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Development and Modeling of the Technological Welding Process of Differentially Heat-Strengthened Rails: Industrial Testing

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Abstract

The article describes the welding process study with the subsequent control of cooling for full-profile rail joints, produced by passing alternating electric current pulses after welding. The welding mode influence on the welded joint quality was investigated. Welding was carried out on a resistance butt welding machine MCP-6301 in conditions of the rail welding company OOO RSP-M (RSP-29). For research, the samples of P65 type full-profile rails of DT350 category 600 mm long were cut out. The isothermal holding conditions after welding were controlled using a personal computer with a change in the program of the SIMATIC S7-300 industrial controller and the software SIMATIC STEP 7, which allows modes of controlled cooling to be set. The control program was written in the LAD graphic language. To search for optimal modes of controlled cooling, a complete factor experiment N = 2k was carried out. Non-heat-treated joints were tested for three-point static bending according to the state standard STO RZD 1.08.002 – 2009 “Railway rails, welded by electric contact method”. Static bending tests were carried out on the press of PMS-320 type. Values of the force arising during bending Pbend and the bending deflection fdef at which the control sample is destroyed, were determined. The maximum values of these indicators were also determined if the sample was not destroyed during the tests. During the experiments, regression models were obtained for output parameters of the bending force and bending deflection. Sample macrostructure and metal hardness distribution on rolling surface of the rails welded joint were studied. A new method of resistance butt welding was developed, which makes it possible to obtain a welded connection of P65 type rails of DT350 category with properties that exceed the technical requirements of the mentioned state standard.

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Funding

The study was carried out with the financial support of the Russian Foundation for Basic Research and the Kemerovo Oblast within the framework of the scientific project no. 20-48-420003 r_a “Development of physicochemical and technological foundations for creating a fundamentally new method of welding differentially heat-strengthened railway rails”.

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Authors and Affiliations

  1. Siberian State Industrial University, 654007, Novokuznetsk, Kemerovo Oblast, Russia

    N. A. Kozyrev, R. A. Shevchenko, A. A. Usol’tsev, A. N. Prudnikov & L. P. Bashchenko

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  1. N. A. Kozyrev
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  2. R. A. Shevchenko
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  3. A. A. Usol’tsev
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  4. A. N. Prudnikov
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  5. L. P. Bashchenko
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Corresponding authors

Correspondence to N. A. Kozyrev, R. A. Shevchenko, A. A. Usol’tsev, A. N. Prudnikov or L. P. Bashchenko.

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Translated by S. Avodkova

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Kozyrev, N.A., Shevchenko, R.A., Usol’tsev, A.A. et al. Development and Modeling of the Technological Welding Process of Differentially Heat-Strengthened Rails: Industrial Testing. Steel Transl. 50, 289–295 (2020). https://doi.org/10.3103/S096709122005006X

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  • DOI: https://doi.org/10.3103/S096709122005006X

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