Computer Simulation And Design For Die Of Bottom Side Door To Open Top Wagon

Downside door of gondola car is of the significant visual part applied to the freight wagon, whose surface quality requires a high degree. Such part features big size and embossing formation, the forging die is very complicating. According to the traditional approach, the die is designed by the designer with his experience. The die need to be tested again and again in manufacturing. Furthermore, the designer had to take the risk of scraping die at last due to the quality not up to the requirement, and the cycle period for the die designing and manufacturing is quite long, production cost is very high, the economic benefit is not satisfactory. With the computer facility, the die of the downside door is applied with the digital simulation analysis and design, the good quality die for the downside door is designed and manufactured within a short time. Quality of the downside door has hit the standard requirement and meet the need of commercialization. Firstly, this essay introduces formation theory for large size covering part, analyzes factors affecting formation quality of downside door, studies some phenomena in terms of defects rebounding and wrinkling of the steel plate formation. The study indicates that the surface quality of the bottom side door after formation will be ensured only by means of changing the structure of the die, using different edge gating approach to achieve the proper pressure-pad-force, eliminating problems of wrinkling and defects rebounding in the process of formation. Secondly, with the DYNAFORM software, the formation process of the die of downside door is simulated in three different kinds of structure, which can demonstrate the whole process of steel plate formation vividly and the distribution of stress and strain, etc. According to the comparison of the simulation results, the process scheme can be finalized for separation of formation and material cutting and one-time-formation. Finally, this essay introduces the design process on the basis of PRO/E in tandem engineering, describes the design course of the die design and its structure in particular. The internal & external duo action pressure edge structure is adopted to this die. The whole piece of polyurethane is used as the resilient part, and finally, as a result, the pressure-pad-force is guaranteed for formation and the superior quality downside door will be completed.