高铁空心车轴三辊斜轧成形仿真及分析

Simulation and analysis of three-roll skew rolling forming of the railway hollow shaft

针对目前高铁空心车轴成形工艺投资大、成本高、材料利用率低等问题,采用三辊斜轧成形高铁空心车轴工艺,利用Simufact有限元软件,对1:5的高铁空心车轴进行三辊斜轧成形仿真,分析其成形过程中金属流动规律,应变场、温度场及轧制力的变化规律,阐明其成形机理.在轧制同等尺寸的空心车轴时斜轧的力能参数明显小于楔横轧的.研究结果表明三辊斜轧成形高铁空心车轴工艺可行,为短流程低成本实现高铁空心车轴精确成形及其国产化奠定理论基础.

Aiming at the existing problems in high-speed railway hollow shaft forming process, e.g. large investment, high cost, and low utilization rate of materials, the paper puts forward a new process of forming high-speed rail hollow axle by three-roll skew rolling. The three-roll skew rolling forming of 1：5 high-speed rail hollow shaft is simulated by Simufact 13.3 finite element software. The law of metal flow, the variation regulation of strain field, temperature field and rolling force are analyzed, and the forming mechanism is clarified. The energy parameter of three-roll skew rolling is obviously smaller than that of cross wedge rolling when rolling the hollow shaft of the same size. The results show that the forming process of high-speed rail hollow axle by three roll skew rolling is feasible. This study lays a theoretical foundation for the realization of accurate forming and localization of high-speed rail hollow axle with short process flow and low cost.