Siberian State Industrial University (Novokuznetsk, Russia):

Umanskiy A. A., Cand. Eng., Ass. Prof., Chair of Iron and Steel Metallurgy, e-mail: umanskii@bk.ru
Kadykov V. N., Cand. Eng., Ass. Prof., Chair of Metal Processing

EVRAZ West Siberian Iron and Steel Works (Novokuznetsk, Russia)

Golovatenko A. V., Head of Rail Production

Development of production of long rails that meet the requirements of world standards is one of the main challenges currently facing the Russian steel industry. Start-up and initial period of operation of the first universal rolling mill in Russia at EVRAZ West Siberian Metallurgical Works (EVRAZ ZSMK), whose main product mix is long (up to 100 m) rails, revealed a number of significant problems. In particular the absence of evidence-based methods of calculating the deformation resistance of rail steel is the limiting factor in the development and improvement of rolling schedule. In order to solve this problem, a complex experimental research of deformation resistance of rail steel grade E78HSFhas been conducted. This research has used installation of «Hydrawedge II», which is part of the «Gleeble System 3800» complex for physical simulation of thermomechanical processes. Synthesis and statistical processing of the results allowed to develop a static model of dependence between deformation resistance of the thermomechanical parameters of rolling (temperature, speed and degree of deformation) and chemical composition of the steel. The authors also have checked the adequacy of the testament, if this rolling mill has showed a sufficiently high convergence of calculated and actual data of the rolling force. Using the calculation model of statistical deformation resistance, the new mode of rail rolling schedule in breakdown stands of the rolling mill at EVRAZ ZSMK has been developed. Reduction of the number of passes in the second break-down stand and moving on rail gauges with sloping side walls up to 18 % of the initial stage formation of the rail profile were the main distinctive features of this schedule. Experimental-industrial testing of the new rail rolling procedure has shown its high technical and economic efficiency, including decrease of the specific consumption of electricity in the break-down stands and rail surface defects.

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