Five Pitch Pin Rail Roll Forging - Die Forging Compound Forming Process Simulation

In this article, the die forging process of five pitch pin rail was analyzed andstudied, and the numerical simulation work was conducted to confirm that thecomposite forming process of roll forging-friction press finish forging methodis rational and feasible. Roll forging is a new technology in forging industry, forit not only increases the productivity, but also improves the working conditionsto workers. The billets before roll forging and finish forging were preciselyobtained using the composite forming process of roll forging-finish die forgingmethod which was performed and simulated by computer. By this method, thematerial utilization was improved, more over, it greatly reduced the die forgingequipment tonnage which was required in forging process, that was, the selectionof3000ton friction screw press in finish forging work compared with theconventional equipment of8000t hot forging press, the equipment investmentwas reduced by50%at least. As a result, the production costs were significantlyreduced.The billets and moulds of3D model of the five pitch pin rail in roll forgingprocess and finish forging process was established using UG software. Based onthe basic principle of rigid-plastic finite element method, the preform and finishforging process were simulated through DEFORM-3D finite element numericalsimulation software. The deformation law in forming process, stress and straindistributions and their changing processes were summarized, and the problemsand solutions in the simulation process were pointed out. After repeatedrevisions and simulations, finally, the fine forming of five pitch pin rail has beenachieved, and the specific forming process parameters has been determined. Bythe analysis of simulation results, the choice of equipment has been determined.It provides the reference basis and the technical support for the developmentand production of die forging process of pin rail and the similar forgings.