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Numerical simulation of manufacturing process chain for pearlitic and bainitic steel rails

Milenin Andrij, Zalecki Władysław, Pernach Monika, Rauch Łukasz, Kuziak Roman, Zygmunt Tomasz, Pietrzyk Maciej

Archives of Civil and Mechanical Engineering

2020

Vol. 20, no. 4

125--142

Computer system for the design of technology of the manufacturing of pearlitic and bainitic rails was presented in this paper. The system consists of the FEM simulation module of thermal–mechanical phenomena and microstructure evolution during hot rolling integrated with the module of phase transformation occurring during cooling. Model parameters were identified based on dilatometric tests. Physical simulations, including Gleeble tests, were used for validation and verification of the models. In the case of pearlitic steels, the process of subsequent immersions of the rail head in the polymer solution was numerically simulated. The objective function in the optimization procedure was composed of minimum interlamellar spacing and maximum hardness. Cooling in the air at a cooling bed was simulated for the bainitic steel rails and mechanical properties were predicted. The obtained results allowed us to formulate technological guidelines for the process of accelerated cooling of rails.

Selection of the best phase transformation model for optimization of manufacturing processes of pearlitic steel rails

Kuziak Roman, Pidvysots'kyy Valeriy, Pernach Monika, Rauch Lukasz, Zygmunt Tomasz, Pietrzyk Maciej

Archives of Civil and Mechanical Engineering

2019

Vol. 19, no. 2

535--546

Selection of the best model for simulation of manufacturing processes of pearlitic steel rails was the objective of the paper. Achieving a proper balance between its predictive capabilities and computing costs was used as a criterion. Review of the pearlitic transformation models was performed and modification of the JMAK equation was selected for further analysis. Empirical models were developed to describe microstructure and mechanical properties of rails. Dilatometric tests were performed to supply data for identification of the phase transformation model. Physical simulations of various thermal cycles were performed to validate and verify the models. Finite element (FE) simulations of the hot rolling provided distributions of the temperature and the austenite grain size at the cross section of the rail, which were used as an input for modelling of phase transformations during cooling. Accelerated cooling by a cyclic immersion of the rail head in the polymer solution was considered as a case study. Performed simulations confirmed good predictive capabilities of the model.