The Knuckle Forging Forming Simulation And Process Research

With the development of computer technology,and the ever-depth study on the theory of finite element. Finite element numerical simulation technology has a lot of applications in the field of plastic forming.Especially in the production of rolling stock is increasingly becoming more apparent.Nowdays, our country’s railway transport to keep the development of overloading direction,and the couplers connecteed the two vehicles is becoming more and more important.Because it is directly related to the security and reliability of freight vehicles.While the main component in coupler is knuckle,so knuckle is critical traction components of overloaded railway trucks.As the knuckle’s shape complexed,so traditional producted knuckle used casting. But the casting process inevitably produced a lot of defects, which seriously affected the quality of the knuckle. This thesis taked forging process to study the production of the knuckle.This thesis based on a vehicle factory resources, and combined Gleeble-1500thermal simulation machine to measure25MnCrNiMoA steel under hot compression flow stress data.It analysis the effect of the25MnCrNiMoA steel flow stress on the deffierent deformation rate, deformation temperature and deformation degree Finally established a mathematical model of the flow stress,and used MATLAB to non-linear regress the mathematical model, which learned that the model had a good fit characteristic. So it could pave the way for the next process design and numerical simulation.According to the knuckle of the two-dimensional size,then used the software of the three-dimensional modeling Pro-e to establish the modeling knuckle. And made the design of the knuckle in the mold forging process step.Under the thermal simulation measured data of25MnCrNiMoA steel,to establish the material model in DEFORM database.Then simulation the die forging process for knuckle.System analysis the knuckle die forging process,which the distribution of the equivalent stress-strain and the temperature field as well as the regular of the metal flow. After a series of optimization and simulation and design reasonable mold to forging qualified knuckle pieces at last.The subject of research organiced combine the finite element numerical simulation,the forging process design and mold design. Be able to effectively achieve the purpose to shorten the product development cycle and reduce production costs. The research results of this project is the knuckle forging process to develop as well as the design of the mold forming process, to pave the way for the follow-up of the actual application.