1. Introduction
A variety of standard sizes of H-beams are usually used in the construction
industry as beams and columns to support loads. However,
conventional H-beam rolling process often yields some defects including
strong axis bending and weak axis bending distortion, as shown in
Fig. 1. These types of errors are normally resulted from improper roller
gap during rolling, the difference of transformation during cooling and
improper placement during transport. Such defects distortion could
result in the elastic–plastic bulking behavior of the supportingmember
[1–3]. Therefore, the quality of H-beams, including perfect flatness and
small residual stress distribution, is an important performance consideration
in design. The leveling process with different leveling methods
for different defects is designed to reduce such defects before their use
as structural members in construction. To ensure effective correction
of the aforementioned defects and quality improvement in the production
of H-beams, it is necessary to develop an effective and robustmodel
to simulate the leveling process and to minimize the defects.
The characteristic of leveling method for rails is similar to that of
H-beams. The contact area with rollers is on the web, flange surface of
the rails or H-beams which depends on their defects type. Based on
the literature survey, many researchers evaluated the residual stress
distribution about the rail with finite element method (FEM) and
some of their results produced good agreement with experimental
results. For example, Betegón Biempica et al. [4] studied the residual
stress reduction in the leveling process for UIC-60 rail and built models
by FEM to simulate one, two and three-dimensional analyses of a rail.
Srimani et al. [5] developed a simulated model using an FEM method
to evaluate the residual stress distribution and to reduce its magnitude
by controlling the relevant parameters of the straightening operation.
They also indicated a suitable procedure for examination of the straightness
of finished rails. In addition, they found that the straightness of the
front and the rear end of the rail are different from each other and they
are different fromthat of themiddle portion of the rail [6]. Talamini et al.
[7] predicted that the magnitude of the contact load is a decisive factor
on the stress field in comparison with the 2 and 3-dimensional residual
stress results. Zhao et al. [8] built a finite elementmodel to simulate the
straightening process and analyzed the web failure effect with the
bending deflection and the roller spacing but without sufficient experimental
validation. Song et al. [9] established an FEM model of nine horizontal
rollers straightening with original curvature for 60 kg/m heavy
rail and analyzed the stress changing rules of heavy rail during the leveling
process just with coarse mesh. Schleinzer et al. [10] presented an
FEM simulation model for the roller straightening process of rails
using Chaboche's multiple component non-linear kinematic hardening
model to account for the plastic behavior with the consideration of the
longitudinal movement of the rail. The obtained results from this
Journal of Constructional Steel Research 102 (2014) 13–23
⁎ Corresponding author. Tel.: +86 023 6510 6999.
E-mail addresses: liuzhifang@cqu.edu.cn (Z. Liu), wyq@cqu.edu.cn (Y.Wang),
h.ou@nottingham.ac.uk (H. Ou), yanxingchun@cqu.edu.cn (X. Yan), yxluo@cqu.edu.cn
(Y. Luo).
http://dx.doi.org/10.1016/j.jcsr.2014.06.010
0143-974X/© 2014 Elsevier Ltd. All rights reserved.
Contents lists available at ScienceDirect
Journal of Constructional Steel Research
1. Introduction
A variety of standard sizes of H-beams are usually used in the construction
industry as beams and columns to support loads. However,
conventional H-beam rolling process often yields some defects including
strong axis bending and weak axis bending distortion, as shown in
Fig. 1. These types of errors are normally resulted from improper roller
gap during rolling, the difference of transformation during cooling and
improper placement during transport. Such defects distortion could
result in the elastic–plastic bulking behavior of the supportingmember
[1–3]. Therefore, the quality of H-beams, including perfect flatness and
small residual stress distribution, is an important performance consideration
in design. The leveling process with different leveling methods
for different defects is designed to reduce such defects before their use
as structural members in construction. To ensure effective correction
of the aforementioned defects and quality improvement in the production
of H-beams, it is necessary to develop an effective and robustmodel
to simulate the leveling process and to minimize the defects.
The characteristic of leveling method for rails is similar to that of
H-beams. The contact area with rollers is on the web, flange surface of
the rails or H-beams which depends on their defects type. Based on
the literature survey, many researchers evaluated the residual stress
distribution about the rail with finite element method (FEM) and
some of their results produced good agreement with experimental
results. For example, Betegón Biempica et al. [4] studied the residual
stress reduction in the leveling process for UIC-60 rail and built models
by FEM to simulate one, two and three-dimensional analyses of a rail.
Srimani et al. [5] developed a simulated model using an FEM method
to evaluate the residual stress distribution and to reduce its magnitude
by controlling the relevant parameters of the straightening operation.
They also indicated a suitable procedure for examination of the straightness
of finished rails. In addition, they found that the straightness of the
front and the rear end of the rail are different from each other and they
are different fromthat of themiddle portion of the rail [6]. Talamini et al.
[7] predicted that the magnitude of the contact load is a decisive factor
on the stress field in comparison with the 2 and 3-dimensional residual
stress results. Zhao et al. [8] built a finite elementmodel to simulate the
straightening process and analyzed the web failure effect with the
bending deflection and the roller spacing but without sufficient experimental
validation. Song et al. [9] established an FEM model of nine horizontal
rollers straightening with original curvature for 60 kg/m heavy
rail and analyzed the stress changing rules of heavy rail during the leveling
process just with coarse mesh. Schleinzer et al. [10] presented an
FEM simulation model for the roller straightening process of rails
using Chaboche's multiple component non-linear kinematic hardening
model to account for the plastic behavior with the consideration of the
longitudinal movement of the rail. The obtained results from this
Journal of Constructional Steel Research 102 (2014) 13–23
⁎ Corresponding author. Tel.: +86 023 6510 6999.
E-mail addresses: liuzhifang@cqu.edu.cn (Z. Liu), wyq@cqu.edu.cn (Y.Wang),
h.ou@nottingham.ac.uk (H. Ou), yanxingchun@cqu.edu.cn (X. Yan), yxluo@cqu.edu.cn
(Y. Luo).
http://dx.doi.org/10.1016/j.jcsr.2014.06.010
0143-974X/© 2014 Elsevier Ltd. All rights reserved.
Contents lists available at ScienceDirect
Journal of Constructional Steel Research
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