机车车轮热成形过程的有限元模拟研究材料加工工程专业论文.docxVIP

上海交通大学硕士学位论文摘要 上海交通大学硕士学位论文 摘要 机车车轮热成形过程的有限元模拟研究 摘要 机车车轮是机车最重要的承载零件，对机车的安全性和平稳性有 着关键性的影响。随着轨道列车在世界范围内的再度振兴，我国的轨 道列车事业特别是高速列车获得了长足的发展。机车的高速化、重载 化对车轮的质量提出了更高的要求,而合理的车轮热成形工艺正是确 保车轮内在质量和形状尺寸精度的基础。因此，深入研究车轮的生产 工艺对促进我国轨道交通事业的发展具有重要意义。 本文以整体式车轮的热成形工艺为研究对象。首先通过热压缩实 验 得 到 了 材 料 的 真 实 应 力 - 应 变 关 系 曲 线 ， 以 此 为 基 础 采 用 DEFORM-3D 建立了锻造过程的有限元模型，研究了锻造过程中的材 料流动规律和静水压力分布，分析了坯料和模具位置、模具倾斜、坯 料质量、温度及锻造速度对车轮成形的影响并与实验结果进行了比较。 采用 DEFORM-3D 建立了车轮轧制过程三维有限元分析模型， 通过建立轧制过程稳定变形条件开发了轧辊进给速度控制方法。通过 轧制力对比验证了模型和稳态条件的可靠性；分析了轧制过程中材料 的流动规律和温度对车轮轧制过程的影响。 通过提出折叠缺陷判定准则并与 DEFORM 软件集成尝试解决了 微小折叠难以直接通过有限元模拟判定的问题，采用此方法分析了正 常工况的模拟结果并与实际生产结果进行了对比，并且还分析了一种 I II II 典型异常工况的模拟结果并与实验结果对比，对比结果均显示此准则 有一定的准确性。分析了两种典型缺陷的成因并提出了工艺制定准则 和改进建议。 关键词：车轮锻造、车轮轧制、有限元模拟、缺陷分析 上海交通大学硕士学位论文AB 上海交通大学硕士学位论文 ABSTRACT PAGE PAGE VI 3D FINITE ELEMENT SIMULATION OF RAIL WHEEL FORMING PROCESS ABSTRACT Wheels play a key role in a railway vehicle especially on the safety aspect. This is especially true for the rapid development of China’s high-speed railway industry. To satisfy the ever increased requirements on the reliability and durability, hot forming becomes the most competitive routine for manufacturing of rail wheel. However, there is only limited research focus on the rail wheel forming and the understanding on the wheel rolling process is still limited, which result many unresolved problems in the manufacturing process. This thesis reports recent research on the rail wheel forming process. Firstly, the material properties including flow stress is obtained by using a hot compression test. Followed by that, the wheel preforming and forging FE model is established in DEFORM-3D and the material flow behavior is investigated. The effect from process parameters, including the initial slug and forging die positioning, the deviation of forging die, the weight of slug, initial temperature and forging speed are studied. The simulation results are verified against experiment results. To obtain a stable wheel rolling process, the feed rate pl