Simulation Research Of60kg/m High-speed Heavy Rail Horizontal Straightening Based On ANSYS Workbench

Railway is one of the foundation of national economy，and the rail is responsible for thesafety and reliability of railway.Nowadays, railway transportation is developing towards thedirection of high-speed and heavy-load，thus it has a higher requirement of the flatness and thecondition of residual stress for high-speed railway track.As the last finishing process in the high-speed heavyrail production process，straightening of high-speed heavyrail has a decisiveimpact on the residual stress after straightening and flatness. Thus, the stress variation law andstraightening rules of the straightening process are studied in this research. The followingstudies are carried out in two aspects.:1、The dissertation is based on elastoplastic theory and straightening principle,combinedwith the fracture of heavy rail during straightening and research status of our country,thestraightening model of60kg/m nine-roller heavy rail straightening is built by Pro/E.Thedynamics module of ANSYS Workbench is applied to make numerical simulations of railstraightening process,analysis of the rail stress evolution law during straightening，straightnessafter straightening and residual stress distribution.The result shows that the stress of rail headvaries from tensile stress to compressive stress alternately，the stress of rail foot varies fromcompressive stress to tensile stress alternately.The stress after straightening distrbuted like wordC，that is the stress state of rail head and rail foot is tensile，the stress in rail waist iscompressive，and the straightness of heavy rail meets the requirement of national standard.2、The ‘four factors and five levels’ orthogonal test is used to make straightening processoptimization，the four press rollers are four factors in the test，and given each factor fivelevels，thus there are25numerical simulations in this orthogonal test，and in the premise ofensuring the straightness of heavy rail by the means of using spss to make comprehensivecomparion and analysis of each simulation，the simulation with the minimum residual stress isthe best straightening process。Then there is a further optimization of straightening velocitybased on the straightening velocity in field manufacture，using increment method to improvestraightening velocity and making several simulations to find a suitable straightening velocity.By the simulation and analysis in this article，there is a optimal straightening processwhich is with smaller residual stress and higher product efficiency than the process in fieldproduction now in the premise of ensuring the straightness meets the national standard.The rail straightening process and velocity optimization has an important guide andreference significance in the improvement of rail quality，formulation of straightening processand straightening efficiency in the field production.