Hot rolling process simulation: Application to UIC-60 rail rolling

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). © 2010 Bentham Science Publishers Ltd.