HDSA车轮立式轧制变形分析

Deformation Analysis of HDSA Railway Wheel in Vertical Rolling

掌握车轮轧制过程的金属变形规律是制定和优化车轮轧制工艺的重要依据。以HDSA车轮为研究对象,采用有限元法对其立式轧制过程进行模拟,分析车轮轧制过程中轮辋扩径、宽度变化、变形深透性、应力分布及辐板拉薄等现象和规律。结果表明:轧制13圈时轮辋扩径速度最大,5.1 mm/圈;轮辋宽展量在14~18圈达到峰值,最大道次宽展量达5.5 mm;终轧时,初始踏面下25 mm范围内,随着深度的增加,等效应变呈线性降低,31 mm深度处的金属有最小应变0.23;车轮轧制时辐板主要承受周向和径向拉应力,并导致辐板被拉薄,终轧后辐板最大拉薄量达到3.3 mm。

Understanding the law of metal deformation in railway wheel rolling process is an important basis for formulating and optimizing the rolling process of railway wheel. Taking HDSA wheel as the research object, the vertical rolling process was simulated by the finite element method, and the phenomena and rules of the wheel rim diameter expanding, rim width variation, deformation distribution, stress distribution and wheel plate thinning during wheel rolling were analyzed. The results show that the rim expanding speed reaches the maximum of5.1 mm/round, when the wheel is rolled 13 rounds. The rim lateral spread reaches peak value during 14-18 rounds,and the maximum value is 5.5 mm. In the final rolling, the effective plastic strain decreases linearly with the increase of the depth within 25 mm of the initial tread, and the minimum strain is 0.23 at the depth of 31 mm.When the wheel is rolled, the main part of the wheel plate is tensile stress both in radial and circumferential direction,which causes the plate thinning, and the maximum thinning after the final rolling reaches 3.3 mm.