Development Of A Simulation System For The Plastic Forming Process Of High Speed Railway Wheels

As a key component of high-speed rail travel,the high-speed rail wheel has an extremely important impact on the safe operation of high-speed rail.In the wheel production process,the forming process has a relatively large influence on the deformation mechanism of the wheel billet at the end of the forming process,so it is particularly important to study the qualitative and quantitative parameters of the forming process.The coupling effect of multiple types and parameters of the continuous forming process of high-speed railway wheels makes the deformation laws and load constraint boundaries of the whole forming process complex.At present,researchers at home and abroad mainly use large finite element simulation software to simulate and analyse the wheel forming process.However,the versatility of existing simulation software and the complexity of the wheel forming process lead to very complicated operations of the pre-and postprocessing modules of wheel forming and are prone to the problem of roll forming mesh distortion.To solve these problems,this paper develops a simulation system based on ABAQUS software for the forming process of high-speed railway wheels.The system is parametric,automated and easy to extract output information instantly.To address the preceding issues,a simulation model for the forming process of high-speed railway wheels is built based on the ABAQUS/Explicit display solver,using the numerical analysis method of thermal-force coupled rigidplasticity,and the parametric development of the kernel program of the pre and post-processing module through a software scripting interface.Based on the customised application in the secondary development of the ABAQUS GUI interface,a platform for the simulation of the plastic forming process of high speed railway wheels was written,and on the basis of the main user CAE interface,the kernel script Python language was used to create the pre and post-processing modules and the corresponding GUI graphical user interface.to an excel sheet.A mesh reconstruction algorithm program written in Python is embedded in the kernel script file of the rolling model,which enables the accurate transfer of field variables such as billet temperature,stress and equivalent plastic strain in the punching result file,solving the problem of mesh distortion caused by plastic deformation during the subsequent rolling process.The user selects the parameters to be output through the post-processing module of the simulation system,and can extract the immediate information of the forming process,analyse the forging temperature field,and investigate the influence of different process parameters on forging and forming.The extracted data of the wheel billet strain field,stress field,mechanical parameters and temperature field are compared and analysed with the data in the literature,which verifies the usability and The data extracted are compared and analysed with data from the literature to verify the usability and accuracy of the simulation platform for the plastic forming process of high-speed railway wheels.