Investigation of conditions leading to critical transitions between abrasive belt wear modes for rail grinding

In abrasive belt rail grinding, understanding the abrasive belt wear mechanisms is important for improving grinding accuracy and abrasive belt service life. Taking a single ceramic grit in a stable grinding state as an example, this study investigated the critical transition conditions and recognition methods between the different wear modes. Based on the crack growth equation, the critical transition condition from abrasion to fracture was modeled by calculating the stress around the cracks hiding in the grit tip. The transition condition between fracture and pull-off was determined by comparing the external stress around the grit root and the bonding strength of the resin binder. These critical conditions were verified by single grit scratching experiments and the improved Sc wear map method. •Two recognition models to distinguish abrasive belt wear modes were established.•Critical condition from abrasion to fracture was given by crack growth equation.•Critical condition from fracture to pull off was related to grits' root stress.•An improved wear map was given to visualize and project the belt wear transition.