Research On The Railway Wagon Wheel Repair And Redesign Based On Adding Material And Remanufacturing

With the rapid development of Chinese industry, Chinese governments set green manufacturing as one of the strategic priorities and tasks of “Industrie 4.0” and put forward the idea to strive to develop the remanufacturing industry, of which one of the essential parts is equipping advanced rail transportation. In recent years, railway freight industry has achieved rapid development. However, the supply deficiency of key parts of railway wagons, which even needs to be supplemented by importing, takes a severe toll on China's social and economic development. The wheels, as the important accessory of the walking units of the railway wagons, bear more complex burden and combined with unfavorable working conditions, they will encounter various damage. The developing mode of highway heavy-loading causes increased failure behaviors. As a result, it is of great necessity to remanufacture and repair the railway wagon wheels with increased material.To start with, according to the research on the growing trend of railway wagon wheel repair technology at home and abroad and the classification of damage types of the railway wagon wheels, the study concluded the feasibility to analyze the remanufacture of wheels with increased material. Then, the review on the technological characteristics of finite element simulation and the simulation of finite element analysis software ANSYS are clearly demonstrated. In addition, laser cladding technology is adopted to carry out the remanufacture and repair simulation test on railway wagon wheels.This article has adopted the form and the material parameters of HDZC wheel type in the whole cast steel wheels and the fatigue crack failure form of the outer rim. With the establishment of 3D simulation model formed with the help of CAD, the numerical simulation analysis has been carried out on the damaged railway wagon wheels by utilizing simulation software ANSYS and APDL programming language. According to the thermal physical parameters of artifacts, the actual situation of laser cladding and APDL command flow, the test has been conducted many times and thus the appropriate heat source load has been uncovered. On the basis of the above, the changing situations of the remanufacture and repair's temperature field and stress field have been analyzed. The conclusion has been drawn that it is feasible to conduct the repair of railway wagon wheels and the process design of repairing based on adding material is reasonable.The above research and analysis on the feasibility of repairing railway wagon wheels with material added and cladding proves that the wheel repair based on adding material and remanufacturing is practical to an extent. According to the product life cycle of the wheel, the redesign theory for the wheel has been proposed and this paper has analyzed the preliminary thought and principle of the design.