Largest Bronx rail straightening lines delivered to Russia

Bronx rail straightener

Fives has designed, manufactured and supplied two high-performance Bronx rail straightening machines to Russia's EVRAZ group, an integrated holding in steel, mining and vanadium sectors.

The Bronx machine is the largest rail straightening equipment ever produced by Fives. It straightens rails that pass the critical residual stress requirements. The first straightening line was delivered to Nizhny Tagil Metallurgical Plant (NTMK) in the Sverdlovsk region of Russia, while the second set of equipment was handed over to Novokuznetsk Iron and Steel Plant (NKMK) in Kemerovo region of Russia.

Bronx rail straighteners at EVRAZ

The Bronx machines were developed jointly with EVRAZ specialists from the technical direction on modernization of rail and beam workshops. The project was a challenge for both teams, as rail production requires high standards in technologies and metal processing. The engineers had to develop a technology that is able to straighten rails in two dimensions - horizontal and vertical. The Bronx line includes a horizontal straightening machine featuring nine staggered rollers with centers of 1600mm and a vertical straightening machine that has 8 staggered rolls pitched at 900mm between centers and is vertically adjustable to match the pass heights by raising and lowering the four corners. The height adjustment is done with heavy duty jacks that employ a guidance system of large diameter round posts.

Bronx machines are capable of straightening railway rails P50, P65, P65K, 60E1, UIC54, UIC60, S49, 115RE, 136RE and 141RE in accordance with Russian state technical standards (GOST), with a capacity of 60 pcs/hour for rails of 52 meters long and 30 pcs/hour for rails of 104 meters long.

The equipment line is designed with the maximum calculated load and deflection required to straighten the rails. The majority of calculated deflection is applied in the first triangle and then gradually reduced at 2/3 and 1/3 and finally zero to guide the rail out of the machine. To achieve the required stable low level of residual stress, it is necessary to provide a level of plastic work at roll N4 approximately equal to the plastic work as provided at roll N3. By using this principle for straightening, the residual stress that is apparent at roll N4 is compensated by the residual stress that is evident at roll N3.  

Bronx rail straightening lines are equipped with COMPASS, a patented, computer-aided setting system. The system utilizes the latest in industrial electrical and electronic technology to provide consistently high quality product and throughput capacity. With the COMPASS system, machine set up times for a size change are reduced, while its data collection and storage is vital to the producer and end user when processing such sensitive and critical components.