道岔异型钢轨跟端加长600mm热锻成形关键技术

Key Technology of 600mm Extension of Heel End of Turnout Special-shaped Rail by Hot Forging

通过分析道岔异型钢轨跟端加长600 mm产品结构,经技术对比确定采用4个工位整体模具进行热锻成形。通过设计初步4个工位热锻模具结构,再利用有限元分析软件对整个热锻成形过程进行数值模拟,根据模拟结果,优化模具结构并指导确定工艺参数和实际生产。设计自动上料系统、四轴联动系统以及下料系统等,使压力机、加热系统以及自动上下料系统数据互联,最终实现钢轨热锻成形生产过程全自动控制,大幅降低工人劳动强度、提高生产效率、节约生产成本。

Based on the analysis of the product structure of 600 mm extension of heel end of turnout specialshaped rail, it is determined, by technical comparison, to adopt the four-station integral mold for hot forging.The preliminary four-station hot forging die structure is designed, and the finite element analysis software is used to numerically simulate the whole hot forging forming process. The die structure is optimized, and the process parameters and actual production are determined, according to the simulation results. The automatic feeding system, four-axis linkage system, and automatic blanking system are designed. Automatic programming technology is employed to allow the data communication among the press machine, heating system, automatic feeding system, and automatic blanking system, thus realizing a full-automatic control of the rail hot forging production process, which greatly reduces the workers’ labor intensity, improves production efficiency, lowers production costs.