铁路货车锻造钩舌成形工艺及数值模拟优化

Forging process and FEM optimization for forged knuckles of railway wagons

锻造钩舌是一种常用的铁路车辆车钩牵引部件,该产品截面变化大、形状复杂、成形困难,存在不容易锻造的薄筋。根据产品的尺寸和形状特点制定了自由锻制坯、两次模锻和两次切边的锻造工艺。以刚塑性有限元法为基础,利用Deform-3D软件对锻造钩舌制坯和模锻过程进行三维有限元模拟,揭示了锻造钩舌在模锻变形过程中金属的流动规律,分析了在两次模锻成形过程中产品的变形受力情况和变形过程中产生的缺陷情况。为优化锻造工艺提供了有力的依据,并通过改进锻造工艺极大的提高了产品的合格率。

The forged knuckle is a kind of common drawing components that it is used in couplers of railway wagons.The product has big section change and complicated shape,so it is difficult to form and forge thin muscle.According to the characters of forged knuckles,the blocking process was designed for hammer forging,which was composed of twice die forging and twice trimming.Based on rigid and plastic FEM,the process of die forging for forged knuckles was simulated using Deform-3D.The metal flowing rule of the process was revealed.The loads and the defects produced by die forging process were analyzed during the forming process of each step.A reliable reference theory was offered for optimizing forging process.The qualified rate of finished products was greatly increased through improving the forging process.