Finite-Element Simulation Of Universal Rolling Process For 60kg/m Rail

In recent years, with the development of high-speed railroad, it needs more and more rails of high precise size in line. More new and high requirement for rail produce is needed. According related study, the difference of rail between abroad and domestic is mainly size precision, but there is less difference of composition and capability . In producing technics aspect, the main effect factors to size are walking beam furnace and universal rolling. The heavy rail must be produced by high precision rolling method, so it is necessary to produce heavy rail by universal mill.This research particular deduced the theory formula for thermal-machinery coupling by explicit FEM. and solved the simulation of large deformation of the slab and geometrical, material and contact nonlinear. By means of ANSYS/LS-DYNA, the element, which has geometrical nonlinear option, could be used. As for material nonlinear, the elastic-plastic model-Bilinear Isotropic Model, 3D solid 164 elements with 8 nodes and set corresponding element option and parameters was introduced. For the contact linear, the contact could be set auto-contact. The mechanical model was established and the load case has been submitted. The result was outputted by the LS-PREPOST to make it visualized.At present, many researches have been done on simulating the process of metal molding, but few for heavy rail that has complex section. The parameters for the simulation were coming from heat analog machine ago, so many things were limited. But this study took rolling temperature, rolling velocity, friction coefficient, universal pass characteristic into account, the results have important appliance value.On the basis of nonlinear FEA code ANSYS/LS-DYNA, rail rolling process of universal rolling unit were simulated by 3D large deformation thermal-mechanical coupled elastic-plastic FEM. And the deformation shape of the work piece, deformation parameters and cross dimensions for each pass were obtained and stress, stain distribution and metal flow in rolling process of typical passes were analyzed in detail. Analyzed typical pass stress and strain distribute, rolling stress and deforming in universal pass last groove in detail, discussed the effect regularity of residual stress distribution and size to safely using rail, detailed to expound universal pass to railhead tread circular arc process. Analyzed temperatures distribute during roughing roll and the effect of rolling parameter to draught pressure, analyzed the effect of rolling parameter to railhead and extension of heavy rail. At last, the research analyzed metal point's flow characteristic and revealed deforming regularity of heavy rail.