Theoretical Analysis And Numerical Simulation Of Preforming In Railway Wheel Forming Process

Integral rolling wheel is extensively used in vehicles of rail transporting for its excellent mechanical performances and inner and outer qualities. Preforming processe plays an important role in the forming of its preliminary shape as well as the improving of its inner material qualities and metallic streamlines. However, because the shape of the train wheel is very complex, accurate theoretical results of the forming pressure in the preforming processes are difficult to obtain, such as forming force and friction conditions. Therefore, the forming process of wheel and design of dies are always calculated based on experiential data and simple theories presently. Sometimes reasonable processing parameters have to be obtained by trial production for several times, which is a waste of time and power.In this paper, preforming process was analyzed theoretically, the mathematical and mechanical model were established. And the process was numerically simulated with FEM software DEFORM-3D. The influnces of different upsetting reductions on the preforming process, the metal flow rule during the preforming of train wheel and the strain and stress field of the deforming areas were also analyzed. Important parameters in the preforming process and their influences on the filling conditions and the forming pressure have been studied. Then the simulation results have been compared with that of the practical production ones, optimized parameters of train wheel forming under practical production have been attained. Meseaures and suggestions have been put forward based on the common problems in the preforming procedure of train wheel.Through the study and analysis of this paper, the rules of the wheel preforming process has been mastered, which provide a theoretical basis for the determination of the preforming process design, the forming production and the subsequent process of the wheel. It is of great significance for the improvment of forging qualities and production efficiency, the increase of the rate of finished products and the decrease of the production cost.