Axle Quick Forging Precision Forming Process Parameter Optimization And Quality Control

Axle is one of the key components in vehicle and locomotive. Its qualityseriously affects the development of railway transport safety and nationalEconomy. Railway axle is a large component of axial symmetry and steppedshaft, which requires high mechanical properties, reliability and internalorganization performance. To improve and forge defects such as segregation,blank, loose and microcrack, reasonable forging process must be taken.Ultimately shaped forgings with accuracy dimensional and internal quality canbe got.Based on one step arc anvil forming process (no changing anvil halfway,no heating) with quick forging machine, by means of DEFORM-3D software,arc structure optimization, process method and process parameters selection areresearched. The whole process of forming railway axle by quick forging issimulated. For the arc structure optimization, effect of transitional section radiuson surface concave defects of the workpiece is analyzed, and reasonabletransitional radius is put forward. It can be seen form the simulation results thattaking the effect of reduction ratio, relative amount of feed and rotation angle onmaterial stress and strain, inner closure, damage and size precision into account,reduction ratio will be15%~25%and relative amount of feed will be0.6.Rotation angle will be45°during rounding forming. While all the processparameters are taken as previously mentioned, quality of workpiece can beimproved and the state of stress can decrease defects. Furthermore formingprocess is proposed and the whole forming process is simulated. Form thesimulation results we can see that the forging process can be finished in thetemperature range. The cross section size precision and radial size of railwayaxle can meet the technique requirement according the established formingprocess. Rationality of forging process and process parameters are tested byanalyzing the stress-strain, coaxially, final forging, compaction and distributionof streamline. All of this can provide scientific basis for production.