Multi-scale characterisation of new and used field rail grinding stones

Effective rail grinding is essential to preserve surface integrity and limit rail deterioration. This study examines the wear behaviour of resin-bonded grinding stones, which directly influence grinding efficiency and the quality of the post-ground rail surface. One new and three field-used stones were analysed using macro- and micro-scale methods. Findings show a rapid transition to a stable worn state, marked by surface tapering, grain pull-out, wear flats, and bond degradation, with topographic variation across the cutting surface suggesting localised grinding behaviour. Understanding these wear patterns supports the optimisation of grinding stone performance and highlights the importance of characterising stones in their worn condition to improve rail outcomes.