Numerical Simulation And Experimental Study On The Precision Roll Forging And Whole Die Forging Forming Process For The Coupler Yokes Of Railway Freight Cars

Recently years,in order to meet the demands of the heavy load and high speed for railway freight cars,the trend of replacing the casting by the forging is more and more obvious,therefore,it is important and necessary to research of the precision roll forging and whole die forging composite technology for the coupler yokes of railway freight cars.The roll forging is one of important means of metal plastic deformation.With the rapid development of computer technical,FEM used in roll forging not only can be fulfilled but also bring much important significance in area of quality controlling,die design optimizing and deforming nature revealing.In this article,several key problems occurred in the forming process of the coupler yokes of railway freight cars has been deeply studied,such as analyzing the transfiguration rule,optimizing technology project,designing the die and so on,and basic on the software of the Deform-3D FEM,the whole process of precision roll forging and die forging for(PRAD)the train coupler yokes was simulated,then get information of the material flowing and energetics,optimize the technology parameter and die structure,exactly analyze the transfiguration trend,guarantee one-off success of the technology,die design and manufacture since optimized the technology parameter and die structure,and solve the main problem occur in the processing of design.Through the study,to advance the veracity of the PRAD composite technology and die design,to shorten the research period,thereby remarkably save the charge of the study of die,reduce the production cost,and this kind of method could be applied to other parts production from casting to forging.The experimental contrast was shown in tho article,and the correctness and validity of technology project were verified,also the rationality and the scientific of die design were proven in the actual production.By contrasting the simulation results with the actual production analysis,summarized success experiences of research,and induced the rule of the precision roll forging and whole die forging composite technology of complex irregular long parts and the die design.