Optimization Design And Manufacturing Technology Of 60 Kg/m Rails 12 Alloy Steel Frog

The cast manganese steel frog and the alloy steel combined frog are two main types of rigid frog which are used in the ordinary speed turnout at present.Cast manganese steel frog has a longer service life,but it has poor weldability with plain track and is not suitable for seamless welding.The alloy steel combined frog is a new type of rigid frog which developed later in 2000,it consists of wing rail,alloy steel nose rail and expansion rail which are connected together by high strength bolts.The nose rail of the frog is forged from the high strength alloy steel,with characteristics of high strength,good abrasion resistance and long life.The wing rail and expansion rail of the frog are made of ordinary rail,which facilitates the welding with plain track,and is suitable for trans-interval continuous welded track.In recent years,the alloy steel combined frog has been widely used on main line turnout.For the alloy steel combined frog,based on a large number of studies and tests and according to its structural features,a lot of optimization is made to meet the demand of the railway track.In the course of study,it was found that the sevice life of alloy steel combined frogs with same structure are different when they are used on the tracks of 120km/h or below and 160km/h.The major damage forms of alloy steel frogs are the vertical wear of wing rail at 40mm?50mm section of nose rail and the spalling at 20mm?50mm section of nose rail.Based on the actual needs,this paper improved the rigid frog of 60kg/m rail 1:12 speed-up turnout,and analyzed the change rule of wheel/rail contact geometry in frog area.Full consideration was taken into structural improvement and process optimization of wing rail and nose rail.In order to improve the stability and safety of the vehicle,the decrease value of nose rail and the increase value of wing rail at key sections are optimized to reduce the impact and wear between the wheel and rail.From the result of actual operation in the railway track,the quality of alloy steel combined frog has been greatly improved,which provided the basis for the production and quality control of the alloy steel combined frog.