轨道车辆S形截面结构件的排样设计与应用

Layout Design and Application of Structural Parts ofS-Shaped Section Rail Vehicles

轨道车辆S形截面结构件冲压成形容易产生回弹变形,回弹变形又会带来制件上的孔洞和局部形状的二次形位误差。以轨道车辆S形截面结构件为对象,参照坯料的排样设计流程,通过制件工艺分析、CAE仿真分析,初步设计了坯料的十工序排样;从成形工艺、模具概要设计角度详细分析了坯料排样各工序的设计目的;依据所设计的坯料排样完成了级进模设计,并在所设计、制造、调试好的级进模上做了实冲试验。结果表明:所设计的十工序排样图适用于轨道车辆S形截面结构件的冲压加工。对该坯料排样设计方法与方案推广应用,具有较好的经济效益和社会效益。

The stamping of S-shaped cross-section structural parts of rail vehicles often produces spring-back deformation,which will cause holes in the parts and secondary form and position errors of local shapes.Taking the S-shaped cross-section structure of railway vehicle as the object,referring to the blank layout design process,through the process analysis and CAE simulation analysis,the ten-process layout of blank is preliminarily designed;The design purpose of each process of blank layout is analyzed in detail from the perspective of forming process and mold outline design;According to the designed blank layout,the progressive die design is completed,and the real stamping test is done on the designed,manufactured and debugged progressive die.The results show that the designed layout of ten processes is suitable for the stamping process of S-shaped structural parts of rail vehicles.The popularization and application of the blank layout design method and scheme should have good economic and social benefits.