Wheel forging is a crucial process in the manufacturing of railway wheels.
The first step in the process is to create a detailed wheel forging diagram. This diagram specifies the dimensions and shapes of the blanks for each step in the forging process. The design of these blanks is usually based on existing wheel forgings, with simple volume calculations and adjustments made according to the designer's experience. In cases where the wheel forging shape is complex, experience alone cannot accurately predict the metal flow during deformation. In such situations, adjustments are made during the trial production of new products.
The design principles for wheel forgings are paramount. The process should ensure high-quality machining that meets all technical specifications outlined in the client’s drawings. The goal is to achieve a high production rate to ensure timely delivery of the products, while also reducing manufacturing costs. Additionally, the design should focus on minimizing the labor intensity of workers and ensuring safety during production.
Typically, the wheel forging diagram is calculated by multiplying the cold wheel forging diagram by a thermal expansion factor. However, when the dimensions of various parts of the forged wheel differ significantly, the cooling rate for smaller parts is faster, and the final forging temperature will be significantly different from larger parts. In such situations, the design of the hot wheel forging diagram should account for different thermal expansion coefficients for various parts.
To begin the forging process, the assembly diagram of the wheel forgings must be analyzed and studied. The following steps are typically involved:
· Determine the Blank: Select the appropriate blank material for forging.
· Draft the Production Process Route: Establish a clear process route for forging the wheels.
· Select Positioning Reference Surface: Choose the appropriate reference surface for the forging process.
· Determine Equipment and Tools: Identify the equipment, tools, fixtures, gauges, and auxiliary tools required for each process.
· Establish Technical Requirements: Set the technical specifications and inspection methods for each critical process.
· Determine Machining Allowances: Calculate the machining allowances, process dimensions, and tolerances.
· Define Cutting Quantities and Labor Hours: Determine cutting quantities and establish labor hour quotas.
The primary materials used in wheel forging are carbon steel and alloy steel, with secondary materials including aluminum, magnesium, copper, titanium, and their alloys. These materials are available in various forms, such as bars, cast ingots, metal powders, and liquid metals.
The ratio of the cross-sectional area before deformation to the cross-sectional area after deformation is known as the forging ratio. Choosing the correct forging ratio, along with the right heating temperature, holding time, starting and finishing forging temperatures, as well as deformation amounts and speeds, is crucial for improving product quality and reducing costs.
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