A railway sleeper casting steel mold and forming method

Abstract

A railway sleeper casting mold and its forming method are disclosed. The mold has a casting space matching the shape of the sleeper and is formed by splicing a middle shell and a pair of side shells. The side shells are symmetrically spliced ​​at both ends of the middle shell. The middle shell has a recessed space I formed by connecting its opposing vertical and top surfaces. The side shells have recessed spaces II formed by connecting their opposing top and vertical surfaces. After splicing the middle shell and the pair of side shells, recessed spaces I and II are connected to form the casting space. The top surface of the side shells has rail-bearing grooves recessed into the casting space. The side shells are connected to the middle shell by end plates. The railway sleeper casting mold is formed by splicing two end shells and a middle shell, which facilitates the processing and manufacturing of the mold. A bending process is used to process and form the railway sleeper casting mold, reducing processing costs and saving processing materials while ensuring basic efficiency.

Description

Technical Field

[0001] This invention relates to the field of railway maintenance section auxiliary equipment manufacturing, specifically a sleeper casting steel mold and forming method. Background Technology

[0002] Railway sleepers are common auxiliary equipment in railway engineering sections, used to support railway rails and limit their position. Early sleepers used timber, but these have been largely replaced by cast-in-place concrete sleepers. Concrete sleepers have advantages such as ease of assembly line production, corrosion resistance, and long service life. Concrete sleepers are typically manufactured by pouring concrete into a molding die in one piece, thus requiring molds for shaping the sleepers. Figure 16 A side view (top) and a top view (bottom) of a railway sleeper are shown. The top view shows that the sleeper has an irregular shape that is wider at both ends and slightly narrower in the middle. The top view also shows that there is a positioning recess on the top for supporting and positioning the rail.

[0003] In existing technologies, the common method for manufacturing individual railway sleeper casting molds is through one-piece stamping. While this process can produce railway sleeper casting molds that meet the requirements, the weight of railway sleepers, which are made of cast concrete and require internal steel reinforcement, necessitates the use of thick steel plates for the main body of the casting mold to withstand the weight during casting. In practical applications, the thickness of the steel plates is typically 5mm or even 10mm. This substantial thickness results in high-performance equipment with stringent parameters for one-piece stamping, making the equipment very expensive and leading to high processing costs. Therefore, it is necessary to improve the forming method and process of railway sleeper casting molds to reduce processing costs.

[0004] Currently, existing technologies include railway sleeper casting molds: A search of invention patent publication number "CN216328997U" entitled "A Railway Sleeper Steel Mold" discloses a railway sleeper steel mold that allows multiple individual steel molds to be stacked and cast simultaneously, saving space and increasing production efficiency. However, the individual molds in this prior art are designed as a single, integrated structure. While this integration is good, the numerous cross-sections of the sleeper being cast make the one-piece mold difficult to manufacture. Therefore, the mold structure needs to be improved to facilitate manufacturing. Furthermore, this prior art document does not disclose a specific forming method for this steel mold.

[0005] Therefore, it is of great significance to propose a sleeper casting steel mold and forming method that is easy to process and manufacture within this field. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a railway sleeper casting steel mold with a casting space matching the shape of the sleeper. It is formed by splicing a middle shell and a pair of side shells, with the side shells symmetrically spliced ​​at both ends of the middle shell. The middle shell has a recessed space I formed by connecting its opposing vertical and top surfaces; the side shells have recessed spaces II formed by connecting their opposing top and vertical surfaces. After splicing, the middle shell and the pair of side shells connect the recessed spaces I and II to form the casting space. The top surface of the side shells has rail-bearing grooves recessed into the casting space; the side shells are connected to the middle shell by end plates.

[0007] Furthermore, the top surface of the side shell and the vertical surface of the side shell are connected by a first connecting slope, and the top surface of the side shell and the top surface of the middle shell are connected by a second connecting slope.

[0008] Furthermore, the rail support groove is formed by welding and splicing the rail support groove plate and the top surface of the side shell. The rail support groove plate is formed by connecting the bottom plate and the side plate of the rail support groove plate. The bottom plate, the side plate and the top surface of the side shell are welded and spliced ​​together.

[0009] A method for forming the above-mentioned railway sleeper casting steel mold is also proposed. The middle shell and a pair of side shells are each formed by bending a whole flat steel plate by a bending machine. The middle shell is formed by first drawing the edge lines of each surface on the steel plate according to the dimensions of the middle shell elevation and the top surface of the middle shell, and then cutting the outer perimeter of the middle shell elevation and the top surface of the middle shell to form the middle shell bending blank. The middle shell is formed by bending the middle shell with the overlapping edge of the middle shell elevation and the top surface of the middle shell as the bending edge.

[0010] The side shell forming process involves first drawing the edge lines of each surface on a steel plate according to the dimensions of the top surface, the vertical surface, the first connecting slope, and the second connecting slope, then cutting the outer perimeter of each surface. The overlapping edge L1 of the second connecting slope and the first connecting slope is cut to form a side shell bending blank. The side shell is then bent with the overlapping edge of the top surface and the first connecting slope as the bending edge, and with the overlapping edge of the first connecting slope and the vertical surface as the bending edge. Finally, the overlapping edge L1 is welded after bending the second connecting slope and the top surface of the side shell. After completing the bending of all the surfaces, the end plates are welded to the side surfaces of the side shell, and the rail support plate is welded to the top surface of the side shell to form the rail support groove, thus finally forming the side shell.

[0011] A pair of side shells are welded and spliced ​​onto both sides of the middle shell to form a sleeper casting mold with a casting space.

[0012] Furthermore, before bending the overlapping edge of the top surface of the shell and the connecting slope, the overlapping edge is partially cut before bending, and then the cut part is welded after bending.

[0013] Furthermore, during the process of forming the side shell bending blank, when cutting the blank, the edge lines of the bottom plate and side plate of the rail groove plate are first drawn on the top surface and the connecting inclined surface of the side shell according to the dimensions of the bottom plate and side plate of the rail groove plate. Then, the entire bottom plate and side plate of the rail groove plate are cut to form the side shell bending blank. After the side shell completes the bending of all the surfaces, the rail groove notch is formed. The cut bottom plate and side plate of the rail groove plate are welded to seal the rail groove notch to form the rail groove.

[0014] Furthermore, during the process of forming the side shell bending blank, when cutting the material, first draw the edge lines of the bottom plate and side plate of the rail groove plate on the top surface and the first connecting slope of the side shell according to the dimensions of the bottom plate and side plate of the rail groove plate. Cut the side plate of the rail groove plate and cut three sides of the bottom plate of the rail groove plate, leaving one side that overlaps with the first connecting slope without cutting to form the side shell bending blank. After the side shell has completed the bending of all the surfaces, bend the bottom plate of the rail groove plate along the uncut side and weld it to the adjacent side of the top surface and the first connecting slope of the side shell. Then weld the side plate of the rail groove plate, the bottom plate of the rail groove plate, and the top surface of the side shell to form the rail groove.

[0015] Furthermore, when bending the overlapping edge L1 of the connecting inclined plane and the top surface of the shell into a bent edge, the bending force is maintained while the overlapping edge L1 is welded.

[0016] Compared with the prior art, the technical solution of this application has the following beneficial effects:

[0017] The railway sleeper casting steel mold of this invention is formed by splicing two end shells and a middle shell, which facilitates the processing and manufacturing of the railway sleeper casting steel mold. The end shells and the middle shell can be processed separately and then spliced ​​together by the splicing part S, making the whole easier to process and more flexible to assemble. The railway sleeper casting steel mold is processed and shaped by bending process, which reduces processing costs and saves processing materials while ensuring basic efficiency. Attached Figure Description

[0018] Figure 1 : Three-dimensional views of Embodiment 1 and Embodiment 2;

[0019] Figure 2 : Bottom view of Example 1 (viewed from the pouring space direction);

[0020] Figure 3 Schematic diagram of steel mold blanking for railway sleeper casting Figure 1 ;

[0021] Figure 4 : The bending process of the steel mold for railway sleeper casting;

[0022] Figure 5 : The bending process of the steel mold for railway sleeper casting (Part 2);

[0023] Figure 6 Three steps in the bending process of the steel mold for railway sleeper casting;

[0024] Figure 7 The fourth step involves bending the steel mold used for railway sleeper casting.

[0025] Figure 8 Schematic diagram of steel mold blanking for railway sleeper casting Figure 2 ;

[0026] Figure 9 Five steps in the process of bending the steel mold for railway sleeper casting.

[0027] Figure 10 Sixth step in the process of bending the steel mold for railway sleeper casting.

[0028] Figure 11 Seven steps in the process of bending the steel mold for railway sleeper casting;

[0029] Figure 12 Schematic diagram of the middle shell material cutting process;

[0030] Figure 13 : Schematic diagram of the bending and blanking process of the middle shell;

[0031] Figure 14 Eight: The bending process of the steel mold for railway sleeper casting;

[0032] Figure 15 Nine steps in the process of bending the steel mold for railway sleeper casting;

[0033] Figure 16 Background Art: Schematic diagram of railway sleeper structure. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1: Steel mold for railway sleeper casting.

[0036] like Figures 1-2As shown, the casting space 3, which matches the shape of the sleeper, is characterized by: being formed by splicing a middle shell 2 and a pair of side shells 1, with the side shells 1 being symmetrically spliced ​​at both ends of the middle shell 2; the middle shell 2 is formed by connecting the opposing middle shell facade 21 and the middle shell top surface 22 to form a concave space 32; the side shells 1 are formed by connecting the opposing side shell top surface 13 and the side shell facade 11 to form a concave space 31; after splicing the middle shell 2 and the pair of side shells 1, the concave space 32 and the concave space 31 are connected to form the casting space 3; the top surface 13 of the side shell has a rail bearing groove 15 that is recessed into the casting space 3; and the side shells 1 are connected to the middle shell 2 by a splicing plate 16.

[0037] Since the two side shells 1 have identical external dimensions, they can be manufactured uniformly during the processing. The side shells 1 are approximately wedge-shaped; processing them individually can be simplified by bending, while processing the entire mold as a whole cannot be done using bending. The middle shell 2 is regular in shape and can be stamped or bent. After the side shells 1 and middle shell 2 are processed, they are symmetrically joined together to form the entire mold. This separate joining process also makes mold assembly more flexible. If individual side shells 1 or middle shells 2 do not meet process requirements during batch processing, they can be replaced with corresponding parts to form the mold. In contrast, if a defect occurs in the overall mold, the entire mold must be scrapped, thus avoiding material waste. Furthermore, since the width and height of the side shells 1 and middle shells 2 can be matched, different side shells 1 can be joined using the same middle shell 2 to form molds of varying lengths, offering high assembly flexibility.

[0038] In this embodiment, the top surface 13 of the side shell and the vertical surface 11 of the side shell are connected by a connecting inclined surface 12, and the top surface 13 of the side shell and the top surface 22 of the middle shell are connected by a connecting inclined surface 14, so as to further form a casting space 3 that meets the requirements.

[0039] Furthermore, the rail support groove 15 is formed by welding the rail support groove plate 4 and the top surface 13 of the side shell. The rail support groove plate 4 is formed by connecting the bottom plate 41 and the side plate 42 of the rail support groove plate. The bottom plate 41, the side plate 42, and the top surface 13 of the side shell are welded together. By also using the splicing method to form the rail support groove 15 from the rail support groove plate 4 and the top surface 13 of the side shell, the processing difficulty of the side shell is further reduced. That is, both the side shell 1 and the rail support groove plate 4 can be bent and processed separately before being welded together, thus further reducing the processing difficulty. Moreover, the material for the rail support groove plate 4 can be obtained by cutting during the bending and blanking of the side shell 1, further saving material.

[0040] Example 2: Forming method of railway sleeper casting steel mold.

[0041] like Figure 12 and Figure 13As shown, the middle shell 2 and the pair of side shells 1 are each formed by bending a whole flat steel plate through a bending machine. The middle shell 2 is formed by first drawing the edge lines of each surface on the steel plate according to the dimensions of the middle shell facade 21 and the middle shell top surface 22, and then cutting the outer periphery of the middle shell facade 21 and the middle shell top surface 22 to form the middle shell bending blank A. The middle shell 2 is formed by bending the middle shell with the overlapping edge of the middle shell facade 21 and the middle shell top surface 22 on the middle shell bending blank A as the bending edge.

[0042] like Figure 3 or Figure 8 As shown, the side shell 1 is formed by first drawing the edge lines of each surface on a steel plate according to the dimensions of the top surface 13, the vertical surface 11, the first connecting slope 12, and the second connecting slope 14. Then, the outer perimeter of each surface is cut, and the overlapping edge L1 of the second connecting slope 14 and the first connecting slope 12 is cut to form the side shell bending blank B. The edge lines drawn for each surface correspond to the contours and dimensions of each surface after the steel mold is unfolded into a plane. The specific dimensions and contours of each surface on the flat steel plate can be determined according to the various surfaces of the steel mold to be processed.

[0043] like Figures 9-11 As shown, the bending process involves bending the side shell 1 with the overlapping edge of the top surface 13 and the connecting inclined surface 12 as the bending edge, and bending the side shell 1 with the overlapping edge of the connecting inclined surface 12 and the side shell 11 as the bending edge. Then, the bending is performed with the overlapping edge of the connecting inclined surface 14 and the top surface 13 of the side shell as the bending edge, and the overlapping edges L1 are welded together. After completing the bending of all surfaces, the end plate 16 is welded to the side of the side shell 1, and the rail support plate 4 is welded to the top surface 13 of the side shell to form the rail support groove 15, thus finally forming the side shell 1. During the bending process, there are no special requirements for the specific bending sequence, but it is preferable to first bend the connecting inclined surface 12 and the side shell 11 before bending the connecting inclined surface 14. Since the final connecting inclined surface 14 needs to be welded to its adjacent overlapping edge L1, if the connecting inclined surface 12 and the side shell facade 11 are formed first, the connecting inclined surface 14 can be bent and then the overlapping edge L1 can be overlapped and welded, making the processing procedure simpler; and the bending angle of the connecting inclined surface 14 is also determined by the formed connecting inclined surface 12 and the side shell facade 11, making the bending process more precise.

[0044] like Figure 14 and Figure 15 After completing the bending and forming of the connecting inclined plane 14 and the welding of the overlapping edge L1, a certain area of ​​redundancy will be generated relative to the overlapping edge L1, as shown by the dotted line in the figure. Preferably, this part should be removed. Of course, since the internal pouring space has already been formed, not removing this part will not affect the use of the steel mold. However, after removal, the shape is more regular and it is beneficial for the stacking of steel molds.

[0045] like Figure 1and Figure 2 As shown, a pair of side shells 1 are welded and spliced ​​on both sides of the middle shell 2 to form a sleeper casting steel mold with a casting space 3.

[0046] Furthermore, such as Figure 3 or Figure 8 As shown, before bending the overlapping edge of the top surface 13 of the side shell and the connecting inclined surface 12, the overlapping edge is partially cut before bending. The cut portion is as follows: Figure 3 or Figure 8 The portion shown by the thick solid line on the top surface 13 of the middle shell is bent and then welded. The reason for partially cutting the bent edge is to ensure that the bent edge is not too long, so that the shape after bending is more regular. After bending and forming, the welding of this cut part is preferably carried out on the outside of the casting space 3, which can minimize the burrs and flash caused by the welding part to the cast sleeper.

[0047] The rail support groove 15 can be formed in two ways. One is as follows: Figure 8-11 as well as Figure 14 , Figure 15 During material preparation, the edges of the bottom plate 41 and side plate 42 of the rail groove plate are first drawn on the top surface 13 and connecting inclined surface 12 of the side shell according to the dimensions of the bottom plate 41 and side plate 42 of the rail groove plate. Then, the entire bottom plate 41 and side plate 42 of the rail groove plate are cut to form the side shell bending blank B. After all the surfaces of the side shell 1 are bent, the rail groove notch 15a is formed. The cut-off bottom plate 41 and side plate 42 of the rail groove plate are welded to seal the rail groove notch 15a to form the rail groove 15. That is, after the bottom plate 41 and side plate 42 of the rail groove plate required to seal the rail groove 15 are hollowed out and cut off, and after all the surfaces are bent into shape, the cut-off bottom plate 41 and side plate 42 of the rail groove plate are used to seal the rail groove notch 15a. Compared to the method of not cutting the rail groove 15 and placing the bottom plate 41 and side plate 42 of the rail groove plate (either separately or as a whole) into the casting space 3 to form the rail groove 15, the method of forming the rail groove 15 by bending after hollowing out the space creates a recessed rail groove 15a relative to the casting space 3. This allows for sealing from the outside of the casting space 3, thus forming the recessed rail groove 15. Compared to internal placement and welding, this external sealing method, even if the sealing exceeds a certain range, does not affect the formation of the recessed rail groove 15 because it is outside the casting space 3. The excess portion can be cut off, reducing the material requirements for sealing. Furthermore, welding after sealing is also done outside the casting space 3, minimizing burrs and flash caused by welding on the recessed rail groove 15 portion of the cast sleeper. Moreover, the sealing material can be obtained from the cutting scraps, saving material costs.

[0048] One such Figure 3-7 as well as Figure 14 , Figure 15 During the process of forming the side shell bending blank B, when cutting the material, first draw the edge lines of the bottom plate 41 and the side plate 42 of the rail groove plate on the top surface 13 and the connecting inclined surface 12 of the side shell according to the dimensions of the bottom plate 41 and the side plate 42 of the rail groove plate. Cut the side plate 42 of the rail groove plate and cut three sides of the bottom plate 41 of the rail groove plate, leaving one side that coincides with the connecting inclined surface 12 without cutting to form the side shell bending blank B. After the side shell 1 completes the bending of all the surfaces, the bottom plate 41 of the rail groove plate is bent along the uncut side and then welded to the adjacent side of the top surface 13 and the connecting inclined surface 12 of the side shell. Then, the side plate 42 of the rail groove plate, the bottom plate 41 of the rail groove plate and the top surface 13 of the side shell are welded together to form the rail groove 15. That is, during the material cutting process, the bottom plate 41 and side plate 42 of the rail groove plate required to seal the rail groove 15 are not completely cut. Only three edges of the side plate 42 and the bottom plate 41 are cut, leaving one edge that coincides with the connecting inclined surface 12 uncut. This edge is used as the bending edge. After bending all surfaces, the bottom plate 41 is bent to seal the rail groove notch 15a using this bending edge. Then, the remaining unsealed part is sealed with the side plate 42. Figure 6 , 7 As shown. This method eliminates the need to cut all the bottom plates 41 and side plates 42 of the rail bearing groove, saving processing time. Furthermore, the bent edges do not need to be welded when the final sealing of the rail bearing groove 15 is formed; welding is only required on the edges that are in contact with the sealing, further saving processing time and reducing burrs and flash generated in the rail bearing groove 15.

[0049] For the formation process of end panel 16, after the side shell 1 is fully bent and formed, the portion of the side shell 1 opposite to the middle shell 2 can be bent, sealed, and welded using matching steel plates, as shown below. Figure 1 and Figure 2 Alternatively, one can use methods such as... Figure 8 , Figure 11 , Figure 14 As shown, during the material cutting process, the cutting edges of the end panel 16 are as follows: Figure 8 The thick solid line section of end panel 16 forms a shape like... Figure 11 The side shell shown is followed by, as in Figure 14 As shown, the end plate 16 is bent and welded, and finally the remaining part is sealed and welded with matching steel plates.

[0050] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0051] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for forming a steel mold for railway sleeper casting, characterized in that: It is formed by splicing a middle shell (2) and a pair of side shells (1), with the side shells (1) symmetrically spliced ​​at both ends of the middle shell (2); the middle shell (2) is formed by connecting the opposing middle shell facade (21) and the middle shell top surface (22) to form a concave space one (32); the side shell (1) is formed by connecting the opposing side shell facade (11) and the side shell top surface (13) to form a concave space two (31), and after splicing the middle shell (2) and the pair of side shells (1), the concave space one (32) and the concave space two (31) are connected to form a casting space (3); the top surface (13) of the side shell has a support groove (15) that is recessed into the casting space (3); the side shell (1) is connected to the end splice plate (16) at the end away from the middle shell (2); The top surface (13) of the side shell and the vertical surface (11) of the side shell are connected by a first connecting slope (12), and the top surface (13) of the side shell and the top surface (22) of the middle shell are connected by a second connecting slope (14). The rail support groove (15) is formed by welding the rail support groove plate (4) and the top surface (13) of the side shell. The rail support groove plate (4) is formed by connecting the bottom plate (41) and the side plate (42) of the rail support groove plate. The bottom plate (41), the side plate (42) of the rail support groove plate and the top surface (13) of the side shell are welded together. The middle shell (2) and the pair of side shells (1) are each formed by bending a whole flat steel plate by bending. The middle shell (2) is formed by first drawing the edge lines of each surface on the steel plate according to the dimensions of the middle shell facade (21) and the middle shell top surface (22), and then cutting the outer periphery of the middle shell facade (21) and the middle shell top surface (22) to form the middle shell bending blank (A). The middle shell (2) is formed by bending the overlapping edge of the middle shell facade (21) and the middle shell top surface (22) on the middle shell bending blank (A) as the bending edge. The side shell (1) is formed by first drawing the edge lines of each surface on the steel plate according to the dimensions of the top surface (13), the vertical surface (11), the first connecting slope (12), and the second connecting slope (14), and then cutting the outer perimeter of each surface. The overlapping edge L1 of the second connecting slope (14) and the first connecting slope (12) is cut to form the side shell bending blank (B). The overlapping edge of the top surface (13) and the first connecting slope (12) is used as the bending edge. The edges are bent and the edge is bent with the overlapping edge of the connecting inclined surface 1 (12) and the side shell facade (11) as the bending edge, and then the overlapping edge L1 is welded after the overlapping edge of the connecting inclined surface 2 (14) and the side shell top surface (13) is bent. After completing the bending of all surfaces, the end plate (16) and the side of the side shell (1) are welded together. The rail support plate (4) and the side shell top surface (13) are welded together to form the rail support groove (15) and finally the side shell (1) is formed. A pair of side shells (1) are welded and spliced ​​on both sides of the middle shell (2) to form a sleeper casting steel mold with a casting space (3); During the process of forming the side shell bending blank (B), when cutting the material, first draw the edge lines of the bottom plate (41) and side plate (42) of the rail groove plate on the top surface (13) and the first connecting slope (12) of the side shell according to the dimensions of the bottom plate (41) and side plate (42) of the rail groove plate. Cut the side plate (42) of the rail groove plate and cut the three sides of the bottom plate (41) of the rail groove plate, leaving one side that overlaps with the first connecting slope (12) without cutting to form the side shell bending blank (B). After the side shell (1) has completed bending of all surfaces, the bottom plate (41) of the rail groove plate is bent along the uncut side and then welded to the adjacent side of the top surface (13) and the first connecting slope (12) of the side shell. Then, the side plate (42) of the rail groove plate, the bottom plate (41) of the rail groove plate, and the top surface (13) of the side shell are welded together to form the rail groove (15).

2. The forming method of the sleeper casting steel mold as described in claim 1, characterized in that: Before bending, the overlapping edge of the top surface (13) of the side shell and the connecting inclined surface (12) is partially cut and then bent. After bending, the cut part is welded.

3. The forming method of the sleeper casting steel mold as described in claim 2, characterized in that: After bending the overlapping edge of the connecting inclined plane 2 (14) and the top surface of the side shell (13) into a bent edge, while maintaining the bending force, the overlapping edge L1 is welded.

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