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A. Ambig^1,2, T. Klünsner², W. Daves², C. Czettl³, W. Kubin⁴ and T. Antretter⁵

¹Chair of Mechanics, Montanuniversität Leoben, Austria
²Department of Simulation, Materials Center Leoben Forschung GmbH, Austria
³R&D Cutting Tools, Ceratizit Austria GmbH, Reutte, Austria
⁴Tool Technology, Linsinger Maschinenbau GmbH, Laakirchen, Austria
⁵Chair of Mechanics, Montanuniversität Leoben, Austria

doi:10.4203/ccc.15.4.5

A. Ambig, T. Klünsner, W. Daves, C. Czettl, W. Kubin, T. Antretter, "High-Speed Rail Milling and Thermo-Mechanical Rail Surface Load Calculations via Automated Iterative Heat Flux and Temperature Exchange Between 2D and 3D Finite Element Models", in J. Pombo, (Editor), "Proceedings of the Seventh International Conference on Railway Technology: Research, Development and Maintenance ", Civil-Comp Press, Edinburgh, UK, Online volume: CCC 15, Paper 4.5, 2026, doi:10.4203/ccc.15.4.5

Keywords: rail milling, finite elements, chip formation, high-speed milling, orthogonal planing, arbitrary Lagrangian-Eulerian simulations.

Abstract

Rail milling is increasingly used for the reprofiling of the rail head as a maintenance strategy under high-speed milling conditions. Several open questions remain regarding how rail surface loading and the resulting temperature evolution influence the inelastic deformation and damage behaviour of rail and tool materials. In this study, industrial rail milling is modelled and analysed using Arbitrary Lagrangian-Eulerian-based finite element simulations. The modelling framework is applied to the milling of rail steel using cemented carbide inserts coated with titanium aluminium nitride. In contrast to earlier work, the present study provides a more detailed analysis of the thermo-mechanical response, with particular emphasis on chip formation and the associated heat transfer. Orthogonal planing simulations based on the Arbitrary Lagrangian-Eulerian framework, together with a coupled three-dimensional heat transfer model, were used to support the calibration of material and simulation parameters for rail milling. The present study contributes to a detailed numerical investigation of industrial rail milling and supports an improved understanding of loading, temperature development and deformation behaviour in rail maintenance operations.

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Front Page Browse CCC CCP CSETS CTR IJRT Other Authors Search Purchase Guide FAQ Contact us	Civil-Comp Conferences ISSN 2753-3239 CCC: 15 PROCEEDINGS OF THE SEVENTH INTERNATIONAL CONFERENCE ON RAILWAY TECHNOLOGY: RESEARCH, DEVELOPMENT AND MAINTENANCE Edited by: J. Pombo Paper 4.5 High-Speed Rail Milling and Thermo-Mechanical Rail Surface Load Calculations via Automated Iterative Heat Flux and Temperature Exchange Between 2D and 3D Finite Element Models A. Ambig^1,2, T. Klünsner², W. Daves², C. Czettl³, W. Kubin⁴ and T. Antretter⁵ ¹Chair of Mechanics, Montanuniversität Leoben, Austria ²Department of Simulation, Materials Center Leoben Forschung GmbH, Austria ³R&D Cutting Tools, Ceratizit Austria GmbH, Reutte, Austria ⁴Tool Technology, Linsinger Maschinenbau GmbH, Laakirchen, Austria ⁵Chair of Mechanics, Montanuniversität Leoben, Austria doi:10.4203/ccc.15.4.5 Full Bibliographic Reference for this paper A. Ambig, T. Klünsner, W. Daves, C. Czettl, W. Kubin, T. Antretter, "High-Speed Rail Milling and Thermo-Mechanical Rail Surface Load Calculations via Automated Iterative Heat Flux and Temperature Exchange Between 2D and 3D Finite Element Models", in J. Pombo, (Editor), "Proceedings of the Seventh International Conference on Railway Technology: Research, Development and Maintenance ", Civil-Comp Press, Edinburgh, UK, Online volume: CCC 15, Paper 4.5, 2026, doi:10.4203/ccc.15.4.5 Keywords: rail milling, finite elements, chip formation, high-speed milling, orthogonal planing, arbitrary Lagrangian-Eulerian simulations. Abstract Rail milling is increasingly used for the reprofiling of the rail head as a maintenance strategy under high-speed milling conditions. Several open questions remain regarding how rail surface loading and the resulting temperature evolution influence the inelastic deformation and damage behaviour of rail and tool materials. In this study, industrial rail milling is modelled and analysed using Arbitrary Lagrangian-Eulerian-based finite element simulations. The modelling framework is applied to the milling of rail steel using cemented carbide inserts coated with titanium aluminium nitride. In contrast to earlier work, the present study provides a more detailed analysis of the thermo-mechanical response, with particular emphasis on chip formation and the associated heat transfer. Orthogonal planing simulations based on the Arbitrary Lagrangian-Eulerian framework, together with a coupled three-dimensional heat transfer model, were used to support the calibration of material and simulation parameters for rail milling. The present study contributes to a detailed numerical investigation of industrial rail milling and supports an improved understanding of loading, temperature development and deformation behaviour in rail maintenance operations. download the full-text of this paper (PDF, 14649 Kb) go to the previous paper go to the next paper return to the table of contents return to the volume description
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