Research On Die Forging Process Of Locomotive Flange Fork

With the development of railway industry towards high speed and heavy load,locomotive manufacturing also faces new technical requirements.As a key part in the transmission system,the forming process of locomotive flange fork also puts forward higher requirements.Influenced by the material and structure of the parts,it is difficult to form the locomotive flange fork by die forging.In the process of forming,it is easy to appear defects such as folding and filling.In this paper,based on the research object of locomotive flange fork,the process design,die design,forming process numerical simulation,billet scheme optimization and process parameter optimization are studied.Process analysis of locomotive flange fork parts,according to its shape characteristics and forming difficulties,combined with the actual situation of the production site,the forging die of the flange fork is designed.DEFROM-3D numerical simulation software is used to simulate the forging process,and the possible forming defects in the forging process are predicted and analyzed.The influence of different upsetting pressure on forming quality is studied and the forming rule is summarized.According to the forming law,a reasonable process plan is designed,and through analyzing the temperature field,filling condition,folding defect and travel-load curve,judging whether the designed billet making scheme is reasonable or not,determining the billet making scheme,selecting scheme four.The effects of initial forging temperature,die preheating temperature and friction coefficient on die life were studied by gradient test.the orthogonal test was designed to determine the optimal parameter combination under simulated experimental conditions with the effect force such as forming load,forgings and die wear depth as the index: the initial forging temperature was 1200?,the die preheating temperature was 300?,and the friction coefficient was 0.20.The actual production verification of the optimized forming process is carried out to verify whether the optimized billet preparation scheme and the optimized process parameters can meet the actual production requirements.Through the actual production,it is found that the forgings are full-filled,the mechanical properties meet the requirements of use,and there are no defects such as folding and filling dissatisfaction,the material utilization rate increased by 10%,the material weight dropped kg 19.30 to 17.10.In this paper,DEFORM-3D numerical simulation software is applied to the optimization study of forging forming process of locomotive flange fork,which improves the forming quality and material utilization ratio of forgings,improves the wear of die,obtains reasonable combination of process parameters,and reduces the production cost of locomotive flange fork.The research contents and results of this paper provide some guidance and reference for die design and forging production of yoke forgings such as flange fork.