The hot preflex cooling and compound straightening are the last two consecutive deformation processes and determine the straightness, residual stress and cross-sectional size for fabricating hundred-meter heavy rail products. The compound straightening process needs to be adjusted by the preflex cooling status. For studying the straightness, residual stress and cross-sectional size of heavy rail products, the preflex cooling model (including the residual stress) of heavy rail after cooling should be taken as straightening model for studying the compound straightening. In this paper, the results by ANSYS implicit analysis (geometry model and stress state of the cold heavy rail) is fully imported to the compound straightening by ANSYS/LS-DYNA explicit analysis through an implicit-explicit conversion method, which resolved the connection problem of coupling and analysis models for solving complex models in multi-physical fields. It is very significant for solving the similar problems in engineering.

Abstract：Based on the real geometry and boundary conditions of the wheels and rails, the models of 60kg/m U75V heavy rail and the wear regions of LM are built using ANSYS/LS-DYNA software. The internal stress value and variation of the heavy rails that were repeatedly crushed by the rolling wheels are analyzed using the ANSYS/LS-DYNA3D software. The relationship of the internal stress and variation of heavy rails with the repeated rolling of the wheels are obtained. It provides an important theoretical proof and reference significance to prevent the different failure behaviors of the rails.