Skew Rolling of Rods from Scrap Rail Heads
Abstract
:1. Introduction
2. Finite Element Method (FEM) Analysis of Two-Stage Rolling of Rods from Scrap Rail Heads
3. Experimental Verification of Rod Rolling in Helical Passes
4. Conclusions
- Rods can be efficiently rolled from scrap rail heads in two passes in a process that combines longitudinal and skew rolling.
- The preform rolled from a scrap rail head in the longitudinal rolling mill can be used to roll rods with a wide range of diameters in one (skew) rolling mill and with one set of helical tools.
- The strains that develop during the rolling of rods in the helical passes are unevenly distributed.
- Despite a nonuniform cross-sectional outline of scrap rail head, the products rolled in the skew rolling mill are characterized by a high quality and precision.
- During skew rolling of rods, cavities form on the end faces of the rods; they are treated as stock allowance.
- Rolling in helical passes is performed at relatively low radial forces and torques.
- The good agreement between the experimental and simulation results supports the use of numerical modelling in the analysis of complex metalworking processes.
- Further research should be carried out to determine the impact of technological parameters on the course of the rolling process and the quality of the products obtained.
Author Contributions
Funding
Conflicts of Interest
References
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Stage | Rail Head | Worn Rail Head | Preform | Rod |
---|---|---|---|---|
Cross-sectional area S, mm2 | 3050 | 2800 | 2400 | 1635 |
Elongation coefficient λ = S0/S1 | - | - | 1.16 | 1.45 |
Parameter/Rolling Mill Type | Skew Rolling Mill | Longitudinal Rolling Mill |
---|---|---|
Position of rolls in the working cage; mm | horizontal | vertical |
Nominal roll diameter; mm | 320 | 320 |
Working length of roll barrel; mm | 400 | 320/160 |
Minimum distance between roll axes; mm | 300 | 310 |
Maximum distance between roll axes; mm | 350 | 330 |
Possible inclination of the shaft axis to the rolling axis; deg | ±12 | - |
Minimum rotational speed of rolls; rpm | 15 | - |
Minimum rotational speed of rolls; rpm | 30 | 30 |
Nominal torque on one roll (for 15 rpm); kNm | 20 | - |
Nominal torque on one roll (for 30 rpm); kNm | 10 | 5 |
Machine dimensions; m | 3.2 × 1.8 × 2.1 | 2.4 × 1.5 × 1.4 |
Machine weight; kg | 17,500 | 4200 |
Motor power; kW | 60/80 | 22 |
Research Method | H; mm | B; mm | h; mm | b; mm | d; mm |
---|---|---|---|---|---|
FEM | 73.9 | 52.5 | 58.9 | 57.6 | 45.1 |
Experiment | 73.9 | 53.0 | 59.2 | 58.0 | 45.3 |
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Tomczak, J.; Pater, Z.; Bulzak, T. Skew Rolling of Rods from Scrap Rail Heads. Materials 2019, 12, 2970. https://doi.org/10.3390/ma12182970
Tomczak J, Pater Z, Bulzak T. Skew Rolling of Rods from Scrap Rail Heads. Materials. 2019; 12(18):2970. https://doi.org/10.3390/ma12182970
Chicago/Turabian StyleTomczak, Janusz, Zbigniew Pater, and Tomasz Bulzak. 2019. "Skew Rolling of Rods from Scrap Rail Heads" Materials 12, no. 18: 2970. https://doi.org/10.3390/ma12182970