Research On The Formation Of L-A Brake Frame

The project comes from the Railway Ministry of China. It is one new product -developed project that was carried on by Chongqing Heavy-Duty Casting & Forging Plant.Brake beam is one of the important parts working for rail vehicles running, which directly affects the security and stability when rail vehicles are running. While the brake beam is one of the main parts, and its' performance is very important. The Railway Ministry of China made the plan that rail vehicles will run over loading, with high speed, safely. Therefore the working performance of brake beam needs to improve, meanwhile the task of developing L-A brake frame was brought out. According to designing request, the forming process of the brake frame needs to improve from casting to forging.The brake frame is a triangle with "+" section, so it is difficult to be formed. Aiming at the structure characteristics and combined with factory condition, the forming scheme: pre-forging—final forging—cutting mouth—drawing was brought out first. And then with the well using FEM software Deform-3D, the working procedure was simulated and analyzed. The defects and problems possible happening in practice were forecasted, at the same time the process parameters were optimized. Based on the simulation result the forming die were designed.This paper states Rigid-porous-plastic finite element method and built the FEM model of the brake frame. With balanceing the two forming schemes, the forming die and drawing equipment were designed. In the section of test and validating, it was sated whether the test result agreed with the simulation result. At last some conclusions were obtained.Through this research the difficult key problems were settled. Thus the whole developing work was promoted. At the same time this research can act as important reference to the form of other similar structure parts.