锻压技术

铁路扣件系统金属铁座的多向锻造成形技术

英文标题：Multi-directional forging process of metal iron seat for railway fastener system

作者：丁金福姚汤伟虞晖辉虞安娒

单位：浙江师范大学浙江省城市轨道交通智能运维技术与装备重点实验室浙江华广精工制造有限公司

分类号：TG316

出版年,卷(期):页码：2021,46(11):18-24

摘要：

为适应高速铁路路段需面临严寒及酷署天气等恶劣环境的要求，研发高强度的轨道扣件系统锻造垫板已迫在眉睫。为实现“以锻代铸”的成形工艺，提出了一种上模“封模锻”、左右插模“对冲压”的多向锻造成形工艺。通过建立物理模型，分析多向锻造的变形力，并运用Forge软件对金属垫板的充型过程进行仿真，模拟金属铁座在锻造过程中的塑性流动、变形力等状况，分析材料流动受阻后可能出现的折叠现象。结果表明：金属铁座在多向锻造成形过程中无折叠现象，理论计算变形力为1033.7 kN，Forge软件模拟变形力约为1000 kN，误差仅为3.3%。通过金属铁座的多向锻造成形技术的研究，为设计高精度复合锻模提供了有利的理论依据，为多向锻造成形工艺提供了有益的借鉴。

In order to meet the harsh environment requirements of high-speed railway sections facing bitter cold and intense heat weather, it is urgent to develop the high-strength forged backing plates in the rail fastener system. To realize the process of “Forging Instead of Casting”, a multi-directional forging process of upper die for “Closed Die Forging” and left and right inserting dies for “Opposite Punching” was proposed, and the deformation force of multi-directional forging was analyzed by establishing a physical model. Then, the filling process of metal backing plate was simulated by software Forge, and the plastic flow, deformation force etc. of metal iron seat during the forging process were simulated to analyze the folding phenomenon that might occur after the material flow was blocked. The results show that there is no folding phenomenon for metal iron seat during the multi-directional forging process. The deformation force calculated theoretically is 1033.7 kN, the deformation force simulated by software Forge is about 1000 kN, and the error is only 3.3%. The study on multi-directional forging technology of metal iron seat provides a favorable theoretical basis for the design of high-precision compound forging dies and a beneficial reference for multi-directional forging process.

基金项目：

浙江省科技重大专项重点计划项目（2015C02055）

作者简介：丁金福（1965-），男，硕士，副教授，E-mail：zsddif@zjnu.cn；通信作者：姚汤伟（1969-），男，硕士，副教授，E-mail：ytw@zjnu.cn

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