resistance of not less than 1 ohm per kilometer.
• Economic efficiency of the top structure of the design path. Bonding should contribute to the high service life of the path elements (in particular, they greatly affect the service life of the sleepers), and optimal conditions of operation.
Classification
In this regard, special attention should be paid to the quality of rail fastenings quality of performance, which largely determines the safety of the railway track. There are a number of structures intermediate rail fasteners, which can be classified on the following grounds [11-24].
• By appointment fixtures:
a) separate when lining to the sleepers and rails attached to the lining of various fastening;
b) inseparable when the liner and the tie and the rail attached to the lining of the same fastening;
c) mixed when attached to the rail with the sleeper as in undivided lining bond and furthermore, a lining secured to a sleeper further separate fastening.
• In the presence of the lining:
a) lining (KB, BP);
b) without lining (ZhB, ZhBR-65, ARS, Pandrol-350).
• The characteristics of the pressing member (terminals):
a) hard (KB, K2);
b) the resilient plate (ZhB, ZhBR);
c) elastic semi finished (ZhBR-65, ARS, Pandrol-350).
• By type of binding to the tie:
a) bolt (KB, BP, ZhB);
b) anchor (Pandrol-350, ARS);
c) screw-dowel (K2, ZhBR-65Sh).
Discussion
One of the most popular on Russian railways is bound bolt (KB-65, Figure 1), in which the lining is pressed against the rail to the rigid terminal worn on the terminal screws, curly head which infest the grooves flanges linings. Under the terminal bolts nuts put spring washers. Lining is fastened to the tie bolts mortgages. In this case the bolt heads rest on the concrete rendered monolithic
metal washer which mounting nuts when tightened evenly distributes the load on the concrete. Electrical pads made from railway sleepers and sleeper padding lining sleeve of the PCB, is put on the rod bolts laying and bury in a hole of the metal lining [2].
Fig. 1. Cleat-bolt fastening KB: 1 - gasket PR-65; 2 - bracket grommet KB; 3 - bushing KB; 4 - gasket PBR-65x7;
5 - gasket KB-10; 6 - cleat bolt M-22-8G-75.48; 7 - embedded bolts M-22-8G-175.36; 8 - female screw M-22-7H5; 9 - cleat PK; 10 - lining; 11 - double-turn washer 25
Bond KB-65 bond has a number of disadvantages, namely.
• A lot of detail (detail 21 in each node).
• Consumption of materials (the total mass of metal and plastic parts for 1 km path is respectively 41.6 tons and 2.1 tons).
• Presence of about 16 thousand. Bolts to 1 km of track, the contents of which (removal of dirt, grease, tightening nuts) is costly.
The main bottleneck binding KB-65 is a threaded connection.
In modern conditions increase the requirements for reliability, maintainability and safety of rail fasteners, so developers and vendors offer new solutions and designs. Among them are such as ARS-4 (Figure 2) and ZhBR-65RSh.
Fig. 2. Anchoring rail-bound ARS-4: 1 - cleat; 2 - regulator; 3 - anker; 4 - knob with lock; 5 - insulating block; 6 - rubber gasket
The main feature of the construction site ARS-4 bonds are rendered monolithic under-rail in the area of reinforced concrete sleepers removable anchor frame-arch type, covering the rail foot and bringing together the work of two clamp nodes, consisting of two B-shaped bar-shaped spring clamp what allows for this bond on the straight sections of the railway line and curves with a radius of 350 m or more, with a width of 1520 mm track gauge and without limit congestion [3, 4].
In the design ZhBR-65RSh weight and number of parts are reduced by more than 1.5 times compared with separate bonding KB-65. Besides rail fasteners of this type allows to: remain unchanged track width; counteracts the "rail movement" of the rails; it provides a spatial elasticity way that affects the level of deterioration of the rail and wheel sets; wood core ensures that affect the intensity of differential settlement of sleepers; it provides the ability to adjust the height of rails in the plane [5].
One of the leading companies engaged in production of rail fastenings is JSC "MMK-METIZ". Company has many years of experience in the production of rail fasteners for the railways and roads of Russia in the former Soviet Union, allowing it to produce more than a dozen different elements of the rail fastenings. Recently, the company has mastered the production technology of screw travel elongated hexagon head (CP-54). These screws are used in bond ZhBR-65 PSh and is widely used in the construction of railways in Russia [6, 7].
Also, it should be noted the existing enterprise development experience bar-shaped terminal. Among the assortment of a large proportion of the discharged enterprise engaged in the production of spring terminals hot bar OP-105 (Figure 3). The disadvantage represented by the terminals is not it high performance, which significantly reduces its competitiveness on the world market of manufacturers of rail fasteners.
Fig. 3. Spring terminals hot bar OP-105
Available modes of technology and equipment used for clamp OP-105 does not allow to produce such clamps ARS and ZhBR. But in view of the similarity of shape of the terminals and ARS, ZhBR, rod diameters and steel grades, these terminals can be manufactured on the same equipment, with the appropriate settings.
Conclusion
Therefore, to maintain their position on the rail fasteners market enterprise mastered production of bar-shaped terminal ZhBR and ARS. This task is only possible in solving a whole range of tasks aimed the possibility of the production, the following can be distinguished among them: the modernization of technological equipment; development of technological modes of production of spring terminals, as well as the provision of appropriate blanks, allowing to fulfill customer requirements for performance.
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