Rail re-profiling method and apparatus

Abstract

A method of milling a profile of a railway rail comprises: rotating a milling cutter including a plurality of face mounted cutting inserts mounted about a periphery thereof, milling a railway rail with cutting edges of the cutting inserts rotating in a predetermined plane corresponding to at least a portion of a desired rail profile while controlling the depth of cut of the cutting inserts; traversing the railway rail with the milling cutter while milling the railway rail and controlling the speed of traverse of the milling cutter along the railway rail.

1 . A method of milling a profile of a railway rail comprising:
 rotating a milling cutter including a plurality of face mounted cutting inserts mounted about a periphery thereof;   milling a railway rail with cutting edges of the cutting inserts rotating in a predetermined plane corresponding to at least a portion of a desired rail profile while controlling the depth of cut of the cutting inserts;   traversing the railway rail with the milling cutter while milling the railway rail; and   controlling the speed of traverse of the milling cutter along the railway rail.   
     
     
         2 . The method of  claim 1 , comprising controlling the speed of traverse of the milling cutter along the railway rail to speeds up to 15 mph. 
     
     
         3 . The method of  claim 1 , comprising controlling the speed of traverse of the milling cutter along the railway rail to speeds greater than 1 mph. 
     
     
         4 . The method of  claim 1 , comprising controlling the speed of traverse of the milling cutter along the railway rail to speeds greater than 3 mph. 
     
     
         5 . The method of  claim 1 , comprising controlling the speed of traverse of the milling cutter along the railway rail to speeds between less than 1 mph to 15 mph. 
     
     
         6 . The method of  claim 1 , comprising controlling the depth of cut of the cutting inserts to a depth no more than 0.040 inches. 
     
     
         7 . The method of  claim 1 , comprising controlling the depth of cut of the cutting inserts to a depth no more than about 0.010 inches. 
     
     
         8 . The method of  claim 1 , comprising controlling the depth of cut of the cutting inserts to a depth between 0.005 inches and 0.010 inches. 
     
     
         9 . The method of  claim 1 , wherein milling the railway rail comprises milling the railway rail using a conventional milling orientation. 
     
     
         10 . The method of  claim 1 , wherein milling the railway rail comprises milling the railway rail using a climb milling orientation. 
     
     
         11 . The method of  claim 1 , further comprising:
 milling the railway rail with a plurality of milling cutters, each milling cutter including a plurality of face mounted cutting inserts mounted about a periphery thereof, wherein cutting edges of the cutting inserts of each milling cutter are rotated in a predetermined plane corresponding to at least a portion of a desired rail profile.   
     
     
         12 . The method of  claim 1 , further comprising controlling a width of cut to about 0.625 inches or less. 
     
     
         13 . The method of  claim 1 , wherein the milling cutter comprises one of a bumper ring and a bumper plate. 
     
     
         14 . The method of  claim 1 , wherein the cutting edge comprises an actual cutting edge, and wherein the actual cutting edge progressively moves along the edge as it wears. 
     
     
         15 . The method of  claim 1 , wherein one or more of the cutting inserts comprises a substantially linear cutting edge. 
     
     
         16 . The method of  claim 1 , wherein the cutting inserts comprise one of uncoated C6 grade cemented carbide and coated C6 grade cemented carbide. 
     
     
         17 . The method of  claim 1 , wherein the milling cutter is positioned in an offset orientation comprising a distance between 35% and 40% of its diameter. 
     
     
         18 . The method of  claim 1 , wherein the milling cutter comprises a diameter between 8 inches and 16 inches. 
     
     
         19 . An apparatus for milling at least a portion of a desired profile on a railway rail in situ, the apparatus comprising:
 a milling cutter including a cutter body comprising a cutter face, wherein the milling cutter is rotatable about a rotation axis; and   a plurality of cutting inserts mounted around a periphery of the cutter face, the plurality of cutting inserts each comprising a cutting edge extending a distance from the cutter face to engage and mill a profile segment on the railway rail, wherein the rotation axis is substantially perpendicular to the plane of the profile segment to be milled on the railway rail by the cutting inserts.   
     
     
         20 .- 41 . (canceled)