EVRAZ United West Siberian Metallurgical Plant (Novokuznetsk, Russia):

A. V. Dobryanskiy, Senior Roll Designer of the Rail and Beam Shop, e-mail: Andrey.Dobryanskij@evraz.com
A. V. Golovatenko, Cand. Eng., Technical Director
V. V Dorofeev, Dr. Eng., Chief Roll Designer of the Rail and Beam Shop

Siberian State Industrial University (Novokuznetsk, Russia):
A. R. Fastykovskiy, Dr. Eng., Associate Prof., Head of the Metal Forming and Metal Science Dept.

Practical experience in mastering new sections at the modern rail-and-structural steel mill of JSC “EVRAZ ZSMK” showed that the greatest difficulties arise in the process of working out the rolling schedules for rail sections, which have a pronounced asymmetric shape. The design rolling scheme for switch point rails presented by the equipment supplier included metal deformation in breakdown stands BD1 and BD2 in seven passes in each stand, followed by rolling in a universal group of stands in three passes. Such a scheme had a number of significant drawbacks associated with the use of straight method of rolling in a closed slitting pass in a breakdown stand BD2. In particular, there was severe sticking of metal around the perimeter of the walls of this pass; there was no possibility of its restoration in width with the specified removal of metal during roll remachining; twisting of the bars occurred when they left the pass of the BD2 stand. Improvement of the roll pass design for rolling of switch point rails in the BD2 stand, including replacing the straight closed slitting pass of the BD2 stand with a diagonal pass and moving the trapezoidal axial pass from the rolls of the BD2 stand onto the rolls of the BD1 stand, allowed to improve the rolling technology, but required an additional turning of the bar from the trapezoidal edging pass, turned 90 degrees when it was fed in a slitting pass. In order to eliminate the disadvantages of the technology for rolling of switch point rails, a new method was developed for rolling of switch point rails in roughing passes. The substance of the new method of rolling of switch point rails in roughing passes is achieved due to the fact that in the trapezoidal edging pass the foot is formed with different lengths of flanges, the ratio of which is determined as to of the ratio of the lengths of the corresponding flanges in the rail slitting pass, and slitting pass is cut in rolls with openings on the short foot flange and head side of the section. Using the proposed method for rolling of switch point rails of type OR65 provided the following advantages in comparison with the existing one: increased accuracy of profile elements; stable rolling process and increased productivity of the mill; reduction of rail surface defects; increased roll life.

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