Simulation And Performance Study On Forming Process Of Aobei Ductile Iron Wheel

Rail transportation, including subway, light railway, and other types, is the infrastructure to keep the stable economic development. Each type of them has various range of applications. In recent years, rail traffic in China is in a stage of vigorous development..However, with the continuous improvement of train speed, the emergence of a variety of security problems in the process of high-speed operation have not been resolved.Peeling, cracks and other defects appeared in existing wheels during operation have not meeting the rapid development of rail transportation needs.This paper aims to research and develop new high strength and toughness austempered ductile iron of vibration and noise reduction as new materials of train wheels.This article from the three aspects of research, design optimization of the chemical composition of ADI, ProCast molding simulation and experiments, and other aspects of temperature quenching process and performance testing analysis.The equilibrium solidification phase, phase transition temperature and segregation is calculated by Jmatpro to analyze basis case composition’s influence on the mechanical properties and the casting process. Effect of alloying elements on the basis of improving the ductile hardenability and segregation of alloying elements to produce insoluble carbides is used to optimize alloying elements and basis elements of ADI wheels.The casting process of train wheels is simulated by ProCast. Using balanced solidification technology is reasonable based on simulation results. Riserless gating system design, extensive use of cold iron, increase casting cooling rate, reducing the casting liquid pouring temperature can reduce the amount of shrinkage, get high-quality non-defective train wheel castings. Experimental results consistent with the simulation results.ADI samples is prepared by orthogonal test different heat treatment process parameters. According to the tensile strength of the after heat-treated sample, testing elongation, hardness, toughness and microstructure analysis to determine the optimum heat treatment process on ADI train wheels. The experimental verification ADI wheel performance testing tensile strength reached 1100MPa, elongation at more than 6%, the spokes sampling sites toughness greater than 8J/cm2, hardness 31HRC or more. Compared with ordinary train wheels ADI has the effect of reducing vibration and noise. Experiments show that ADI comply with the performance requirements of the train wheels.