The Numerical Simulation Of Forging Process And The CAD System For Forging Dies Of Railway Wheel

Rail transport has played a pivotal role in our national economic development. In the past decade, the railway in our country developed rapidly, the mileage, running speed and carrying capacity have reached the world advanced level. Train wheel is the key part of railway transportation vehicle. With the increase in the number of vehicles and railway speed, the request for quality and quantity of the railway wheel is getting higher."Rolled steel method" is the most widespread production process used by wheel manufacturers in the world, and the process can be divided into three main steps: Preforming and forming, rolling expanding and bending punching. Due to the complicated forming process, the dies design cycle of train wheel is long, the workload is heavy, the cost of design is high, and so the traditional design method has been unable to meet the real needs of production. Therefore, it is of important significance to Chinese railway industry and train wheel production enterprises to study the train wheels forming process, to enhance the efficiency of wheels forging dies design, to reduce the cost of dies design, to improve the comprehensive quality of dies and make high-quality wheels.This paper first introduced the train wheel production technology of the domestic production enterprises, compared the advantages and disadvantages of each line, and took Magang line three as an example to introduce the train wheel forming process and the characteristics and regularity of each step in detail. Based on the analysis of train wheel forming process, this paper established the numerical simulation models of preforming, forming, bending and punching process, did numerical simulation to train wheel forming process using software DEFORM and analyzed the metal flow law, equivalent stress, equivalent strain distribution and load-displacement curve of the train wheel each forming process. Moreover, based on the analysis of forming force and metal filling situation in the process of preforming and forming, the research found the effect law of the indentation die width, height, radius and the preforming reduction amount on the forming process. Based on the numerical simulation of bending process, we found out a better design method of S shaped wheel plate.On the basis of the analysis and research of the train wheel forming process, this article according to the train wheel forming process numerical simulation results developed the train wheel die CAD system taking VC++6.0as the tool, UG three-dimensional modeling software as a platform. The system includes forming blank design module, dies generation module and the frame generation module. It can not only realize the dies rapid design function, but also can test and optimize the design results in the design phase.