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Utilizing scrapped rail axles is very popular lately. Products such as mill balls, rods, flat bars,
ploughshares and shovels [1,2] are manufactures. This article presents the results of the
analysis of the possibility of manufacturing sling hooks (Fig. 1) from the central part of the
bottom of the scrapped rail. Sling hooks are used in mining for fastening and stabilizing rails
of suspended monorail systems. A process of roll forging of preform and die forging of the
sling hook. The preform was manufactured by roll forging in 3 impressions. The developed
technology was verified using FEM numerical modelling. Numerical simulations were carried
out in Deform 3D software. On the basis of the numerical calculations the energy parameters
of the process were determined. Distributions of effective strain, Cockcroft-Latham damage
criterion and temperature were determined. Moreover, the possibility of the occurrence of
phenomena disturbing the process were analysed.
