Train Wheel Forging Process Analysis

The wheel blank adopts a cylindrical blank with a diameter between 380mm and 406mm. Billets are sawn into segments with a high-speed table. After heating, the manipulator holds the upper press for performing. In the forming process, the upper grinding tool adopts the forming die, and the lower mold adopts the indentation die with the center protruding, so as to realize the metal volume distribution of the rim and the hub. The press forging process adopts static forging, and the whole forging process is completed in one stroke. The excellent wheel forming process can not only ensure the formation of the initial shape of the wheel, but also play a dual role in improving the internal structure of the wheel and the metal flow line. However, if the process at this stage is not reasonable, it will directly lead to defects such as wheel eccentricity and incomplete filling. It will bring difficulties to the operation of the subsequent processing stage, and it will directly lead to the scrap of the wheel.

In the wheel forming stage, the main shape of the hub and the press spoke plate is obtained, and the main part of the rim is formed. The process is a typical open die forging without flash. After the die is depressed, the first pressure is the spoke plate of the wheel, and the inner metal of the wheel is subjected to the force from the central punch, driving the outer metal to flow in a horizontal direction. With a sharp increase in pressure, the outermost metal of the wheel blank is in contact with the inner wall of the forming die. Under the joint action of the center punch and the inner wall of the forming die, the metal in the wheel blank forms a shunt surface that flows to the lower and upper sides of the hub and rim, respectively. In this process, it is best to fill the bottom of the edge. In addition, due to the different height of the wedge die in this process, the metal deformation in different parts of the wheel blank is not the same, among which the deformation at the spoke plate is the most prominent, and the deformation at the rim part is the least. The wheel forming process is the key process of matching the rolling capacity of the thermoforming unit. The reasonable and scientific forming process must not only ensure that the pressure limit value of the press meets the pre-set process value, but also meet the rolling capacity demand of the next process mill.