To investigate the material removal mechanism in rail grinding by abrasive belt, the contact situation is analyzed initially based on elastic Hertzian contact theory, the curved face touch between contact wheel and rail surface is considered. Meanwhile, the contact area as well as the contact pressure distribution is calculated. Then the relationship between grinding pressure and maximum cut depth is introduced based on statistic model of grains' protrusion height and force bearing analysis on the single grit to deal with the irregularity and randomness of grains' shape and distribution. Finally, the mathematical model of material removal depth and material removal amount are derived, involved with grains' protrusion height, grains' shape, grains' density, abrasive belt velocity, driving speed, grinding normal force, contact wheel hardness, relative principal curvature and so on. The maximum deviation between the predicted values and the experimental results for material removal depth and material removal amount are 3.6% and 11.95%, respectively, which verifies correctness and validity of the above mentioned models.
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