Development of a Method for Calculating Metal Deformation in Universal Four-Roll Stands during the Rolling of Asymmetric Rail Profiles

A method has been developed for calculating metal deformation in universal four-roll stands during the rolling of asymmetric rail profiles on universal rail-beam mills equipped with a continuously-reversible group of cages. The profile features different dimensions of elements relative to the vertical and horizontal axes. The condition of equality of draw coefficients across all profile elements during deformation is achieved by separately determining the deformation coefficients of the neck and flanges in the upper and lower parts of the stand relative to the horizontal axis. The proposed geometric model of dividing the universal stand along the horizontal axis into equal areas allows for the most accurate determination of the set of deformation parameters for each element of this stand, ensuring equality of their draws. The set of deformation parameters for the elements in the stand includes the determination of the magnitude of lateral compression, the increase or reduction of the flanges at the base and head of the rolled profile, and the extent of neck widening. When the draws of the profile elements in the stand are equal, there is no metal flow between the profile elements.