Inlaid frog wing rail insert and local forging blank manufacturing method thereof

Abstract

According to the embedded frog wing rail insert and the local forging blank manufacturing method thereof, firstly, a local die forging blank of the embedded frog wing rail insert is cast through a casting forming technology, and then local die forging is conducted on a partial area in the section range from the frog throat to the point rail width of 50 mm of the local die forging blank of the embedded frog wing rail insert; and carrying out water toughening treatment at 1000-1100 DEG C after local die forging to obtain a machined blank of the embedded frog wing rail insert. According to the method, the later machining amount can be effectively reduced, the manufacturing period is shortened, the cost is reduced, it is guaranteed that the insert has good service performance, the practical value and application prospects are high, the service life of a finished product is prolonged, and the safety performance of the finished product is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of forging an inlaid frog wing rail insert, and in particular relates to an inlaid frog wing rail insert and a partial forging blank making method thereof. Background Art

[0002] The traditional manufacturing method of the inlaid frog wing rail insert is usually to forge a square blank by free forging, and then to manufacture it by machining. The wing rail insert obtained by this method has good service performance, but the machining amount in the manufacturing process is huge, the manufacturing cycle is long, and the cost is high. In this regard, the following improved technical solution is proposed. Summary of the invention

[0003] The technical problem solved by the present invention is to provide an inlaid frog wing rail insert and a local forging blank making method thereof, so as to solve the technical problems of the existing insert preparation method, such as huge machining amount, long manufacturing cycle and high cost.

[0004] The technical scheme adopted by the present invention is a method for partially forging a blank of an inlaid frog wing rail insert. First, a local die forging blank of the inlaid frog wing rail insert is cast by a casting molding process, and then a partial area within a cross-section range of 50mm from the frog throat to the heart rail of the local die forging blank of the inlaid frog wing rail insert is locally die forged; after the local die forging, it is subjected to a water toughening treatment at 1000-1100°C to obtain a machined blank of the inlaid frog wing rail insert.

[0005] The present invention comprises the following steps:

[0006] Step 1, determine the local die forging area of ​​the inlaid frog wing rail insert machining blank: divide the inlaid frog wing rail insert machining blank into three areas along the longitudinal direction, namely local die forging area I, transition area I and non-forging area I; local die forging area I is located within the 50mm width section from the frog throat to the heart rail; transition area I is provided on both sides of the local die forging area I, and the local die forging area I is connected to the non-forging area I through the transition area I.

[0007] Step 2, design the shape and size of the local die forging area I of the embedded frog wing rail insert machining blank: design the shape and size of the embedded frog wing rail insert machining blank with reserved machining allowance according to the shape and size of the finished product. The machining allowance of the embedded frog wing rail insert machining blank is 6-8mm. The two sides of the local die forging area I have different draft angles. The draft angle of the step side of the local die forging area I is 3°, and the draft angle of the non-step side of the local die forging area I is 1°; the parting surface height is not higher than the step height.

[0008] Step 3, design the shape and size of the transition zone I of the machining blank of the inlaid frog wing rail insert: the transition zone I smoothly transitions the local die forging zone I and the non-forging zone I into one, and the length of the transition zone I is 0.25 to 1.5 times the height of the machining blank of the inlaid frog wing rail insert.

[0009] Step 4: Design the shape and size of the non-forging area I of the machining blank of the inlaid frog wing rail insert: The non-forging area I does not need to be forged. According to the shape and size of the finished product and combined with the sand casting process, the machining allowance of each part of the non-forging area I is determined to be 6 to 8 mm.

[0010] Step 5. Design the shape and size of the local die forging area II of the local die forging blank of the inlaid frog wing rail insert: the height of the local die forging area II is 40 to 80 mm higher than the upper end surface of the corresponding position of the machined blank of the inlaid frog wing rail insert. The higher height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local die forging area II is not less than 0.5. The top of the local die forging area II is a fillet tangent to both sides, and the fillet radius is 8 to 10 mm.

[0011] Step 6, designing the shape and size of the non-forging area II of the local die forging blank of the inlaid frog wing rail insert: the shape and size of the non-forging area II are consistent with the shape and size of the non-forging area I of the machined blank of the inlaid frog wing rail insert.

[0012] Step 7, design the shape and size of transition zone II of the local die forging blank of the inlaid frog wing rail insert: transition zone II smoothly transitions the local die forging zone II and the non-forging zone II of the local die forging blank of the inlaid frog wing rail insert into one, and the length and shape of transition zone II are consistent with the shape, length and size of transition zone I of the machined blank of the inlaid frog wing rail insert.

[0013] Step 8: According to the designed shape and size of the partial die forging blank of the inlaid frog wing rail insert, a partial die forging blank of the inlaid frog wing rail insert is prepared by a casting molding process.

[0014] Step 9, the prepared inlaid frog wing rail insert partial die forging blank is partially die forged, and then subjected to water toughening treatment at 1000-1100° C. to finally obtain the inlaid frog wing rail insert machined blank.

[0015] Among the above technical schemes, as the preferred technical scheme of the present invention: the cross-section of the local die forging blank of the inlaid frog wing rail insert is designed in three sections from top to bottom; the three sections of the local die forging blank of the inlaid frog wing rail insert are designed in three sections from top to bottom, namely, a large deformation zone, a small deformation zone and a non-deformation zone.

[0016] Among the above technical solutions, as the preferred technical solution of the present invention: the shape of the large deformation zone is approximately an isosceles triangle; the shape of the small deformation zone is approximately an isosceles trapezoid; the shape of the non-deformation zone is the same as the shape of the corresponding part of the bottom of the machined blank rail of the embedded frog wing rail insert.

[0017] The present invention also claims protection for an inlaid frog wing rail insert, which is made from a blank made by a local forging blank making method for any inlaid frog wing rail insert; the blank includes an inlaid frog wing rail insert local die forging blank and an inlaid frog wing rail insert machined blank; the inlaid frog wing rail insert local die forging blank is cast by a casting molding process; the inlaid frog wing rail insert machined blank is made by local die forging of the inlaid frog wing rail insert local die forging blank within the cross-section range of 50mm from the frog throat to the heart rail, and then subjected to a 1000-1100°C water toughening treatment; the inlaid frog wing rail insert is made by machining the inlaid frog wing rail insert machined blank to remove the excess.

[0018] Among the above technical schemes, as the preferred technical scheme of the present invention: the machined blank of the inlaid frog wing rail insert is divided into three areas along the longitudinal direction, including local die forging area I, transition area I and non-forging area I respectively; the local die forging area I is located within the cross-sectional range of 50 mm from the frog throat to the heart rail; transition areas I are provided on both sides of the local die forging area I, and the local die forging area I is smoothly transitioned to the non-forging area I through the transition area I.

[0019] Among the above technical solutions, as a preferred technical solution of the present invention: the machining allowance of the machining blank of the inlaid frog wing rail insert is 6 to 8 mm.

[0020] Among the above technical schemes, as the preferred technical scheme of the present invention: the two sides of the local die forging zone I have different draft angles, the draft angle of the step side of the local die forging zone I is 3°, and the draft angle of the non-step side of the local die forging zone I is 1°; the height of the parting surface is not higher than the step height.

[0021] Among the above technical solutions, as the preferred technical solution of the present invention: the length of transition zone I is 0.25 to 1.5 times the height of the machined blank of the inlaid frog wing rail insert.

[0022] Among the above technical schemes, as the preferred technical scheme of the present invention: the local die forging blank of the inlaid frog wing rail insert is divided into three areas along the longitudinal direction, including local die forging zone II, transition zone II and non-forging zone II respectively; the local die forging zone II is located within the cross-sectional range of 50 mm from the frog throat to the heart rail; transition zones II are provided on both sides of the local die forging zone II, and the local die forging zone II is smoothly transitioned to the non-forging zone II through the transition zone II.

[0023] Among the above technical schemes, as the preferred technical scheme of the present invention: the height of the local die forging zone II of the local die forging blank of the inlaid frog wing rail insert is 40 to 80 mm higher than the upper end surface of the corresponding position of the machined blank of the inlaid frog wing rail insert, and the higher height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local die forging zone II is not less than 0.5; the top of the local die forging zone II is a fillet tangent to both sides, and the radius of the fillet is 8 to 10 mm.

[0024] Among the above technical solutions, as the preferred technical solution of the present invention: the shape of the non-forging area II of the local die forging blank of the embedded frog wing rail insert is consistent with the shape and size of the non-forging area I of the machined blank of the embedded frog wing rail insert.

[0025] Among the above technical solutions, as the preferred technical solution of the present invention: the shape and length of the transition zone II of the local die forging blank of the embedded frog wing rail insert are consistent with the shape and length of the transition zone I of the machined blank of the embedded frog wing rail insert.

[0026] The advantages of the present invention compared with the prior art are:

[0027] 1. The present invention can prepare a machining blank of an inlaid frog wing rail insert that meets the requirements through the above processing process, which can effectively reduce the amount of subsequent machining, shorten the manufacturing cycle, and reduce costs.

[0028] 2. Due to the existence of local die forging, the key parts of the present invention have sufficient deformation, thereby ensuring that the insert has good service performance. This method is suitable for the manufacture of embedded frog wing rail inserts and has high practical value and application prospects.

[0029] 3. The processing method of the present invention can ensure that the key parts of the wing rail insert have sufficient deformation, and can also ensure that the wing rail insert has good service performance, thereby improving the service life and safety performance of the finished insert. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is an assembly diagram of the embedded frog wing rail insert of the present invention;

[0031] Figure 2 It is an enlarged stereoscopic view of the embedded frog wing rail insert of the present invention;

[0032] Figure 3 A three-dimensional diagram of a blank machined by an inlaid frog wing rail insert of the present invention;

[0033] Figure 4 for Figure 3 A schematic front view of a local die forging area;

[0034] Figure 5 For the present invention Figure 3 , Figure 4 BB cross-section enlarged detail diagram;

[0035] Figure 6 It is a three-dimensional diagram of a partial die forging blank of an inlaid frog wing rail insert of the present invention;

[0036] Figure 7 for Figure 6 BB cross-section enlarged detail diagram;

[0037] In the figure: 1-partial die forging blank of inlaid frog wing rail insert, 1-1partial die forging zone II, 1-2 transition zone II, 1-3 non-forging zone II; 2-machined blank of inlaid frog wing rail insert, 2-1partial die forging zone I, 2-2 transition zone I, 2-3 non-forging zone I, 3-large deformation zone, 4-small deformation zone, 5-non-deformation zone. DETAILED DESCRIPTION

[0038] The following will be combined with the attached embodiment of the present invention Figure 1-7 , the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] A method for partially forging a mosaic frog wing rail insert is provided. First, a mosaic frog wing rail insert partial die forging blank 1 is cast by a casting process, and then a partial area within a cross section of 50 mm from the frog throat to the heart rail of the mosaic frog wing rail insert partial die forging blank 1 is partially die forged; after the partial die forging, the partial die forging is subjected to a water toughening treatment at 1000-1100°C to obtain a mosaic frog wing rail insert machined blank 2.

[0040] It should be noted that the mechanical properties of the frog wing rail insert material can be effectively improved by partial forging. The forging process can bridge the defects such as shrinkage cavities and shrinkage that may occur during the casting process, making the material structure more compact, thereby improving the strength, toughness and wear resistance of the material. Forging can also refine the grains and improve the comprehensive mechanical properties of the material, so that it can better adapt to the use requirements of the frog under complex working conditions. The frog wing rail insert made by partial forging can significantly extend the service life of the frog due to the improvement of its material properties. This advantage is particularly obvious on heavy-loaded and high-speed railway lines. The forging process can also reduce the cracks, spalling and other diseases that occur in the frog during service, and improve the reliability and stability of the frog. The frog wing rail insert made by partial forging has a more precise shape and size, which is conducive to subsequent mechanical processing and assembly. The partial forging method can flexibly adjust the forging process parameters and die design according to the specific use conditions and requirements of the frog to meet the needs of different lines and vehicles.

[0041] The present invention provides a method for partially forging a blank of an inlaid frog wing rail insert, comprising the following steps:

[0042] (like Figure 3 (as shown) Step 1, determine the local die forging area 2-1 of the inlaid frog wing rail insert machined blank 2: divide the inlaid frog wing rail insert machined blank 2 into three areas along the longitudinal direction, namely the local die forging area Ⅰ2-1, the transition area Ⅰ2-2 and the non-forging area Ⅰ2-3; the local die forging area Ⅰ2-1 is located within the cross-section range of 50mm width from the frog throat to the heart rail; transition areas Ⅰ2-2 are provided on both sides of the local die forging area Ⅰ2-1, and the local die forging area Ⅰ2-1 is connected to the non-forging area Ⅰ2-3 through the transition area Ⅰ2-2.

[0043] In this step, the local die forging area Ⅰ2-1 is precisely positioned within the cross-section range of 50mm width from the throat of the frog to the heart rail, which is the area where the frog is subjected to the greatest impact and wear during operation. Through local die forging, the material properties of this area, such as strength, hardness and wear resistance, can be significantly improved, thereby extending the overall service life of the frog. The machined blank is divided into three areas, namely the local die forging area Ⅰ2-1, the transition area Ⅰ2-2 and the non-forging area Ⅰ2-3, to achieve effective utilization of materials. The non-forging area Ⅰ2-3 can maintain a low processing cost, while the local die forging area Ⅰ2-1 is strengthened by the forging process, avoiding the high cost and unnecessary material waste caused by the overall forging. The setting of the transition area Ⅰ2-2 enables the local die forging area Ⅰ2-1 to smoothly transition to the non-forging area Ⅰ2-3, reducing the processing difficulty and cost caused by the sudden change of material properties. At the same time, the existence of the transition area Ⅰ2-2 also helps to alleviate stress concentration and improve the overall stability of the frog. Clear regional division makes the machining process more orderly and efficient. Processing personnel can select appropriate processing technology and parameters according to the characteristics of different areas, thereby improving processing accuracy and efficiency. Through local die forging, the load-bearing capacity and wear resistance of the frog in key areas are improved, and failures and accidents caused by wear and fatigue are reduced, thereby enhancing the reliability and safety of the frog.

[0044] (like Figure 5 (as shown) Step 2, design the shape and size of the local die forging area Ⅰ2-1 of the embedded frog wing rail insert machining blank 2: design the shape and size of the embedded frog wing rail insert machining blank 2 with reserved machining allowance according to the shape and size of the finished product, the machining allowance of the embedded frog wing rail insert machining blank 2 is 6-8mm, and the local die forging area Ⅰ2-1 has different draft angles on both sides, the draft angle of the local die forging area Ⅰ2-1 with a step side is 3°, and the draft angle of the local die forging area Ⅰ2-1 without a step side is 1°; the parting surface height is not higher than the step height.

[0045] In this step, a machining allowance of 6 to 8 mm is accurately reserved according to the shape and size of the finished product, ensuring the smooth progress of the subsequent machining process. This reserve will neither cause excessive material waste nor affect the accuracy and quality of the final product. Different draft angles are designed on both sides of the local die forging area Ⅰ2-1, that is, 3° on the step side and 1° on the non-step side. This design helps to smoothly demold during the forging process and reduce the risk of die wear and blank damage. At the same time, different draft angles can also adjust the fluidity and formability of the material according to actual needs to ensure the shape and dimensional accuracy of the forging. The design that the parting surface height is not higher than the step height is conducive to the manufacture and installation of the mold and reduces the complexity and cost of the mold. At the same time, this design can also reduce stress concentration and deformation during the forging process and improve the dimensional stability and surface quality of the forging. By accurately designing the shape and size of the local die forging area Ⅰ2-1 and reserving the machining allowance, material waste can be minimized and material utilization can be improved. At the same time, the reasonable design of draft angle and parting surface height can also help improve production efficiency and reduce production costs.

[0046] (like Figure 3 As shown in step 3, design the shape and size of the transition zone Ⅰ2-2 of the inlaid frog wing rail insert machined blank 2: the transition zone Ⅰ2-2 smoothly transitions the local die forging zone Ⅰ2-1 and the non-forging zone Ⅰ2-3 into one, and the length of the transition zone Ⅰ2-2 is 0.25 to 1.5 times the height of the inlaid frog wing rail insert machined blank 2.

[0047] In this step, the design of transition zone Ⅰ2-2 enables the local die forging zone Ⅰ2-1 and the non-forging zone Ⅰ2-3 to smoothly transition and connect into one. This smooth connection helps to reduce the stress concentration phenomenon caused by the sudden change of material properties, thereby improving the overall strength and stability of the frog wing rail insert. During forging and subsequent use, stress concentration is one of the main causes of cracks and fractures. By designing a reasonable transition zone Ⅰ2-2, this risk can be effectively reduced and the service life of the frog can be extended. Due to the existence of transition zone Ⅰ2-2, the connection between the local die forging zone and the non-forging zone is tighter and more stable, reducing the scrap rate caused by poor connection. The length of transition zone Ⅰ2-2 is 0.25 to 1.5 times the height of the machined blank 2 of the inlaid frog wing rail insert. This design provides greater flexibility and can be adjusted and optimized according to different usage requirements and process conditions.

[0048] Step 4, design the shape and size of the non-forging area Ⅰ2-3 of the inlaid frog wing rail insert machined blank 2: the non-forging area Ⅰ2-3 does not need to be forged. According to the shape and size of the finished product and combined with the sand casting process, the machining allowance of each part of the non-forging area Ⅰ2-3 is determined to be 6 to 8 mm.

[0049] In this step, the non-forging area Ⅰ2-3 does not need to be forged, which directly reduces the use of forging processes and related equipment, thereby reducing production costs. According to the shape and size of the finished product, combined with the sand casting process, the machining allowance of each part of the non-forging area Ⅰ2-3 is accurately determined, avoiding unnecessary material waste and improving material utilization efficiency. The forging link of the non-forging area Ⅰ2-3 is removed, which simplifies the production process, reduces the production cycle, and improves the overall production efficiency. Although the sand casting process is not as significant as the forging process in refining grains and improving material properties, for the non-forging area, it can meet the basic strength and size requirements, while avoiding internal defects that may occur during the forging process, such as cracks, shrinkage holes, etc. By accurately controlling the machining allowance of each part of the non-forging area Ⅰ2-3 to 6 to 8 mm, it is ensured that the excess material can be removed smoothly in the subsequent processing process to achieve the expected finished product size and shape accuracy.

[0050] (like Figure 7 (as shown) Step 5, design the shape and size of the local die forging area Ⅱ1-1 of the local die forging blank 1 of the inlaid frog wing rail insert: the height of the local die forging area Ⅱ1-1 is 40 to 80 mm higher than the upper end surface of the corresponding position of the inlaid frog wing rail insert machined blank 2, and the higher height is used to ensure that the cumulative plastic equivalent strain of the top part of the local die forging area Ⅱ1-1 is not less than 0.5, and the top of the local die forging area Ⅱ1-1 is a fillet tangent to both sides, and the fillet radius is 8 to 10 mm.

[0051] In this step, the height of the local die forging area Ⅱ1-1 is designed to be 40 to 80 mm higher than the upper end surface of the corresponding position of the inlaid frog wing rail insert machining blank 2. This height design ensures that the top part of the local die forging area Ⅱ1-1 can accumulate sufficient plastic equivalent strain (not less than 0.5) during the forging process. This strain accumulation helps to refine the grains and improve the material structure, thereby improving the strength, hardness and wear resistance of the material. The increase in the accumulated plastic equivalent strain significantly improves the material properties of the local die forging area Ⅱ1-1, which can better adapt to the use requirements of the frog under complex working conditions and extend the service life of the frog. The top of the local die forging area Ⅱ1-1 is designed to be a fillet tangent to both sides, with a fillet radius of 8 to 10 mm. This fillet design helps to reduce stress concentration during the forging process and avoid defects such as cracks. At the same time, the fillet design also makes the subsequent machining process smoother and improves the processing efficiency and precision. Through reasonable shape and size design, the local die forging area Ⅱ1-1 can better fill the die during the forging process, reduce forging defects, and improve the yield and quality of forgings.

[0052] (like Figure 7As shown) Step 6, design the shape and size of the non-forging area II1-3 of the local die forging blank 1 of the inlaid frog wing rail insert: the shape and size of the non-forging area II1-3 are consistent with the shape and size of the non-forging area I2-3 of the machined blank 2 of the inlaid frog wing rail insert.

[0053] In this step, the shape and size of the non-forged area II1-3 are consistent with the shape and size of the non-forged area I2-3 of the machined blank 2 of the inlaid frog wing rail insert. This design ensures the structural unity and coordination of the entire frog wing rail insert. During the assembly and installation process, the close fit between the components can be ensured, reducing assembly problems caused by size differences. The uniformity of the shape and size of the non-forged area II1-3 makes the subsequent machining process more convenient. Since the shape and size of the two "non-forged areas" are the same, the same inspection standards and inspection methods can be used during the quality control process. This helps to ensure the quality stability and consistency of the various components of the frog wing rail insert and improve the overall product quality level.

[0054] (like Figure 6 As shown in step 7, design the shape and size of the transition zone II1-2 of the local die forging blank 1 of the inlaid frog wing rail insert: the transition zone II1-2 smoothly transitions the local die forging zone II1-1 and the non-forging zone II1-3 of the local die forging blank 1 of the inlaid frog wing rail insert into one, and the length and shape of the transition zone II1-2 are consistent with the shape and length of the transition zone I2-2 of the machined blank 2 of the inlaid frog wing rail insert.

[0055] In this step, the design of transition zone II1-2 enables a smooth transition between the local die forging zone II1-1 and the non-forging zone II1-3, avoiding stress concentration caused by sudden changes in material properties, which helps to reduce the risk of cracks and fractures caused by stress concentration during the use of the frog and improve the service life of the frog. The shape and length of transition zone II1-2 are consistent with those of transition zone I2-2 of the machined blank 2, which means that the same process parameters and processing methods can be used during the processing, simplifying the processing flow and improving the processing efficiency. By designing the same transition zone shape and size, it can be ensured that the frog wing rail inserts in different batches and under different production conditions are structurally consistent, thereby ensuring the stability and reliability of product quality.

[0056] Step 8: According to the designed shape and size of the inlaid frog wing rail insert partial die forging blank 1, the inlaid frog wing rail insert partial die forging blank 1 is prepared by a casting molding process.

[0057] In this step, the casting process can accurately manufacture the blank according to the designed shape and size, ensure that the size and shape of the local die forging area Ⅱ1-1, the transition area Ⅱ1-2, and the non-forging area Ⅱ1-3 meet the design requirements, and improve the accuracy and consistency of the product. Accurate casting reduces the workload of subsequent machining, reduces processing costs and processing time, and improves production efficiency. During the casting process, through reasonable pouring process and heat treatment process, the material organization can be made denser, internal defects can be reduced, and the strength and toughness of the material can be improved. The blanks formed by casting are more uniform in material properties, which is conducive to the maintenance and performance of material properties during subsequent die forging and processing. The casting process has strong adaptability and can be adjusted and optimized according to different design requirements and material properties to meet the preparation requirements of local die forging blanks of frog wing rail inserts of various complex shapes and sizes. Accurate casting can reduce material waste and improve material utilization. Accurate casting can ensure smooth transition of the transition zone, reduce stress concentration, and improve the fatigue resistance and durability of the product.

[0058] Step 9, the prepared inlaid frog wing rail insert partial die forging blank 1 is partially die forged, and then subjected to water toughening treatment at 1000-1100° C., to finally obtain the inlaid frog wing rail insert machined blank 2.

[0059] In this step, water toughening treatment is a process of heating the material to the austenite single phase region and then rapidly cooling it to obtain a uniform austenite structure. This process can significantly improve the mechanical properties of the material, such as improving the hardness, strength and toughness of the material, so that the frog wing rail insert has better fatigue resistance and durability when subjected to the impact and wear of the train passing. During the local die forging process, the material will be subjected to a large deformation force and easily generate internal stress. Water toughening treatment can effectively eliminate these internal stresses and avoid cracks and fractures caused by stress concentration during use. Local die forging can ensure that the shape and size of the frog wing rail insert meet the design requirements, especially in key areas such as transition areas and local die forging areas, high-precision forming can be achieved. Through local die forging, the workload of subsequent machining can be reduced, the processing cost and processing time can be reduced, and the production efficiency can be improved. Local die forging can accurately control the shape and size of the material, avoid excessive waste during the forming process, and improve the utilization rate of the material. Efficient material utilization helps save raw material resources and meets the requirements of sustainable development. After partial die forging and water toughening treatment, the frog wing rail insert has better processing performance, such as machinability and weldability, which is conducive to the smooth progress of subsequent processing. Partial die forging and water toughening can enhance the structural strength of the frog wing rail insert, so that it can better withstand various loads and impacts during use.

[0060] (like Figure 7As shown in the above embodiment, as a preferred embodiment of the present invention: the cross-section of the embedded frog wing rail insert partial die forging blank 1 is designed in three sections from top to bottom; the embedded frog wing rail insert partial die forging blank 1 is designed in three sections from top to bottom, which are respectively a large deformation zone 3, a small deformation zone 4 and a non-deformation zone 5.

[0061] Among them, the three-stage design makes the local die forging and subsequent processing more orderly and efficient. The clear division of the large deformation zone 3 and the small deformation zone 4 helps to determine the processing sequence and process parameters, reducing the processing difficulty and cost. The existence of the non-deformation zone 5 provides a stable reference surface for the installation of the insert. By accurately controlling the size and shape of the non-deformation zone 5, it can be ensured that the insert is closely matched with other components of the track system during installation, thereby improving the stability and safety of the entire frog system.

[0062] In the above embodiment, as a preferred embodiment of the present invention: the shape of the large deformation zone 3 is approximately an isosceles triangle; the shape of the small deformation zone 4 is approximately an isosceles trapezoid; the shape of the non-deformation zone 5 is the same as the shape of the corresponding part of the rail bottom of the machined blank 2 of the embedded frog wing rail insert.

[0063] Among them, the shape of the approximate isosceles triangle enables the large deformation zone to better disperse and absorb the impact energy during the die forging process, which is conducive to reducing stress concentration and thus improving the toughness of the material. The large deformation helps to refine the grain structure of the material, improve the strength and hardness of the material, and improve the comprehensive mechanical properties of the material. The shape of the isosceles trapezoid, as a transition area between the large deformation zone and the non-deformation zone, can gradually reduce the deformation, make the deformation behavior of the material more stable, and reduce the internal defects caused by uneven deformation. The trapezoidal structure has good stability and can improve the deformation resistance and fatigue resistance of the entire insert to a certain extent. The shape of the non-deformation zone is the same as the corresponding part of the bottom of the machined blank 2 rails, ensuring that a stable reference surface can be maintained during the processing and assembly process, and improving the assembly accuracy and reliability. As a stable part of the entire insert, the non-deformation zone can enhance the overall performance of the insert and ensure that it can stably withstand various loads and impacts during use.

[0064] The present invention also claims protection for an inlaid frog wing rail insert, the insert is made from a blank made by any of the inlaid frog wing rail insert local forging blank making methods; the blank comprises an inlaid frog wing rail insert local die forging blank 1 and an inlaid frog wing rail insert machined blank 2; the inlaid frog wing rail insert local die forging blank 1 is cast by a casting molding process; the inlaid frog wing rail insert machined blank 2 is made by the inlaid frog wing rail insert local die forging blank 1 in the range of a frog throat to a heart rail width of 50mm, and then subjected to a 1000-1100°C water toughening treatment; the inlaid frog wing rail insert (such as Figure 2As shown in the figure, the inlaid frog wing rail insert is obtained by machining the blank 2 of the inlaid frog wing rail insert and removing the excess.

[0065] Specifically: the area within the cross-section range of 50 mm from the throat of the billet frog to the heart rail is located within the range of 172 mm to 772 mm from the maximum cross-section of the billet.

[0066] (like Figure 3 , Figure 4 In the above embodiment, as a preferred embodiment of the present invention: the inlaid frog wing rail insert machined blank 2 is divided into three areas along the longitudinal direction, including a local die forging area Ⅰ2-1, a transition area Ⅰ2-2 and a non-forging area Ⅰ2-3; the local die forging area Ⅰ2-1 is located within the cross-section range of 50mm from the frog throat to the heart rail; transition areas Ⅰ2-2 are provided on both sides of the local die forging area Ⅰ2-1, and the local die forging area Ⅰ2-1 is smoothly connected to the non-forging area Ⅰ2-3 through the transition area Ⅰ2-2. The advantages have been described in the previous text and will not be repeated.

[0067] (like Figure 5 As shown in the above embodiment, as a preferred embodiment of the present invention: the machining allowance of the machining blank 2 of the inlaid frog wing rail insert is 6-8mm. The advantages have been described above and will not be repeated here.

[0068] Specifically, a machining allowance of 6 mm is reserved for the machining blank 2 of the inlaid frog wing rail insert to facilitate subsequent machining.

[0069] In the above embodiment, as a preferred embodiment of the present invention: the local die forging area Ⅰ2-1 of the inlaid frog wing rail insert machined blank 2 has different draft angles on both sides, the draft angle of the local die forging area Ⅰ2-1 with a step side is 3°, and the draft angle of the local die forging area Ⅰ2-1 without a step side is 1°; the parting surface height is not higher than the step height, specifically, the parting surface height is 115mm, and the step height is 130mm.

[0070] Draft angle is an important parameter in mold design, which is used to reduce the resistance of the part when it is demolded from the mold. In the local die forging area Ⅰ2-1, the step side is designed with a larger draft angle (3°), which can significantly reduce the demolding resistance on this side, making the part smoother during demolding. Different draft angle designs can adapt to the deformation characteristics of different parts of the part. Setting a larger draft angle at the step helps to maintain the shape stability of the part during demolding and reduce the deformation of the part caused by improper demolding. By accurately controlling the draft angle and the parting surface height, it can be ensured that the part maintains a high dimensional accuracy after demolding to meet the design requirements. The design of the parting surface height not higher than the step height can ensure that the part can be separated from the mold smoothly during demolding, avoiding demolding difficulties caused by the parting surface being too high. This design helps to simplify the mold structure and reduce the difficulty and cost of mold manufacturing. At the same time, it also helps to improve the reliability and service life of the mold.

[0071] (like Figure 4 In the above embodiment, as a preferred embodiment of the present invention, the length of the transition zone I2-2 of the inlaid frog wing rail insert machined blank 2 is 0.25 to 1.5 times the height of the inlaid frog wing rail insert machined blank 2. Specifically, the lengths of the transition zone I2-2 are 60 mm and 172 mm respectively. The height of the inlaid frog wing rail insert machined blank 2 is 180 mm.

[0072] Among them, the transition zone Ⅰ2-2 is the key part connecting the large deformation zone and the small deformation zone (or non-deformation zone). The reasonable design of its length helps to achieve a smooth transition of stress. When the length of the transition zone Ⅰ2-2 is within the range of 0.25 to 1.5 times the height of the machined blank, it can ensure that the stress can be evenly distributed during the force-bearing process, reduce the stress concentration phenomenon, and thus improve the fatigue resistance and durability of the frog wing rail insert. The appropriate length of the transition zone Ⅰ2-2 can enhance the overall bearing capacity of the frog wing rail insert. The reasonable design of the length of the transition zone Ⅰ2-2 helps to simplify the processing process. During the machining process, the existence of the transition zone Ⅰ2-2 makes the machining path smoother and reduces the machining difficulty and cost caused by shape mutations. By accurately controlling the length and shape of the transition zone Ⅰ2-2, it can ensure that the frog wing rail insert maintains a high dimensional accuracy during the machining process, which is of great significance for improving the overall performance and stability of the frog.

[0073] (like Figure 6In the above embodiment, as a preferred embodiment of the present invention: the local die forging blank 1 of the inlaid frog wing rail insert is divided into three areas along the longitudinal direction, including the local die forging area II1-1, the transition area II1-2 and the non-forging area II1-3; the local die forging area II1-1 is located within the cross-section range of 50mm from the frog throat to the heart rail; transition areas II1-2 are provided on both sides of the local die forging area II1-1, and the local die forging area II1-1 is smoothly connected to the non-forging area II1-3 through the transition area II1-2. The advantages have been described in the previous text and will not be repeated.

[0074] (like Figure 7 As shown in the above embodiment, as a preferred embodiment of the present invention: the height of the local die forging area Ⅱ1-1 of the local die forging blank 1 of the inlaid frog wing rail insert is 40 to 80 mm higher than the upper end surface of the corresponding position of the machined blank 2 of the inlaid frog wing rail insert, and the higher height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local die forging area Ⅱ1-1 is not less than 0.5; the top of the local die forging area Ⅱ1-1 is a fillet tangent to both sides, and the fillet radius is 8 to 10 mm. The advantages have been described in the previous text and will not be repeated here. Specifically, the height of the local die forging area Ⅱ1-1 of the local die forging blank 1 of the inlaid frog wing rail insert is 45 mm higher than the upper end surface of the corresponding position of the machined blank 2 of the inlaid frog wing rail insert. The top of the local die forging area Ⅱ1-1 of the local die forging blank 1 of the inlaid frog wing rail insert is a fillet tangent to both sides, and the fillet radius is 8 mm.

[0075] In the above embodiment, as a preferred embodiment of the present invention, the shape of the non-forging area II1-3 of the partially die-forged blank 1 of the embedded frog wing rail insert is consistent with the shape and size of the non-forging area I2-3 of the machined blank 2 of the embedded frog wing rail insert. The advantages have been described above and will not be repeated here.

[0076] In the above embodiment, as a preferred embodiment of the present invention, the shape and length of the transition zone II1-2 of the partially forged blank 1 of the embedded frog wing rail insert are consistent with the shape and length of the transition zone I2-2 of the machined blank 2 of the embedded frog wing rail insert. The advantages have been described above and will not be repeated.

[0077] From the above description, it can be found that the present invention can prepare a machining blank of an inlaid frog wing rail insert that meets the requirements through the above processing process, which can effectively reduce the amount of subsequent machining, shorten the manufacturing cycle, and reduce costs.

[0078] Due to the existence of local die forging, the key parts of the invention have sufficient deformation, thereby ensuring that the insert has good service performance. This method is suitable for the manufacture of embedded frog wing rail inserts and has high practical value and application prospects.

[0079] The processing method of the present invention can ensure that the key parts of the wing rail have sufficient deformation and be designed on the principle of good service performance, thereby improving the service life and safety performance of the finished product.

[0080] It should be understood that although the present specification is described according to an implementation method, the implementation method does not only include an independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in this embodiment can also be appropriately arranged and combined to form other implementation methods that can be understood by those skilled in the art.

[0081] The above preferred embodiments are not intended to limit the scope of implementation of the present invention, so all equivalent changes made to the contents described in the claims of the present invention should be included in the scope of the claims of the present invention; it should be noted that the components and materials used in the above embodiments are commercially available unless otherwise specified.

Claims

1. A method for partially forging a blank for an inlaid frog wing rail insert, characterized in that: First, a local die forging blank (1) of an inlaid frog wing rail insert is cast by a casting process, and then a partial area within a cross section of 50 mm from the frog throat to the heart rail of the local die forging blank (1) of the inlaid frog wing rail insert is locally die forged; after the local die forging, the inlaid frog wing rail insert is subjected to a water toughening treatment at 1000-1100° C. to obtain a machined blank (2) of the inlaid frog wing rail insert.

2. The local forging method according to claim 1, characterized in that: The steps include: Step 1, determining the local die forging area (2-1) of the inlaid frog wing rail insert machining blank (2): dividing the inlaid frog wing rail insert machining blank (2) into three areas along the longitudinal direction, namely the local die forging area I (2-1), the transition area I (2-2) and the non-forging area I (2-3); the local die forging area I (2-1) is located within the cross-section range of 50 mm from the frog throat to the heart rail; transition areas I (2-2) are provided on both sides of the local die forging area I (2-1), and the local die forging area I (2-1) is connected to the non-forging area I (2-3) through the transition area I (2-2); Step 2, designing the shape and size of the local die forging area I (2-1) of the embedded frog wing rail insert machining blank (2): designing the shape and size of the embedded frog wing rail insert machining blank (2) according to the shape and size of the finished product and reserving the machining allowance, the machining allowance of the embedded frog wing rail insert machining blank (2) is 6-8mm, the two sides of the local die forging area I (2-1) have different draft angles, the draft angle of the local die forging area I (2-1) with a step side is 3°, and the draft angle of the local die forging area I (2-1) without a step side is 1°; the parting surface height is not higher than the step height; Step 3, designing the shape and size of the transition zone I (2-2) of the inlaid frog wing rail insert machined blank (2): the transition zone I (2-2) smoothly transitions and connects the local die forging zone I (2-1) and the non-forging zone I (2-3) into one, and the length of the transition zone I (2-2) is 0.25 to 1.5 times the height of the inlaid frog wing rail insert machined blank (2); Step 4, designing the shape and size of the non-forging area I (2-3) of the machining blank (2) of the embedded frog wing rail insert: the non-forging area I (2-3) does not need to be forged, and according to the shape and size of the finished product, combined with the sand casting process, the machining allowance of each part of the non-forging area I (2-3) is determined to be 6 to 8 mm; Step 5, designing the shape and size of the local die forging area II (1-1) of the local die forging blank (1) of the embedded frog wing rail insert: the height of the local die forging area II (1-1) is 40 to 80 mm higher than the upper end surface of the corresponding position of the embedded frog wing rail insert machined blank (2), and the higher height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local die forging area II (1-1) is not less than 0.5, and the top of the local die forging area II (1-1) is a fillet tangent to both sides, and the fillet radius is 8 to 10 mm; Step 6, designing the shape and size of the non-forging area II (1-3) of the local die forging blank (1) of the embedded frog wing rail insert: the shape and size of the non-forging area II (1-3) are consistent with the shape and size of the non-forging area I (2-3) of the machined blank (2) of the embedded frog wing rail insert; Step 7, designing the shape and size of the transition zone II (1-2) of the local die forging blank (1) of the inlaid frog wing rail insert: the transition zone II (1-2) smoothly transitions and connects the local die forging zone II (1-1) and the non-forging zone II (1-3) of the local die forging blank (1) of the inlaid frog wing rail insert into one, and the length and shape of the transition zone II (1-2) are consistent with the shape and length of the transition zone I (2-2) of the machined blank (2) of the inlaid frog wing rail insert; Step 8, preparing the inlaid frog wing rail insert partial die forging blank (1) by a casting molding process according to the designed shape and size of the inlaid frog wing rail insert partial die forging blank (1); Step 9, the prepared inlaid frog wing rail insert partial die forging blank (1) is partially die forged, and then subjected to water toughening treatment at 1000-1100° C., to finally obtain the inlaid frog wing rail insert machined blank (2).

3. The local forging method according to claim 1, characterized in that: The cross section of the embedded frog wing rail insert partial die forging blank (1) is designed in three sections from top to bottom; the three sections of the embedded frog wing rail insert partial die forging blank (1) from top to bottom are respectively a large deformation area (3), a small deformation area (4) and a non-deformation area (5).

4. The cross-sectional shape design method according to claim 3, characterized in that: The large deformation zone (3) is approximately in the shape of an isosceles triangle; the small deformation zone (4) is approximately in the shape of an isosceles trapezoid; the shape of the non-deformation zone (5) is the same as the shape of the corresponding part of the rail bottom of the inlaid frog wing rail insert machined blank (2).

5. An inlaid frog wing rail insert, characterized in that: The insert is made of a blank made by the local forging method for making a mosaic frog wing rail insert according to any one of claims 1 to 4; the blank comprises a mosaic frog wing rail insert local die forging blank (1) and a mosaic frog wing rail insert machined blank (2); the mosaic frog wing rail insert local die forging blank (1) is cast by a casting molding process; the mosaic frog wing rail insert machined blank (2) is made by local die forging the mosaic frog wing rail insert local die forging blank (1) within the cross-section range of 50 mm from the frog throat to the heart rail, and then subjected to water toughening treatment at 1000-1100°C; the mosaic frog wing rail insert is made by machining the mosaic frog wing rail insert machined blank (2) to remove the excess.

6. The inlaid frog wing rail insert according to claim 5, characterized in that: The inlaid frog wing rail insert machined blank (2) is divided into three areas along the longitudinal direction, including a local die forging area I (2-1), a transition area I (2-2) and a non-forging area I (2-3); the local die forging area I (2-1) is located within a cross-section range of 50 mm from the frog throat to the heart rail; transition areas I (2-2) are provided on both sides of the local die forging area I (2-1), and the local die forging area I (2-1) is smoothly transitionally connected to the non-forging area I (2-3) through the transition area I (2-2).

7. The inlaid frog wing rail insert according to claim 5 or 6, characterized in that: The machining allowance of the machining blank (2) of the inlaid frog wing rail insert is 6-8 mm.

8. The embedded frog wing rail insert according to claim 6, characterized in that: The two sides of the local die forging zone I (2-1) have different draft angles. The draft angle of the step side of the local die forging zone I (2-1) is 3°, and the draft angle of the non-step side of the local die forging zone I (2-1) is 1°. The height of the parting surface is not higher than the step height.

9. The embedded frog wing rail insert according to claim 6, characterized in that: The length of the transition zone I (2-2) is 0.25 to 1.5 times the height of the machined blank (2) of the embedded frog wing rail insert.

10. The inlaid frog wing rail insert according to claim 5, characterized in that: The local die forging blank (1) of the embedded frog wing rail insert is divided into three areas in the longitudinal direction, including a local die forging area II (1-1), a transition area II (1-2) and a non-forging area II (1-3); the local die forging area II (1-1) is located within a cross-section range of 50 mm from the frog throat to the heart rail; transition areas II (1-2) are arranged on both sides of the local die forging area II (1-1), and the local die forging area II (1-1) is smoothly transitionally connected to the non-forging area II (1-3) through the transition area II (1-2).

11. The embedded frog wing rail insert according to claim 10, characterized in that: The height of the local die forging area II (1-1) of the local die forging blank (1) of the embedded frog wing rail insert is 40 to 80 mm higher than the upper end surface of the corresponding position of the machined blank (2) of the embedded frog wing rail insert, and the higher height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local die forging area II (1-1) is not less than 0.5; the top of the local die forging area II (1-1) is a fillet tangent to both sides, and the fillet radius is 8 to 10 mm.

12. The inlaid frog wing rail insert according to claim 10, characterized in that: The shape of the non-forging area II (1-3) of the partially die-forged blank (1) of the embedded frog wing rail insert is consistent with the shape and size of the non-forging area I (2-3) of the machined blank (2) of the embedded frog wing rail insert.

13. The inlaid frog wing rail insert according to claim 10, characterized in that: The shape and length of the transition zone II (1-2) of the partially forged blank (1) of the embedded frog wing rail insert are consistent with the shape and length of the transition zone I (2-2) of the machined blank (2) of the embedded frog wing rail insert.

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