澳煤车转向架工艺研制与开发

Research and Development of Australia Coal Car Bogie

C32型煤漏斗车是齐车公司为出口澳大利亚开发的新型货车,该车采用30 t轴重转向架,采用呋喃树脂自硬沙有箱造型工艺在造型线上生产。由于生产试制周期短、技术水平要求高,为此齐车公司决定在转向架生产过程中大量采用数值模拟技术。本文将以澳车转向架侧架的开发生产过程为例,阐述ProCAST在澳车开发过程中的应用情况。首先分析了澳车转向架侧架的结构特点,并根据车间现有的生产条件及产品的批量确定了生产工艺。然后按照ProCAST在铸件产品工艺上应用技术线路要求,应用ProCAST基本模块、流动模块和应力分析模块对澳车侧架充型和凝固过程流场、温度场和应力场进行详细模拟分析,预测了缩孔、缩松、热裂等缺陷。通过数值模拟验证,提出工艺改进意见,优化铸造工艺,实现工艺的完整性。使如此复杂而关键的铸件一次试验成功,极大地缩短了工艺准备周期,降低了试制成本,对实际生产起到了重要的指导作用。

C32 coal hopper ear is the development of new freight ear for exporting Australia, the ear uses 30 t axle load and produeted by furan resin having box shape in the form of line. Because of short production eyele, high requirement of technieal level, Qiqihaer Railway Roiling Stock （Group） Co, . Ltcl decide to use large numerieal simulation teehnology in bogie production. This paper will be as an example for Australian ear bogie side frame the development and produetion process, introduce ProCAST applieation in the process of developing. First analysis structure eharaeteristie of side frame and base the workshop production eondition and produet quantifies to determine the production process. Then with ProCAST applieation of technology product line requirement on easting production process, applieation ProCASr basie module, mobile module and stress analysis module on the side frame filling and solidifieation process mobile, temperature and stress field for detail simulation analysis, forecast shrinkage pore, shrinkage porosity, thermal eraek defects. Through numerieal simulation validation, raise eomment of process improvement, optimize easting process, realize integrity of process.So the complex and erux easting sueeessful test one time, shorten process prepare Cyele greatly, reduce trial produetion eosts, play an important guiding role in actual production.