In modern day industry of heavy engineering, parts made from billets comprising large-sized pipe forgings are widely used. The paper presents results of the study of various methods of broaching on mandrel of large-sized pipe forgings and presents the results of industrial testing of the developed methods of broaching and designs of mandrels.

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To extend the life of air tuyeres and reduce heat losses through their surfaces, boron carbide seal ant is applied to tuyeres with a sprayed aluminum coating after heat treatment. The influence of the B 4 C based sealant on the heat losses is theoretically assessed. The efficiency of the sealant is confirmed by industrial trials at OAO NLMK and by metallographic investigation of samples from used tuyeres.

A procedure has been developed for calculating the geometric, kinematic and energy-power parameters of helical rolling, which allows a comparative analysis of the processes carried out in stands of various designs. Based on the results of this analysis, a helical rolling mill was designed and manufactured which allows to roll materials with high deformation resistance at high temperatures. The results of the study of the mechanical characteristics of molybdenum bars and wires made by new technology are presented.

The paper discusses the prospects of creating an algorithm for designing a roll forming mill. The algorithm scheme implies a parametric input of the initial data of technology requirements, a calculation of structural elements taking into account requirements of the customer and the output of the algorithm result in the form of design documentation for the rolling facility.