Features of the Universal Rail Rolling Process
- What are the main differences between the universal rolling process and the traditional pass - rolling process?
The universal rolling process uses horizontal and vertical rolls to act on the rail section simultaneously, enabling symmetrical processing and precisely controlling the geometric dimensions of the rail, such as the width of the rail head and the thickness of the rail waist. In contrast, the traditional pass - rolling process forms the rail gradually through a single pass, with lower dimensional accuracy. The rail produced by the universal rolling process has a more uniform internal structure and better mechanical properties because the metal deformation is more sufficient during rolling, and the residual stress is small. The traditional pass - rolling process may have stress - concentration problems. In addition, the universal rolling process has higher production efficiency and can continuously roll long - length rails, while the traditional process has limited rolling length and frequent roll - changing, resulting in a slow production rhythm.
- How does the universal rolling process ensure the straightness of the rail?
In the universal rolling process, the straightness of the rail is ensured through high - precision roll - shape design and an advanced automatic control system. The precise coordination of horizontal and vertical rolls can apply uniform pressure to each part of the rail during rolling, preventing the rail from bending, twisting, and other deformations. At the same time, on - line detection equipment real - time monitors the straightness of the rail. Once a deviation is found, the control system immediately adjusts the roll gap and rolling speed for dynamic correction. For example, when a slight upward arch is detected in the rail head, the system will automatically reduce the pressure of the horizontal roll and increase the pressure of the vertical roll to restore the rail head to the correct shape, ensuring that the overall straightness of the rail meets high - standard requirements.
- What are the advantages of the rail produced by the universal rolling process in terms of welding performance?
The rail produced by the universal rolling process has better welding performance due to its uniform material and dense internal structure. During welding, the weld and the base metal are better fused, reducing the occurrence of welding defects such as pores and slag inclusions. Because during the universal rolling of the rail, the metal impurities are more evenly distributed, and after sufficient rolling and compaction, the impurities are not easy to accumulate at the weld during welding. In addition, the universal - rolled rail has low residual stress, and the stress - concentration phenomenon at the weld is not obvious after welding, which can effectively improve the strength and toughness of the welding joint, making the welding joint more firm and less prone to cracking, ensuring the overall performance and service life of the rail after welding.
- What improvements does the universal rolling process bring to the surface quality of the rail?
The universal rolling process improves the surface quality of the rail by optimizing the roll - surface quality and rolling speed during rolling. The high - precision roll - surface processing makes the rail surface smoother, reducing surface defects such as scratches and scabs. At the same time, the stable rolling speed and uniform pressure distribution avoid the folding phenomenon on the rail surface caused by uneven metal flow. In addition, the advanced descaling technology used in the universal rolling process can more effectively remove the oxide scale on the rail surface, making the rail surface cleaner. This not only improves the appearance quality of the rail but also enhances the corrosion - resistance of the rail, prolonging the service life of the rail during operation.
- How does the application of the universal rolling process affect the cost control of rail - producing enterprises?
Although the initial equipment investment in the universal rolling process is relatively large, it is conducive to cost control in the long run. On the one hand, its production efficiency is high, and it can continuously roll long - length rails, reducing the number of rolling passes and roll - changing times, and reducing labor and equipment maintenance costs. For example, the traditional pass - rolling process may require multiple rollings and roll - changings to produce a 100m - long rail, while the universal rolling process can form it at one time, greatly improving production efficiency. On the other hand, the rail produced by the universal rolling process has high quality and low defective - rate, reducing the waste loss and rework cost caused by product quality problems. In addition, this process can better adapt to the production of rails of different specifications. By adjusting the roll - shape, the product model can be quickly switched, reducing the production - conversion cost of the enterprise and improving the enterprise's response ability to market demand, thus achieving effective cost control as a whole.