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Kushnarev A.V., Kirichkov A.A., Bogatov A.A., Puzyrev S.S. Railway wheel manufacturing process improvement

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Abstract

This work summarises the results of research on the railway wheel manufacturing process focused on reduction of the metal consumption index, material and energy savings, and better wheel performance reproducibility and durability. "EVRAZ NTMK" Open Joint Stock Company has completed a comprehensive and ambitious initiative to find and apply new technical solutions for improved converter treatment and secondary metallurgy, continuous casting processes, new process flow charts of wheel deformation processing by forging, rolling, dishing, restriking, and preforming.
The rough wheel accuracy increased and the wheel block weight decreased due to a combination of upsetting, spreading and sizing of wheel blocks at blocker-type forging, as well as the application of the method of forging self-alignment in final molding dies. The forging and rolling line is highly automated; process measurement capabilities ensure occurrence of online setting correction prompts and minimization of wastes. Hard wheels (320 НВ) and super hard wheels (350 НВ) of sustainable quality have been manufactured due to strengthening of requirements on wheel austenitizing temperature accuracy and the application of a rational wheel-tread quenching rate. Railway wheel service performance has been increased by 50% due to the implementation of a full-profile wheel machining, wheel plate shot peening, and tougher ultrasonic and fluorescent magnetic particle methods of quality control.

Keywords

Railway wheel; cast billet; dies; forging; secondary metallurgy; continuous casting; modification; vacuum degassing; computer simulation; measurements; size precision; quenching; tempering; machining; shot peening; instrumental quality monitoring.

 

Kushnarev Aleksey Vladislavovich – D.Sc. (Eng.), Managing Director of EVRAZ NTMK Open Joint Stock Company, Nizhni Tagil, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it..
Kirichkov Anatoly Aleksandrovich – Ph.D. (Eng.), Advisor to the Managing Director of EVRAZ NTMK for Research and Technology Advancement, Nizhni Tagil, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it..
Bogatov Aleksander Aleksandrovich – D.Sc. (Eng.), Professor, Head of the Metal Forming Department, Ural Federal University named after the First President of Russia B.N. Yeltsin, Yekaterinburg, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it..
Puzyrev Sergey Sergeyevich – Postgraduate Student, Ural Federal University named after the First President of Russia B.N. Yeltsin, Yekaterinburg, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it..
  1. Kushnarev A.V. Ispolzovanie inzhektsionnykh tekhnologiy vnepechnoy desulfuratsii vanadisoderzhashchego chuguna-poluprodukta v konverternom tsekhe NTMK [Application of the DeV hot metal desulfurizing injection processes at the BOS of the NTMK]. Metallurg [Metallurgist]. 2004, no. 10, pp. 36–38.
  2. Kushnarev A.V., Smirnov L.A. Sovremennoe sostoianie i perspektivy pererabotki titano-magnetitovogo vanadisoderzhashchego syria v Rossii [Present and future of titanium and vanadium iron ore processing in Russia]. Chiornaya metallurguia. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii [Ferrous metallurgy. Science, Technology and Economy Bulletin]. 2013, no. 5, pp. 3–20.
  3. Kushnarev A.V. (et al.) Razrabotka i razvitie peredela vanadisoderzhashchikh chugunov kislorodno-konverternym protsessom [Engineering and improvement of vanadium-bearing cast iron LD processing]. Stal [Steel]. 2013, no. 9, pp. 32–36.
  4. Kushnarev A.V. Novaya tehnologuia proizvodstva kolesnoy stali na OAO «EVRAZ NTMK» [New wheel steel manufacturing process at “EVRAZ NTMK” OJSC]. Chiornye metally [Ferrous metals]. 2014, no. 3, pp. 33–37.
  5. Kushnarev A.V. Povyshenie kachestva nepreryvnolitogo slitka iz kolesnoy stali na OAO «EVRAZ NTMK» [Improvement of the quality of continuous wheel steel cast billet at “EVRAZ NTMK” OJSC]. Chiornye metally [Ferrous metals]. 2014, no. 3, pp. 28–32.
  6. Kushnarev A.V., Bogatov A.A., Kropotov V.A. Vybor ratsionalnogo sootnoshenia obzhatiy pri shtampovke i prokatke zheleznodorozhnykh kolios [Selection of an efficient ratio of reductions during railway wheel forging and rolling]. Proizvodstvo prokata [Rolled steel manufacturing]. 2010, no. 3, pp. 21–24.
  7. Kushnarev A.V., Kirichkov A.A., Shestak V.D., Petrenko Yu.P., Vasilev A.A., Sultinskikh I.E., Zudov A.F. Sposob shtampovki zagotovok dlya tselnokatanykh kolios [All-rolled wheel block forging technique]. Patent no. 2335373 Russian Federation, 2008.
  8. Kushnarev A.V., Bogatov A.A., Kirichkov A.A., Kropotov V.A., Shestak V.D., Petrenko Yu.P. Sposob izgotovlenia tselnokatanykh zheleznodorozhnykh kolios [All-rolled railway wheel manufacturing technique]. Patent no. 2404009 Russian Federation, 2010.
  9. Kushnarev A.V., Bogatov A.A., Kropotov V.A. Matematicheskoe modelirovanie chernovoy i chistovoy shtampovki nepreryvnolitykh zagotovok, ispolzuemykh pri proizvodstve zheleznodorozhnykh kolios [Mathematical modeling of rough and fine die forging of continuous cast blocks used for railway wheel manufacturing]. Kuznechno-shtampovochnoe proizvodstvo [Die forging]. 2010, no. 1, pp. 34–38.
  10. Kushnarev A.V. (et al.) Razvitie i osvoenie v OAO «Nizhnetagilsky metallurguichesky kombinat» novoy tekhnologuii proizvodstva zheleznodorozhnykh kolios vysokogo kachestva [Development and assimilation of a new process of high-quality railway wheel manufacturing at the "Nizhni Tagil Metallurgical Plant" OJSC]. Proizvodstvo prokata [Rolled steel manufacturing]. 2008, no. 1, pp. 24–28.
  11. Kushnarev A.V., Kirichkov A.A., Shestak V.D. [et al.] Introduction of wheel production on a new pressing and rolling line. Steel in Translation. 2010, vol. 40, no. 12, pp. 1098–1100.
  12. Kushnarev A.V., Kirichkov A.A., Petrenko Yu.P., Bogatov A.A. Production of high-quality railroad wheels. Steel in Translation. 2010, vol. 40, no. 3, pp. 268–272.
  13. Kushnarev A. V. Razrabotka nauchnykh osnov i vnedrenie sovremennoy tekhnologuii proizvodstva zheleznodorozhnykh kolios s vysokimi ekspluatatsionnymi kharakteristikami [Development of scientific principles and implementation of a modern high-performance railway wheel manufacturing process]. Innovatsionnye tekhnologuii v metallurguii i mashinostroenii [Innovative steelmaking and machine building processes]. 2013, pp. 626–637.
  14. Kushnarev A.V., Vasilev A.A., Shestak V.D., Bogatov A.A. Improved wheel rolling. Steel in Translation. 2010, vol. 40, no. 5, pp. 485–487.
  15. Kushnarev A.V., Bogatov A.A. Razrabotka i teoreticheskoe issledovanie novykh sposobov izgotovlenia zheleznodorozhnykh kolios na OAO «NTMK» [Development and theoretical exploration of new railway wheel manufacturing techniques at "NTMK" OJSC].  Nizhni Tagil, 2009, p. 46.
  16. Kushnarev A.V., Bogatov A.A. Teoretichesky metod otsenki tochnosti pokovok i zheleznodorozhnykh kolios [Theoretical evaluation method of forging and railway wheel accuracy]. Proizvodstvo prokata [Rolled steel manufacturing]. 2015, no. 9, pp. 23–26.
  17. Kushnarev A.V. (et al.) Stoikost shtampovogo instrumenta pri izgotovlenii zheleznodorozhnykh kolios [Forging tool durability in railway wheel manufacturing]. Proizvodstvo prokata [Rolled products manufacturing]. 2015, no. 5, pp. 46–48.
  18. Kushnarev A.V. (et al.) Strukturno-fazovye prevrashchenia pri nepreryvnom okhlazhdenii staley dlia tselnokatanykh zheleznodorozhnykh kolios [Structural and phase transformations in continuous cooling of steels for all-rolled railway wheels]. Stal [Steel]. 2014, no. 4, pp. 78–83.
  19. Teoreticheskoe obosnovanie i otrabotka konkretnykh rezhimov termoobrabotki kolios s tseliu poluchenia tverdosti 320–360 HB [Theoretical justification and development of specific wheel heat treatment conditions to obtain 320–360 HB hardness]: annotirovanny otchiot [annotation report]: rabota D 1084/2006 / Transmetall.
  20. Razrabotka tehhnologuii izgotovlenia tselnokatanykh kolios s tverdostiu oboda 350–390 HB na novom termouchastke KBTs OAO «NTMK» [Development of an all-rolled wheel manufacturing process to obtain 350–390 HB tread hardness at a new wheel heat treatment plant of the "NTMK" OJSC wheel shop]: annotirovanny otchiot [annotation report]: Rabota DGNT3-2679. 2010. ISO-lab.
  21. Opredelenie vliyania skorosti okhlazhdenia na prevrashchenia pereokhlazhdionnogo austenita v staliakh [Determination of the cooling rate impact on undercooled austenite transformations in steels]: tekhnicheski otchiot [technical report]. Rabota DGNT3-00-7408/2013 / FGBOU VPO Magnitogorsky gosudarstvenny tekhnichesky universitet im. G.I. Nosova [Nosov Magnitogorsk State Technical University].
  22. Kushnarev A.V. (et al.) Sovremenny kompleks termoobrabotki zheleznodorozhnykh kolios [Modern railway wheel heat treatment complex]. Chiornaya metallurguia. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii [Ferrous metallurgy. Science, Technology and Economy Bulletin]. 2010, no. 4, pp. 38–39.
  23. Filatov S.V. (et al.) Proizvodstvo na OAO «NTMK» kolios povyshennoy tviordosti [Hard wheel manufacturing at "NTMK" OJSC]. Chiornaya metallurguia. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii [Ferrous metallurgy. Science, Technology and Economy Bulletin]. 2011, no. 3, pp. 52–57.
  24. Kushnarev A.V., Fomichev M.S., Kirichkov A.A., Telyashov N.V., Timofeev V.V., Petrenko Yu.P., Flatov V.G. Sposob termicheskoy obrabotki zheleznodorozhnykh kolios [Railway wheel heat treatment technique]. Patent no. 2451093 Russian Federation, 2012.
  25. Kushnarev A.V. (et al.) Tekhnologuia proizvodstva zheleznodorozhnykh kolios povyshennoy tviordosti iz stali T [Hard T-steel wheel manufacturing process]. Stal [Steel]. 2011, no. 11, pp. 122–124.
  26. Kushnarev A.V. (et al.) Nauchnoe obosnovanie i vnedrenie novoy tekhnologuii i oborudovania dlia termicheskoy obrabotki kolios [Scientific rationale and implementation of new wheel heat treatment process and equipment]. Chiornaya metallurguia. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii [Ferrous metallurgy. Science, Technology and Economy Bulletin]. 2015, no. 6, pp. 19–23.
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