Rolling Process Design of 115RE Steel rail

Rolling Process Design of 115RE  rail

115RESteel rail introduction:

The 115RE Steel rail is one of the standard sections formulated by the US railway department. Its theoretical unit weight is 56.89 kg/m, and it is the main type of rail that the US undertakes for railway operations. Pangang Steel rail and Beam Factory designs and develops the key points and technical difficulties in the rolling process, such as the installation of fishplates, the control of the bottom width of the Steel rail, the control of the flatness, and the distribution of the common extension coefficient, according to the specifications and technical conditions of the 115RE rail. The success has made the 115RE hot-rolled Steel rail the first high-end export Steel rail developed by Panzhihua Iron and Steel in accordance with American standards, successfully opened the door to the US railway steel market, and further enhanced the international reputation and competition of Panzhihua Steel’s Steel rail. force.

Design ideas for the rolling process

2.1.  115RE rail Specifications and Dimensions

The 115RE Steel rail is one of the standard sections formulated by the American railway department. Its theoretical unit weight is 56.89kg/m. The Steel rail profile is shown in Figure 1.

2.2   Design Ideas for the rolling process

From the analysis of the rolling process of the universal line, the key factor affecting the development cost and development cycle of the new product of the universal line is the new rolling of the BD mill. In order to reduce the development cost and shorten the development cycle to meet the contract requirements, it is considered to share the pass pattern with other varieties of BD machines. After comparing the main specifications and dimensions of each variety, the specifications and dimensions of the 60 kg/m Steel rail are the closest to those of the 115RE Steel rail, see Table 1.

Table 1. Comparison of main dimensions of 115RE Steel rail and 60kg/m Steel rail

Rail type	Rail height/mm	railhead/mm	web thickness/mm	rail base/mm	Web height/mm
115RE 60kg/m(TB)	168.3 176.0	69.1 73.0	15.9 16.5	139.7 150.0	100.8 102.5

In order to analyze whether the hole pattern of the BD machine shared with the 60kg/m Steel rail is appropriate, the main factors that must be considered are: whether the distribution ratio of the metal amount of the incoming head, web, and bottom of the pilot hole of the 60kg/m Steel rail is sufficient and whether each rack in the universal area is sufficient. Whether the deformation is uniform. The metal distribution ratio and elongation coefficient of the head, web, and bottom of the 115RE Steel rail and the comparison of the 60kg/m Steel rail is shown in Table 2 and Table 3.

Table 2. Metal distribution amount and the ratio of Steel rail head, rail web, and Steel rail base

Rail type	Railhead Qty/mm2     P/%	Rail web Qty/mm2    P/%	Rail base Qty/mm2   P/%	The total area/mm
115RE 60kg/m(TB)	2536      34.96 2867      37.00	1931      26.63 1993      25.73	2786      38.41 2888      37.27	7253 7748

Table 3. The extension coefficient of the pilot hole to the finished hole head, web, and base

Rail type	railhead	Rail web	Rail base	total extension
115RE 60kg/m(TB)	3.210 2.931	2.230 2.395	2.650 2.649	2.735 2.740

In order to analyze whether the hole pattern of the BD machine shared with the 60kg/m Steel rail is appropriate, the main factors that must be considered are: whether the distribution ratio of the metal amount of the incoming head, web, and base of the pilot hole of the 60kg/m Steel rail is sufficient and whether each rack in the universal area is sufficient. Whether the deformation is uniform. The metal distribution ratio and elongation coefficient of the head, web, and base of the 115RE Steel rail and the comparison of the 60kg/m Steel rail is shown in Table 2 and Table 3.