Numerical Simulation In Hot Forming Process Of The Train Wheel

This topic comes from a domestic enterprise train wheel production line project.The train wheel as an important load-bearing parts of railway transportation, plays a vital role. Along with the rapid development of the high-speed railway industry in our country, which put forward higher requirements on the comprehensive performance of train wheel. While the hot forming process not only determines the shape and size of the wheel, but also provides enough deformation for each part of the wheel to ensure its mechanical properties.This wheel production line of hot forming use the Forging&Rolling process, which heat only once, and the billet deformation step by step. Through the reasonable design of gradually forming and scientific accumulative deformation, which access to quality blank, making the hot forming process of the wheel to keep at a high productivity and coordinate production rhythm, at the same time ensuring the product quality requirements to meet the comprehensive performance of the actual production, so as to provide technical support and theoretical guidance for practical production. This paper mainly aims at the hot forming process analysis and numerical simulation of the train wheel except rolling process, the main research contents are as follows:Establish the train wheel commonly used material CL60-Steel’s material model, through thermal simulation compression experiment measured its true stress strain curve, use the numerical fitting method to get the available constitutive equation model, and combine the CL60-Steel’s other physical performance parameters curves, improve the wheel steel material model library, lay a foundation for numerical simulation.Based on the above material model, analyze the hot forming process of840HDSA’s forging, punching, bending, heat treatment and make a numerical simulation with DEFORM-2D software to analyze the cavity filling, deformation force, metal flow, and strain distribution rule in the deformation process. In order to guarantee reasonable design of the hot forming process and the die, prevent forming defects, improve production efficiency and product quality. In addition, the eccentric defects in the forging process has been studied in this paper, the factors of producing forging eccentric defects has been analyzed, and then make a simulation prediction according to the two of these factors by use of DEFORM-3D software, expounds the harms of forging eccentric defects and puts forward the measures to improve.