Roll-forming die and forming process for a wheel axle of a rail vehicle

Abstract

The application relates to a roller forming die and a forming process of an axle for a rail vehicle, and belongs to the technical field of plastic forming, and solves the technical problems of low plastic forming efficiency and unguaranteed quality of the axle for the rail vehicle, and the solution is as follows: a double-clamping guiding device is designed to ensure that the axle is not twisted or bent during the forming process; the forming die is formed by two contact rollers with recesses arranged in the contact rollers, a special-shaped metal flow guide groove is arranged at the contact position of the contact rollers, the metal flow guide groove avoids the metal flowing into the roller gap to form a thin flash, influences the forming quality, obtuse-angle flash generated by the metal flow guide groove in the first-pass pre-forming process can be eliminated by reverse forming in the second pass, and the problem of difficult metal flow at the center of the recess is solved. The application is a multi-roller forming method, can effectively improve the problem of difficult metal flow of the blank at the center of the recess of the roller, effectively reduces the load borne by the roller, and can improve the service life of the equipment.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of plastic forming, and particularly relates to a roller forming die and forming process for a railway vehicle axle. BACKGROUND

[0002] At present, the production of railway vehicle axles mainly adopts radial forging process (i.e. precision forging) and drop-down fast forging process, and the four-pass turning roller forging method is involved in the axle roller forging process, but the following deficiencies exist.

[0003] (1) The roller forging times are many, the production efficiency is low, and the precision of each roller forging is difficult to control, and the step misplacement is prone to occur;

[0004] (2) In the roller forging process, since there is no guiding control, the shaft blank is prone to torsion and bending in the forming process;

[0005] (3) The metal is prone to extrusion into the roll gap in the forming process, resulting in flash and burr, and folding defects are prone to occur in the subsequent forming, affecting the subsequent processing, and further affecting the quality of the axle. SUMMARY

[0006] The main purpose of the present application is to overcome the deficiencies in the prior art, solve the technical problems of low plastic forming efficiency and quality guarantee of the railway vehicle axle, and provide a roller forming die and forming process for a railway vehicle axle.

[0007] The design concept of the present application is to design a double-clamping guiding device to ensure that the axle does not twist or bend during the forming process; three roller wheels that are in contact with each other and have recesses inside are used as the forming die, the contact parts of the roller wheels are designed as special-shaped metal flow guide grooves, the metal flow into the roll gap is avoided to form thin flash and affect the forming quality, the obtuse angle flash generated by the metal flow guide groove in the first pass forming process can be eliminated by the reverse shaping in the second pass. This design optimizes the roller forging forming equipment and solves the problem of difficult metal flow at the center of the recess.

[0008] In order to achieve the above-mentioned application purposes, the technical scheme adopted by the present application is:

[0009] A roller forming die for a railway vehicle axle, comprising at least three forming rollers arranged uniformly in the circumferential direction, and a plurality of forming rollers contacting each other, wherein: the outer circumferential surfaces of the plurality of forming rollers form a forming cavity, and a flow guide groove is arranged at the contact position of the edges of adjacent forming rollers, and the included angle of the opening of the flow guide groove is 51°-53°; a reference positioning boss is arranged on the outer circumferential surface of the forming roller, one end of the reference positioning boss is provided with an L1' groove for forming a first journal, the other end of the reference positioning boss is provided with an L7' groove for forming a second journal, the opposite outer circumferential surface of the reference positioning boss is provided with an L4' groove for forming a shaft body, one end of the L4' groove is provided with an L3' groove for forming a first wheel seat, the other end of the L4' groove is provided with an L5' groove for forming a second wheel seat, the L1' groove and the L3' groove are provided with an L2' groove for forming a first dustproof seat, and the L7' groove and the L5' groove are provided with an L6' groove for forming a second dustproof seat;

[0010] The arc length of each section of the L1' groove, the L2' groove, the L3' groove, the L4' groove, the L5' groove, the L6' groove and the L7' groove on the forming roller is 0.85-0.9 times the design length of the corresponding section of the railway vehicle axle; the connecting positions of the L1' groove and the L2' groove, the L2' groove and the L3' groove, the L3' groove, the L5' groove and the L4' groove, the L5' groove and the L6' groove, and the L6' groove and the L7' groove are respectively connected by grooves for forming shaft shoulders.

[0011] Further, the edges at the opening positions of the flow guide grooves and the forming surfaces of the forming rollers are connected by a circular arc with a radius of 15 mm, and the contact positions of the edges of adjacent forming rollers at the bottom of the flow guide grooves are connected by a circular arc with a radius of 5.4 mm.

[0012] Further, the inner walls of the L1' groove, the L2' groove, the L3' groove, the L4' groove, the L5' groove, the L6' groove and the L7' groove are etched with circumferential anti-slip fine lines.

[0013] A forming process using the above roller forming die for a railway vehicle axle, comprising the following steps:

[0014] S1, A clamping device A and a clamping device B are arranged on both sides of the roller forming die respectively, and a feeding and discharging manipulator sends an axle blank to the position of the clamping device A, the clamping jaw of the clamping device A fixes one end of the axle blank, and the axle blank is sent into the roller forming die along the axial direction and into the L7' groove;

[0015] S2, preforming, comprising the following steps:

[0016] S2-1, the motor drives the forming roller to rotate forward, the A clamping device assists in feeding, the axle blank is compressed radially and elongated axially in the forming cavity, and the second axle neck is formed;

[0017] S2-2, the clamping jaw of the B clamping device fixes the second axle neck formed in step S2-1, the clamping jaw of the A clamping device is loosened, and the axle blank is transferred from the A clamping device to the B clamping device;

[0018] S2-3, the motor drives the forming roller to continue to rotate forward, passes through the forming cavity under the guidance of the B clamping device, and sequentially forms the second dustproof seat-second wheel seat-axle body-first wheel seat-first dustproof seat-first axle neck on the axle blank, after preforming is completed, the first axle neck is located in the L' groove', the forming roller and the B clamping device stop, and the preformed axle blank is prepared;

[0019] S3, the forming is completed, and the following steps are included:

[0020] S3-1, the clamping jaw of the B clamping device drives the preformed axle blank prepared in step S2 to rotate circumferentially by 60 degrees;

[0021] S3-2, the forming roller and the B clamping device are started at the same time, the motor drives the forming roller to rotate reversely, and the B clamping device reversely feeds the preformed axle blank rotated in step S3-1 into the roller forming die again;

[0022] S3-3, after the first axle neck is completely formed through the roller forming die, the clamping jaw of the A clamping device fixes the first axle neck, the clamping jaw of the B clamping device is loosened, and the preformed axle blank is transferred from the B clamping device to the A clamping device again;

[0023] S3-4, the motor drives the forming roller to continue to rotate reversely, passes through the forming cavity under the guidance of the A clamping device, and sequentially performs the forming on the first dustproof seat-first wheel seat-axle body-second wheel seat-second dustproof seat-second axle neck on the preformed axle blank, and the axle for a railway vehicle is prepared;

[0024] S4, after the forming roller is reset after the forming in step S3 is completed, the axle for a railway vehicle is transferred to a conveying roller by the feeding and discharging manipulator, and the roller forming process of the axle for a railway vehicle is completed.

[0025] Compared with the prior art, the beneficial effects of the present application are as follows:

[0026] ①The present application is multi-roller forming, which can effectively improve the problem that the blank metal flows difficultly at the center part of the groove of the roller, effectively reduces the load borne by the roller, and can improve the service life of the equipment;

[0027] ②The present application can make the metal which is not easy to deform in the forming process flow into the guide groove, form the obtuse angle flash with clear profile, and facilitate the elimination in the subsequent shaping, avoid the defects such as folding in the subsequent shaping process, and affect the subsequent machining.

[0028] ③The present application adopts the method of double clamping equipment guidance, forward preforming and reverse shaping, which ensures that the axle does not twist or bend in the forming process. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 It is a schematic diagram of the axle structure for railway vehicles.

[0030] Figure 2 It is a schematic diagram of the three-dimensional structure of the roll forming die.

[0031] Figure 3 It is a schematic diagram of the top view structure of the roll forming die.

[0032] Figure 4 It is Figure 3 It is a schematic diagram of the local enlarged structure at position A.

[0033] Figure 5 It is a schematic diagram of the main view and section view structure of the forming roller.

[0034] Figure 6 It is a schematic diagram of the forming process flow of the axle for railway vehicles.

[0035] In the figure, 1 is the first journal, 2 is the first dustproof seat, 3 is the first wheel seat, 4 is the shaft body, 5 is the second wheel seat, 6 is the second dustproof seat, 7 is the second journal, 1' is the L1' groove, 2' is the L2' groove, 3' is the L3' groove, 4' is the L4' groove, 5' is the L5' groove, 6' is the L6' groove, 7' is the L7' groove; 8 is the reference positioning boss, 9 is the guide groove, 10 is the axle blank, 11 is the A clamping equipment, 12 is the B clamping equipment, and 13 is the preformed axle blank. DETAILED DESCRIPTION

[0036] The present application will be further described in detail below in combination with the drawings and examples.

[0037] The present embodiment is used for forming the axle for railway vehicles as shown in Figure 1 The first journal 1 and the second journal 7 are respectively arranged at the two ends of the axle, the shaft body 4 is arranged at the middle part of the axle, the first wheel seat 3 and the second wheel seat 5 are respectively arranged at the two ends of the shaft body 4, the first dustproof seat 2 is arranged between the first wheel seat 3 and the first journal 1, and the second dustproof seat 6 is arranged between the second wheel seat 5 and the second journal 7; and the chamfer is arranged on the end face of the dustproof seat close to the journal, and the chamfer is arranged on the end face of the wheel seat and the two side end faces of the wheel seat.

[0038] In this specific embodiment, the design dimensions of the axle for the rail vehicle are shown in Table 1 below.

[0039] Table 1. Axle design dimensions (unit: mm)

[0040]

[0041] like Figures 2 to 5 The roller forming mold shown includes at least three forming rollers evenly arranged along the circumference. The forming rollers are in contact with each other in pairs. The outer surfaces of the forming rollers form a forming cavity. Guide grooves 9 are provided at the contact positions of adjacent forming roller edges, with the included angle of the openings of the guide grooves 9 being 51°~53°. A reference positioning boss 8 is provided on the outer surface of the forming rollers. One end of the reference positioning boss 8 is provided with an L1' groove 1' for forming a first journal 1, and the other end of the reference positioning boss 8 is provided with a groove for forming a second journal 1. The journal 7 has an L7' groove 7'. The outer circular surface of the reference positioning boss 8 is provided with an L4' groove 4' for forming the shaft body 4. One end of the L4' groove 4' is provided with an L3' groove 3' for forming the first wheel seat 3. The other end of the L4' groove 4' is provided with an L5' groove 5' for forming the second wheel seat 5. An L2' groove 2' for forming the first dustproof seat 2 is provided between the L1' groove 1' and the L3' groove 3'. An L6' groove 6' for forming the second dustproof seat 6 is provided between the L7' groove 7' and the L5' groove 5'.

[0042] Due to the forward slippage effect between the roll forming blank and the roller, based on experience, the arc length of each segment of L1´Gutter 1´, L2´Gutter 2´, L3´Gutter 3´, L4´Gutter 4´, L5´Gutter 5´, L6´Gutter 6´, and L7´Gutter 7´ on the forming roller is 0.85 to 0.9 times the design length of the corresponding segment of the rail vehicle axle. The connection positions of L1´Gutter 1´ and L2´Gutter 2´, L2´Gutter 2´ and L3´Gutter 3´, L3´Gutter 3´ and L5´Gutter 5´ and L4´Gutter 4´ respectively, L5´Gutter 5´ and L6´Gutter 6´, and L6´Gutter 6´ and L7´Gutter 7´ are respectively connected by grooves used for forming shoulder chamfering.

[0043] In this specific embodiment, the design dimensions of each groove on the forming roller are shown in Table 2 below.

[0044] Table 2 Design dimensions of each groove on the forming roller (unit: mm)

[0045]

[0046] Further, the edge of the opening position of the flow guide groove 9 and the forming surface of the forming roller are connected by a circular arc transition connection, and the circular arc radius is 15 mm; the contact position of the bottom of the flow guide groove 9 and the edge of the adjacent forming roller is connected by a circular arc transition connection, and the circular arc radius is 5.4 mm.

[0047] Further, the inner walls of the L1' groove 1', the L2' groove 2', the L3' groove 3', the L4' groove 4', the L5' groove 5', the L6' groove 6', and the L7' groove 7' are etched with circumferential anti-slip fine lines.

[0048] As shown in a forming process of a roller type forming die using the above-mentioned railway vehicle axle, the forming process comprises the following steps: Figure 6

[0049] S1, A clamping device 11 and a B clamping device 12 are respectively arranged on the two sides of the roller type forming die, and an upper and lower material loading manipulator sends an axle blank 10 to the position of the A clamping device 11, the clamping jaw of the A clamping device 11 fixes one end of the axle blank 10, and the axle blank 10 is sent into the roller type forming die along the axial direction, and the axle blank 10 is sent into the L7' groove 7';

[0050] S2, pre-forming, comprising the following steps:

[0051] S2-1, the motor drives the forming roller to rotate forward, the A clamping device 11 assists in feeding, the axle blank 10 is radially compressed and axially elongated in the forming cavity, and the second journal 7 is formed;

[0052] S2-2, the clamping jaw of the B clamping device 12 fixes the second journal 7 formed in step S2-1, the clamping jaw of the A clamping device 11 is loosened, and the axle blank 10 is transferred from the A clamping device 11 to the B clamping device 12;

[0053] S2-3, the motor drives the forming roller to continue to rotate forward, and the axle blank 10 passes through the forming cavity under the guidance of the B clamping device 12, and the second dust cover 6, the second wheel seat 5, the shaft body 4, the first wheel seat 3, the first dust cover 2, and the first journal 1 are sequentially formed on the axle blank 10, after the pre-forming is completed, the first journal 1 is located in the L1' groove 1', the forming roller and the B clamping device 12 stop, and a pre-formed axle blank 13 is prepared; during the first pass pre-forming, a small part of the metal blank flows into the flow guide groove under the action of the forming groove, and a clear obtuse angle burr is formed, and during the second pass shaping, the burr disappears under the action of the forming groove;

[0054] S3, shaping, comprising the following steps:

[0055] S3-1, the clamping jaw of the B clamping device 12 drives the pre-formed axle blank 13 prepared in step S2 to rotate circumferentially by 60°; ​

[0056] S3-2, the forming roller is started at the same time with the B clamping device 12, the motor drives the forming roller to rotate reversely, the B clamping device 12 reversely sends the preformed axle blank 13 rotated in step S3-1 into the roller forming die again;

[0057] S3-3, after the first journal 1 is formed by the roller forming die, the clamping jaw of the A clamping device 11 fixes the first journal 1, the clamping jaw of the B clamping device 12 is loosened, and the preformed axle blank 13 is retransferred from the B clamping device 12 to the A clamping device 11;

[0058] S3-4, the motor drives the forming roller to continue to rotate reversely, passes through the forming cavity under the guidance of the A clamping device 11, and sequentially forms the first dustproof seat 2, the first wheel seat 3, the shaft body 4, the second wheel seat 5, the second dustproof seat 6 and the second journal 7 on the preformed axle blank 13, so that the railway vehicle axle is prepared;

[0059] S4, after the forming of step S3 is completed, the forming roller is reset, the railway vehicle axle is transferred to the conveying roller by the feeding and discharging manipulator, and the roller forming process of the railway vehicle axle is completed.

[0060] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited to this, any person skilled in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A forming process using a roller forming die for a railway vehicle axle, characterized in that, A roller forming die for a railway vehicle axle comprises at least three forming rollers arranged uniformly in the circumferential direction, the forming rollers contact each other in pairs, and the outer circumferential surfaces of the forming rollers form a forming cavity; a reference positioning boss (8) is arranged on the outer circumferential surface of the forming roller, one end of the reference positioning boss (8) is provided with an L1' groove (1') for forming a first journal (1), the other end of the reference positioning boss (8) is provided with an L7' groove (7') for forming a second journal (7), the opposite outer circumferential surface of the reference positioning boss (8) is provided with an L4' groove (4') for forming a shaft body (4), one end of the L4' groove (4') is provided with an L3' groove (3') for forming a first wheel seat (3), the other end of the L4' groove (4') is provided with an L5' groove (5') for forming a second wheel seat (5), an L2' groove (2') for forming a first dustproof seat (2) is arranged between the L1' groove (1') and the L3' groove (3'), and an L6' groove (6') for forming a second dustproof seat (6) is arranged between the L7' groove (7') and the L5' groove (5'); The forming process using the roller forming die for the railway vehicle axle comprises the following steps: S1, A clamping device (11) and a B clamping device (12) are arranged on both sides of the roller forming die respectively, a feeding and discharging manipulator sends an axle blank (10) to the position of the A clamping device (11), the clamping jaw of the A clamping device (11) fixes one end of the axle blank (10), and the axle blank (10) is sent into the roller forming die along the axial direction and into the L7' groove (7'); S2, pre-forming, comprising the following steps: S2-1, the motor drives the forming rollers to rotate forward, the A clamping device (11) assists in feeding, the axle blank (10) is radially compressed and axially elongated in the forming cavity, and the second journal (7) is formed; S2-2, the clamping jaw of the B clamping device (12) fixes the second journal (7) formed in step S2-1, the clamping jaw of the A clamping device (11) is loosened, and the axle blank (10) is transferred from the A clamping device (11) to the B clamping device (12); S2-3, the motor drives the forming rollers to continue to rotate forward, and the axle blank (10) passes through the forming cavity under the guidance of the B clamping device (12), and the second dustproof seat (6) - the second wheel seat (5) - the shaft body (4) - the first wheel seat (3) - the first dustproof seat (2) - the first journal (1) are formed on the axle blank (10) in sequence, after pre-forming is completed, the first journal (1) is located in the L1' groove (1'), the forming rollers and the B clamping device (12) stop, and a pre-formed axle blank (13) is prepared; S3, final forming, comprising the following steps: S3-1, the clamping jaw of the B clamping device (12) drives the pre-formed axle blank (13) prepared in step S2 to rotate circumferentially by 60°. S3-2, the forming roller is started at the same time with the B clamping device (12), the motor drives the forming roller to rotate reversely, the B clamping device (12) reversely sends the preformed axle blank (13) rotated in step S3-1 into the roller forming die again; S3-3, after the first journal (1) is formed by the roller forming die, the clamping jaw of the A clamping device (11) fixes the first journal (1), the clamping jaw of the B clamping device (12) is loosened, and the preformed axle blank (13) is retransferred to the A clamping device (11) by the B clamping device (12); S3-4, the motor drives the forming roller to continue to rotate reversely, passes through the forming cavity under the guidance of the A clamping device (11), and sequentially forms the first dustproof seat (2), the first wheel seat (3), the shaft body (4), the second wheel seat (5), the second dustproof seat (6) and the second journal (7) on the preformed axle blank (13), so that the railway vehicle axle is prepared; S4, after the forming of step S3 is completed, the forming roller is reset, the railway vehicle axle is transferred to the conveying roller by the feeding and discharging manipulator, and the roller forming process of the railway vehicle axle is completed.

2. A forming process using a roll forming die for a wheel axle of a rail vehicle according to claim 1, characterized in that: A flow guide groove (9) is arranged at the contact position of the edges of adjacent forming rollers, the included angle of the opening of the flow guide groove (9) is 51°-53°, the edges at the opening position of the flow guide groove (9) are connected to the forming surface of the forming roller through arc transition, and the radius of the arc is 15 mm; the edges of the adjacent forming rollers at the contact position of the bottom of the flow guide groove (9) are connected through arc transition, and the radius of the arc is 5.4 mm.

3. A forming process using a roll forming die for a wheel axle of a rail vehicle according to claim 1, characterized in that: The arc lengths of the L1' groove (1'), the L2' groove (2'), the L3' groove (3'), the L4' groove (4'), the L5' groove (5'), the L6' groove (6') and the L7' groove (7') on the forming roller are 0.85-0.9 times the design length of the corresponding section of the railway vehicle axle; the connection positions of the L1' groove (1') and the L2' groove (2'), the L2' groove (2') and the L3' groove (3'), the L3' groove (3') and the L4' groove (4'), the L4' groove (4') and the L5' groove (5'), the L5' groove (5') and the L6' groove (6'), and the L6' groove (6') and the L7' groove (7') are connected through grooves for forming shoulder chamfers; The inner walls of the L1' groove (1'), the L2' groove (2'), the L3' groove (3'), the L4' groove (4'), the L5' groove (5'), the L6' groove (6') and the L7' groove (7') are etched with circumferential anti-slip fine lines.

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