Research On Materials And Forming Technology Of Aluminum Alloy Cast Traction Beam For Urban Rail Vehicle

The aluminum alloy traction beam was the main load-bearing structure of the chassis of the car body,and its mechanical properties were required to be high.At present,the forming method for the traction beam was die forging using 7050 aluminum alloy.However,the cost of the product was very high,which limits its popularization and application."Substitute forging by casting" process was an important means to improve quality and reduce consumption.Comprehensively considering the structural characteristics and performance requirements of the traction beam,the casting method was used to form the traction beam.In this paper,a combination method of test and simulation was used to study the traction beam material and forming process of urban rail vehicles.The material ZL205 Awas selected,a reasonable forming process was formulated.The influence of the forming process on casting stress was clarified,and the traction beam sample was completed Trial production of pieces.The key contents and achievements of this study were as follows:(1)Combined with the working conditions of the traction beam,comprehensively considering the mechanical properties,manufacturability and economics of the materials,the test materials were selected,and the material forming tests of different process methods were completed,and the material properties under the forming conditions of different process methods were obtained.The forming process method of the traction beam was determined;(2)Useing the solidification numerical simulation software Pro CAST to complete the ZL205 A casting stress simulation,the casting forming process simulation analysis of different process schemes was carried out for the influence of the casting process parameters on the casting stress.The casting forming process scheme of the traction beam was optimized and thetrial production of traction beam samples was completed.(3)The neural network combined with genetic algorithm was used to train and predict the relationship between the process parameters and the effective stress of the casting.The effect of the casting process parameters on the casting stress was systematically studied and the rule between the process parameters and the casting stress was clarified.The research results obtained in this paper provided a theoretical basis and technical support for the forming process method of aluminum-copper alloy materials,casting stress control and the forming process of traction beams for urban rail vehicles,which were important for improving the performance index of aluminum-copper alloy casting and improving the quality of forming Engineering application value.