螺旋道钉多工位冷镦成形工艺优化及数值模拟

Process optimization and numerical simulation of multi-stage cold heading for railway screw spike

螺旋道钉多工位冷镦成形工艺存在多种可选择的方案,为得到最佳的工艺方案,采用工艺优化数学模型与Deform-3D模拟相结合的方法。讨论了各工艺方案的载荷行程曲线和模拟得出的重要参数变化规律,并将参数代入工艺优化数学模型进行计算。结果表明:采用冷镦工艺第1种方案时,预镦、粗镦、精镦工位的变形程度分配合理;最大的损伤和应变值随工位变形程度的增加而增大,并在成形六角头部时值最大。经计算得出最佳工艺方案,采用优化后的方案生产的螺旋道钉整体组装疲劳试验达300万次。

There were many alternative processes of railway screw multi-stage cold heading to get the optimal technological scheme. Using the optimization mathematical model and Deform-3D simulation method, the load-stroke curves and variation laws of important simulated parameter values were discussed, which were took into the process optimization mathematical model. The results show that for the first scheme the deformation degree of cold forming process is properly distributed ; the maximum damage and the strain values increase with the increasing of station deformation degree, and reach the maximum when forming the six angular head. The optimal scheme was calculated and the compose fatigue strength tests of anchor screws reached three million times.