Hot Rolling Process Simulation: Application to UIC-60 Rail Rolling

Abstract

The aim of this paper is to present the developed procedure for the simulation of the hot rolling process also referring to some patents. Rolling is a 3D process but using the generalized plane strain method, the real 3D problem can be solved using 2D Finite Element Model (FEM), saving an important computing time. Thus, this procedure is really useful to give assistance in the roll design and to obtain the stock cross-section temperature distribution in the whole rolling process. On the other hand, it is also presented the thermo-mechanical characterization of the R260 quality steel, 0.7% C pearlitic steel, commonly used in rail rolling. Finally, the procedure is applied to simulate the UIC-60 rail hot rolling. A good agreement between FEM results and the sample shapes was obtained in the ArcelorMittal, S.A. rail mill facility in Asturias (Spain). The thermo-mechanical properties of the steel were obtained by means of an extensive testing program and the adjustment of the Peirce model was performed and verified to take into account the viscoplastic behavior of the steel. Finally, the simulation results were compared with sample geometries of the rolling rail after every pass given into all the different shape grooves. These samples were obtained in the ArcelorMittal, S.A. rail mill facility in Asturias (Spain), and the agreement between both simulation and sample geometry was evaluated.