The Research On Forging Process Of Railway Axle With10MN Automatic Fast Forging Machine And Process Software Development

Abstract:With the rapid development of railway construction in our country, the demand for the railway axle is growing year by year. It has become a problem for production enterprise that how to improve production efficiency and expand capacity of railway axles. Independent research and development of10MN quick forging machine is the domestic first automatic production equipment for railway axle forgings to meet the market demand, and fast forging process is the core technology to realize the automatic forging. Based on the fast forging process for railway axles, combining the railway axle forgings’feature of many varieties and specifications, the research on forging process of railway axle with10MN automatic fast forging machine and process software development was carried out by numerical simulation combined with industrial test in this paper. The following research achievements have been achieved:(1) The influences of anvil type parameters on the efficiency of stretching with arc anvil were investigated by the numerical simulation of stretching process of railway axle forgings. The results show that both the efficiency of stretching with arc anvil and the maximum forging force increase as the arc radius of arc anvil decreases and the central angle increases; It is feasible anvil parameter for the arc anvil of10MN fast forging machine when the arc radius is150mm and the central angle is110°.(2) Fast forging forming simulation models of railway axle were established with Deform-3D finite element simulation platform. Under different process conditions, the numerical simulations of chamfer rolling and forming rolling process of railway axle forgings of many specifications were carried out, and the railway axles’material rheological law of forging forming was achieved. On this basis, railway axle’s fast forging process control model was established, which provided a theoretical basis for the design of railway axle’s fast forging process.(3) On the basis of the control model of railway axle fast forging forming process, railway axle fast forging process design software was developed with the Visual Basic and Access software. Through the numerical simulation of railway axle forging forming process, the correctness of the railway axle fast forging process design software was verified, which shows that the software can satisfy process design requirements of railway axle forgings of many varieties and specifications.(4) The automatic fast forging industrial tests of railway axle forgings were carried out on10MN fast forging production line. The test results show that when railway axle automatic forging forming is controlled by the process parameters which are outputted by the railway axle fast forging process design software, the railway axle forgings has a good dimensional stability and its dimensional accuracy can meet the technical requirements, and the production cycle is7to10minutes. It has effectively shortened the time of forging and improved the production efficiency.