The Digital Analysis Of Special Machine Center For High-speed Rail Turnout And Milling Process Research

Rail is one of our most important transport modes, which has the characters of strongadaptability, good security and high transport efficiency. The high-speed railway hasthe advantages of high speed, more comfortable, and large transport ability comparewith ordinary railway, which has been developing rapidly in recent years. Turnout isone of the key parts of the high-speed rail, the machine quality has direct effect on themaximum lateral allowable speeds, and then the overall transport capacity andsecurity are affected, In order to improve the machine quality of turnout, thecharacteristics of machine tool and the machining parameters selection are researched.The materials used in the high-speed railway turnout is high-manganese steelZGMn13, which has the property of high hardness, a kind of difficult machinematerial; the blank is formed by roll and the processing volume is large; at same time,enterprises require a relatively high processing efficiency. According to theseprocessing characteristics, the formed milling cutters are used in this project. Higherrequirements are put forward for the vibration and stiffness of machine tool as thecutting force is heavy. In order to ensure the processing quality of the workpiece, theproperties of machine vibration and stiffness, static and dynamic characteristics areresearched to prevent resonance and deformation. In the first part of the article,ANSYS is used as analytical tool for the modal analysis, we got the natural frequency,vibration mode and deformation data, and the modal tests are carried out to obtain theactual natural frequencies, vibration mode and the corresponding frequency responsecurve, the simulation results agree well with test results, which means the machinetool structure design is reasonable. At the same time, the first-order natural frequencyis more than50Hz, indicating that the rigidity is higher, which can meet the cuttingrequirements. The simulation analysis results provided theoretical reference formachine tool design, the design efficiency is improved and reliability is ensured; testresults validate the rationality of the design and reliability of the machine, thusensuring good processing performance and providing reliable guarantee for machiningsimulation and parameters optimization.Manufacturers tend to obtain the processing parameters through the trial of cut,which is not only time consuming, but also cost increasing and production cycleextending. The second part of the article uses the processing simulation softwareVERICUT to simulate the actual processing, the real-time and dynamic results can beobtained, which can help the users to assess the rationality of the process planning andaccurately identify the errors in the NC code, reducing the workpiece scrapped, tooldamage and machine collision, and then quickly improve the cutting quality andincrease the cutting efficiency. And optimize NC code using a constant volumeremoval based on the principle of cutting speed optimization, at last, the processing efficiency is significantly improveIn the process of forming milling, cutting force is one of the key factors, whichhas direct effect on machine tool processing performance, processing parametersselection and processing quality. In order to obtain the change law of the millingforce, in the third part of the article, the theoretical milling force model for formedmilling cutter is built based on the theory of metal cutting, and the working profile ofcurved switch rail is chosen as processing object to carry out the milling processexperiments, it is found that the theoretical milling force model is correct. And alsothe milling force is an important constraint in the parameter optimization.Cost and efficiency are important economic and technical indicators of themodern enterprise, the processing efficiency can be significantly improved whenusing the optimized milling parameters. In the fourth part of the article, the designvariables, objective function and constraints were determined according to the actualprocessing conditions, and the parameters optimization model was built, and geneticalgorithm was used in the optimize calculation, the best combination of parameterswithin the parameters were obtained.Through the dynamic characteristics of machine tools, the built of the theoreticalmilling force model of the formed milling cutter, adn analysis of the processingparameters, the processing quality of high-speed turnouts were ensured, the efficiencyof production was significantly improved, and have significant social benefit,economic benefit and urgent practical significance.