The Study Of Formability Of Thrust Cone Forging

ST bumper used to resist shock is a pivotal part in railway vehicle transportation. As primary load-transfer component of this part, thrust cone required very high precision and surface quality. The quality of thrust cone directly affected the stability and security of the startup and function of rail vehicle. Quality and performance of the product play an important part in developing of implement "heavy load, velocity rise and security" to railway van.Thrust cone has deep cavity and thin wall. Wall margin is hard to control during the forging process. Previously the Chongqing heavy forging factory had produced the component, which did not meet the demand of railway department since it has bad precision and surface quality and its wall margin is hard to control confined by equipment condition. Whereas the demand of railway department, it pressed for solving the problem that wall margin is over big during the thrust cone forging and molding process. At the same time, the implement of this item has important meaning for studying the molding processing feature of deep cavity and thin wall forging component.This task adopted advanced numerical simulation and forging processing theory to research thrust cone forging and molding processing. The main content as follows:Based on the further study of the key technical problem of rigid-viscoplasticity finite element theory, different forging processing have been simulated by making use of plastic molding software DEFORM-3D. Metal flow law and field mechanical quantity in the molding process have been analyzed. The forging processing of thrust cone has been optimized by simulating and analyzing the two different processing schemes. So the production of thrust cone forging component with wall margin within 1.5mm has become true.According to the optimized processing scheme to trial-manufacture the component, it indicates that current processing flow can produce the thrust cone forging component which completely met the technical demand. The processing flow is: saw cutting to get blank (the size of blank is 90×136 ); upset to biscuit on the 500 kilogram pneumatic hammer (after upset, the height of biscuit is 70mm, the maximum radius is 125mm. Clear oxide skin on the two end surface of blank with steel brush.); preforging on the 750 kilogram pneumatic hammer (ensure the bottom three pyramidal faces...