钩舌闭式模锻的数值模拟研究及工艺优化
李丽1孟凡响2唐振兴1张海沧3张富军4
Numerical Simulation Study and Process Optimization of Closed-die Forging for Coupler Knuckle
LI Li1MENG Fanxiang2TANG Zhenxing1ZHANG Haicang3ZHANG Fujun4
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作者信息:1.中车长春轨道客车股份有限公司机电装备分公司，130062，长春
2.吉林大学材料科学与工程学院，130022，长春
3.中车长春轨道客车股份有限公司工程技术中心，130062，长春
4.中车长春轨道客车股份有限公司城铁事业部，130062，长春
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Affiliation:1.Mechanical and Electrical Equipment Branch, CRRC Changchun Railway Vehicles Co., Ltd., 130062, Changchun, China
2.College of Materials Science and Engineering, Jilin University, 130022, Changchun, China
3.Engineering Technology Center, CRRC Changchun Railway Vehicles Co., Ltd., 130062, Changchun, China
4.Urban Transit Division, CRRC Changchun Railway Vehicles Co., Ltd., 130062, Changchun, China
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关键词:
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Key words:
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DOI:10.16037/j.1007-869x.2025.02.024
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中图分类号/CLCN:U260.34
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栏目/Col:应用技术
摘要:
［目的］为了保证铁路钩舌满足严格的力学性能要求，并克服传统铸造与开式模锻工艺在成型质量、工艺流程复杂度等方面的局限性，本研究旨在探索一种更高效、质量更可控的制造工艺。［方法］选取铁路货车钩舌作为研究对象，设计并实施了一次预成形过渡的闭式模锻工艺。采用刚黏塑性有限元法，对闭式模锻成形过程进行了详尽的数值模拟，以深入分析钩舌在闭式模锻过程中可能出现的缺陷类型及温度场分布特征。研究了锻件及模具初始预热温度对成形质量的具体影响，并以锻件填充率作为核心评价指标，通过数值分析获得了优化的工艺参数。在此基础上，结合锻件成形过程中金属流动的详细情况及成形缺陷的具体位置、成因，对钩舌闭式模锻工艺进行了再优化设计。随后，依据优化调整后的闭式模锻工艺进行了试验验证，并对终锻件进行了全面的成形误差分析。［结果及结论］优化后的闭式模锻工艺显著提升了钩舌锻件的成形质量，整体偏差分布均匀，锻件填充情况良好，表面光洁度高且平坦，未观察到任何成形缺陷。数值模拟结果与试验结果高度一致，验证了数值模型的准确性。工艺改进成效显著，所得锻件质量优良，完全满足实际生产需求。
Abstracts:
［Objective］ To ensure that railway coupler knuckles meet strict mechanical performance requirements and to overcome the limitations of traditional casting and open-die forging processes in terms of forming quality and process complexity, it is aimed to explore a more efficient and quality-controlled manufacturing process. ［Method］ Taking the railway freight train coupler knuckle as research object, a closed-die forging process with a preforming transition is designed and implemented. The rigid-viscoplastic finite element method is used for an in-depth numerical simulation of the closed-die forging process to analyze potential defect types and temperature field distribution characteristics during the forging process. The specific impact of the initial preheating temperature of both the forging and the die on forming quality is studied, with the forging filling rate as the core evaluation criterion, and the optimized process parameters are obtained through numerical analysis. On this basis, the closed-die forging process is further refined by considering detailed metal flow characteristics and the specific locations and causes of forming defects during the forging process. A validation test is then conducted using the adjusted optimized process, followed by a comprehensive error analysis of the final forging. ［Result & Conclusion］ The optimized closed-die forging process significantly improves the forming quality of the forged coupler knuckle, with uniform overall deviation distribution, good filling, high surface smoothness, and no forming defects are observed. The numerical simulation results are highly consistent with the experimental results, confirming the accuracy of the numerical model. The process improvements are proved effective, yielding high-quality forgings that fully meet actual production requirements.
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