JSC “EVRAZ ZSMK” (Novokuznetsk, Russia):

A. V. Golovatenko, Cand. Eng., Director of Rail Production
V. V. Dorofeev, Dr. Eng., Chief Roll Pass Designer
A. V. Dobryansky, Senior Roll Pass Designer of Rail and Structural Steel Shop, E-mail: Andrey.Dobryanskij@evraz.com
D. E. Pervushin, Senior Roll Pass Designer of Rail and Structural Steel Shop

The experience in development of the rails rolling in Rail and Structural Steel Shop of JSC «EVRAZ ZSMK», commissioned in 2013 according to the project programs of roll pass design, developed by the specialists of the German company «SMS Meer», has shown that the greatest difficulties in the process of rolling arise during the formation of section in box closed nonsymmetrical rail passes. Small slopes of flanges in the closed grooves of these passes (2–4%) and a signifi cant difference in the deformation–speed conditions of the metal forming in the components of closed passes leads to a significant pinching of the breakdown bar in the closed flanges and the bending of its front end, as well as to a general twisting at the exit. Because of small taper of groove of the rail closed passes they were quickly worn on width, and their full restoration was complicated in connection with need of the big metal removal from rolls at roll remachining. Significant deficiencies of the rail rolling mode, presented by the Supplier of Rail and Structural Steel Shop equipment, stipulated the need to develop a new rolling mode, the main features of which were: the use of an intensified mode of reductions in the first breakdown stand; reducing the number of passes in the second breakdown stand; the use in the second breakdown stand of rail passes of skew type with diagonal splits instead of closed-type rail passes. To solve the technical problems for improving the rolling mode of longlength railway rails, a new method of grooving of skew passes with alternating direction of skew in the rolls of the duo stand for rolling of railway rails was developed and introduced into production. This method eliminates the influence of support cones in rolls with skew passes with alternating direction of skew for rolls approaching up to zero on the collars. The introduction of this method made it possible to achieve high-quality design of the geometric parameters of the pass during the rolling process by expanding the range of passes settings, improving the quality of rails, roll resistance and rolling mill yield. The introduction of an improved mode of railway rails rolling showed a significant improvement in technical and economic indicators. Reducing of the number of passes in the breakdown stands and the use of a new method of grooving of skew rail passes with alternating direction of skews in the rolls of the breakdown stand allowed to increase the rolling mill yield when rolling of rails of R65 type to 195 t/h, reduce the specific power consumption by 0,51 kWh/t and the consumption of rolling rolls by 0,51 kg/t, reduce the rejection of rails by the defect «scab» by 0,5%.

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