Structure And Process Design Of Wheel Forged Steel Brake Disc For High Speed Train

At present,high-speed trains generally use circular disc brakes as fundament braking mode.Brake disc is a key component of disc braking equipment.Its performance is determined by the materials,configuration structure,forming methods and other factors.Also,it will directly affect the safety and reliabilityofthe train operation.In this paper,thedesign and test of a new type of wheel-mounted forged steel brake disc is carried outagainst 200km/h?250km/h high speed train.The finite element simulation method is used to simulate the brake disc structure and the forging forming process.The structure design process and the actual production link are instructed.Finally,a qualified brake disc sample is prepared.The new forged steel brake disc can meet the requirements of 200km/h?250km/h high speed trainby passing a 1:1 brake dynamic test.The main contents and conclusions in this paper are as follows:The ZDPH low-alloy steel afterpurification treatmentis the high-speed train brake disc material.The heat treatment process and the mechanical properties research are carried out.The optimized heat treatment process can make the ZDPH material have excellent comprehensive mechanical properties,and the relevant performance index can meet the Chinesestandard requirements of forged steel brake discs for high-speed trains.According to the interface dimensions of the high-speed train wheel in our country,the structure of the wheel-mounted brake disc is preliminarily designed to reduce the stress of the bolt in brake disc and facilitate the forging forming.The finite element software was used to simulate the wheel-mounted brake discs with different structures.The thickness of the friction ring and the number of the heat radiation ribs are calculated optimally as the structural characteristics.Finally,the brake disc structure with 18mm thickness friction ring and 36 pieces of heat radiation ribs is finally determined.By simulating an emergency braking at 275km/h initial velocity and two successive emergency braking at 250km/h initial velocity,the results show that the wheel-mounted brake disc has high heat capacity and structural strength,and can meet thedesign requirements for emergency braking of 250km/h high speed train.On the basic of the wheel-mounted brake disc structure,the disc plate forging,forging die,blank size and forging process parameters are determined.The finite element simulation indicates that the design of the wheel-mounted brake disc forgings and the forming process in this paper can obtain the qualified-sized and defect-free disc forgings.With the simulation results as a guide,the wheel-mounted brake disc sample was prepared,and a good quality formed brake disc forging was obtained.The heat treatment process of ZDPH material is used to make quenching-tempering treatment for the brake disc body.The mechanical properties of the brake disc samples were proved by the test with the furnace test block and the brake disc body.The results of ultrasonic flaw detection and magnetic flaw detection show that there are no obvious defects in the internal and the surface of the brake disc,and the brake disc samples meet the requirements of the wheel-mounted brake disc standard.According to the TJ/CL310-2014 standard,the brake dynamic test of the wheel-mounted brake disc was carried out.After the test,the surface of the brake disc was free of hot crack and abnormal loss.Also,the friction coefficient was stable.The results show that the performance of the wheel-mounted brake disc meets the requirements of 250km/h high speed trains.In this paper,the design and related experimental research of wheel-mounted forged steel brake discsprovide technical reservesfor our country's rail vehicle brake disc independent development and production.In addition,it has a certain positive significanceprocess for China's high-speed railway autonomy.