National University of Science and Technology “MISiS” (Moscow, Russia):

S. P. Galkin, Dr. Eng., Prof., Chair of Metal Forming, e-mail: glk-omd@yandex.ru
B. A. Romantsev, Dr. Eng., Prof., Chair of Metal Forming
Dinh Xuan Ta, Post-graduate
Yu. V. Gamin, Cand. Eng., Senior Lecturer, Chair of Metal Forming

The paper presents the research of the resource saving technology for production of rolled round bars from the used shaft of rolling railroad stock. This technology is based on the method of the radial shearing rolling (RSR) using the mini rolling mill with the original design. The finite element modeling (FEM) of the non-stationary RSR process for the stepped shaft, which was performed by QFORM 3D software package, has shown the feasibility of the process. It has been found that variation in the energy-force parameters during the process is characterized by sufficient smoothness. Moreover, the strain non-uniformity connected with the diff erence of shaft billet diameters along its length does not exceed transversal non-uniformity across its section that is typical for conventional RSR process. Full-scale testing of the developed technology has been carried out on the MISiS-130 rolling mill for the real shafts that were removed from railroad operation. The technological scheme for this production has been developed; the consumption indexes have been also estimated. Volumetric design of the mini-mill has been chosen and its principal construction for shaft rolling has been developed; all technical parameters of this equipment have been determined as well.

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