Numerical Analysis And Die Design For Stamping Process Of Railway Wagon Down-Side Door

Down-side door of wagon is a typical middle-thick plate stamping product, which exists quality problems of cracking, thinning, scratches, wrinkle in the process of forming. Nowadays the production process of design of this kind of products still uses analogy method, relying on qualitative analysis, physical simulation and experimental validation, with theoretical analysis seriously lagging. With the drawbacks of unintuitive and none-systemic of the production experience, and the numerical simulation research of forming can show the dynamic calculation results, guide the actual production, reduce scrap rate, improve the service life of mould, therefore the numerical simulation system of this kind of parts is valuable both in theory and in practice. This paper adopted Dynaform software to predict the problems and drawbacks in the down-side door forming process, optimized the whole forming crafts process, modified and optimized the model design parameters, provided theoretical fundaments of down-side door forming and model design, and proposed the idiographic projects.Firstly, the paper adopted Dynaform software to conduct the numerical simulation of down-side door of wagon of the two forming plans, compared the simulation results, and finally established the two-step stamping process of undulate forming under hydraulic press of 2500T and punching of 2000T.Secondly, the paper studied the factors, which influence the forming quality, such as materials properties, blank shape and mold clearance via Dynaform. Through the analysis of numerical simulation, An optimal parameter combination was obtained that the material should be 09CuPCrNi, the rectangular shape should be 1425×1120, the clearance of the moulds should be 1.0 times of blank thickness and the blank-holder force should be 120T. The numerical simulation provided reliable parameters in the mould design so as to shorten the development period and reduce the development cost.Thirdly, the paper researched the mould design and stamping process of the down-side door under the guidance of numerical simulation. The experiments show that the Dynaform software can simulate the down-side door forming well, the simulation can match the practice very well, the developing time is shortened and the cost is reduced. Finally the mould commission time was shorter more than 50%, and the difference of product thickness was within 5%, with other shapes and sizes meeting the requirements of the product design diagram.