60E1A1尖轨跟端模锻成形工艺数值模拟

Numerical simulation on die forging process for 60E1A1 pointed rail heel end

60E1A1尖轨跟端是尖轨与标准导曲线钢轨连接的一端,为便于连接,尖轨跟端需要通过锻造加工成60E1标准钢轨截面形状。通过分析60E1A1尖轨跟端锻件的结构和截面形状特点,并比较截面各部分的锻比,发现各部位的锻比相差较大,成形较为困难。提出了模压复合成形60E1A1尖轨跟端锻件的工艺方法,并利用有限元软件对锻件的模锻成形过程进行数值模拟,全面探究了60E1A1尖轨跟端锻件在初锻、中锻和终锻过程中的金属流动规律。结果表明,该成形工艺可有效调控锻造过程中的金属流动,并能控制锻造过程中的成形力及锻件温度变化,最终成形出所需形状的锻件。

The 60E1A1 pointed rail heel end is the end of pointed rail connected to the standard guide curve steel rail,and in order to facilitate the connection,the pointed rail heel end needs to be processed into the cross-sectional shape of 60E1 standard steel rail by forging.Therefore,by analyzing the structure and cross-sectional shape characteristics of 60E1A1 pointed rail heel end forgings and comparing the forging ratios of various parts for the cross section,it was found that there were significant differences in the forging ratios among different parts,and it was difficult to form.Then,a process method of die forging composite forming for 60E1A1 pointed rail heel end forgings was proposed,and the die forging process of forgings was numerically simulated by finite element software.Furthermore,the metal flow laws of 60E1A1 pointed rail heel end forgings during initial forging,intermediate forging and final forging processes were comprehensively explored.The results show that this forming process can effectively regulate the metal flow during the forging process,and can control the forming force and temperature changes of forgings during the forging process.Ultimately,the forgings with the required shape can be formed.