Embedded frog die forging point rail blank

Abstract

The utility model provides an embedded frog die-forged point rail blank, wherein a cross-sectional area reference value of the embedded frog die-forged point rail blank is a value obtained by multiplying a die-forged part cross-sectional area value of an embedded frog die-forged point rail die forging by a coefficient 1.035; the section of the embedded frog die forging point rail blank is bilaterally symmetrical and is in a three-section type design from top to bottom; the embedded frog die forging point rail blank is designed into a large deformation area, a small deformation area and a non-deformation area from top to bottom in a three-section mode. The utility model has the advantages of simple section shape, convenience in manufacturing and high material utilization rate; according to the blank, the defects of folding, misrun and the like are not prone to occurring, the plastic equivalent strain of key parts of a die forging area of the embedded frog point rail can be guaranteed to reach 0.5 or above, the deformation is in gradient distribution from top to bottom, the closer to the rail top, the larger the deformation is, and therefore it is guaranteed that the embedded frog point rail manufactured through the blank has the good service performance.

Description

TECHNICAL FIELD

[0001] The utility model belongs to metal pressing method technical field, concretely relates to a kind of mosaic switch frog die forging rail base material. BACKGROUND

[0002] Switch frog is the important component of railway turnout, and its quality is the key factor influencing turnout service performance. In recent years, a new technology of mosaic switch frog die forging rail casting-forging composite forming has appeared. The technology has the advantages of greatly reducing machining amount, shortening processing cycle and reducing manufacturing cost on the premise of maintaining product quality. To obtain mosaic switch frog die forging rail forging, the technology must first prepare mosaic switch frog die forging rail base material of rail by casting. Whether the structure and shape of the base material are reasonable is a decisive factor for the quality of mosaic switch frog rail forging. For this purpose, the following technical scheme is proposed. SUMMARY

[0003] The utility model solves the technical problems: provide a kind of mosaic switch frog die forging rail base material, solve how to design and manufacture the technical problems of mosaic switch frog die forging rail base material.

[0004] The utility model employs the technical scheme: a kind of mosaic switch frog die forging rail base material, the cross-sectional area reference value of mosaic switch frog die forging rail base material is the value after the cross-sectional area value of die forging part of mosaic switch frog die forging rail forging part is multiplied by coefficient 1.035;The cross section of mosaic switch frog die forging rail base material is symmetrical left and right, and is designed into three sections from top to bottom;Mosaic switch frog die forging rail base material is designed into three sections from top to bottom respectively as large deformation zone, small deformation zone and non-deformation zone.

[0005] In the above technical scheme, as preferred technical scheme of the utility model: the shape of large deformation zone is approximately isosceles triangle;The shape of small deformation zone is isosceles trapezoid;The shape of non-deformation zone is same as the shape of bottom part corresponding to rail bottom of mosaic switch frog die forging rail forging part.

[0006] In the above technical scheme, as preferred technical scheme of the utility model: the included angle between side and bottom of isosceles triangle of large deformation zone is 75°-85°, large value is taken when cross section is narrow, and small value is taken when cross section is wide;The top of isosceles triangle of large deformation zone is circular arc, circular arc radius is 7-15mm, small value is taken when cross section is narrow, and large value is taken when cross section is wide;The bottom width of isosceles triangle of large deformation zone is 0.8 times of rail top width of mosaic switch frog die forging rail forging part;The height of isosceles triangle of large deformation zone is 1.1-1.5 times of rail top height of mosaic switch frog die forging rail forging part, large value is taken when cross section is narrow, and small value is taken when cross section is wide.

[0007] In the above technical solution, as the preferred technical solution of the utility model: the top of the small deformation area is equal in width with the bottom of the large deformation area; the bottom of the small deformation area is equal in width with the top of the non-deformation area; the height of the small deformation area is according to the area of the inlaid frog forging heart rail blank, so that the area of the inlaid frog forging heart rail blank corresponds to the cross-sectional area reference value calculated after the area of the inlaid frog forging heart rail blank is multiplied by the coefficient.

[0008] In the above technical solution, as the preferred technical solution of the utility model: the height of the non-deformation area is equal to the height of the parting surface of the rail bottom corresponding part of the inlaid frog forging heart rail forging piece.

[0009] In the above technical solution, as the further improvement of the utility model: the sidewall of the large deformation area and the small deformation area is transitioned through a large circular arc, and the circular arc radius of the large circular arc is greater than or equal to 50 mm; the sidewall of the small deformation area and the non-deformation area is transitioned through a circular arc, and the radius of the circular arc is greater than or equal to 10 mm.

[0010] In the above technical solution: the ratio of the cross-sectional area of the inlaid frog forging heart rail blank to the cross-sectional area of the inlaid frog forging heart rail forging piece is less than or equal to 1.05.

[0011] Compared with the prior art, the utility model has the advantages of:

[0012] 1. The cross-sectional shape of the inlaid frog forging heart rail blank is simple, which is convenient to manufacture and has high material utilization.

[0013] 2. The inlaid frog forging heart rail blank is not prone to defects such as folding and meat loss during forging, can ensure that the plastic equivalent strain of the key part of the inlaid frog heart rail forging area is greater than or equal to 0.5, and the deformation amount presents a gradient distribution from top to bottom, and the closer to the rail top, the greater the deformation amount, so as to ensure that the inlaid frog heart rail manufactured by using the blank has good service performance. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 It is a schematic view of the inlaid frog forging heart rail forging piece of the utility model;

[0015] Figure 2 It is an enlarged schematic view of the cross section of the inlaid frog forging heart rail forging piece of the utility model;

[0016] Figure 3 It is a schematic view of the inlaid frog forging heart rail blank of the utility model;

[0017] Figure 4 It is an enlarged schematic view of the cross section of the inlaid frog forging heart rail blank of the utility model;

[0018] Figure 5 It is a cross-sectional size example of the inlaid frog forging heart rail forging piece of the utility model;

[0019] Figure 6 Example of the cross-sectional dimensions of the forged core rail blank for the inlaid frog of this utility model;

[0020] In the figure: 1-Inset forged frog mandrel forging part, 2-Inset forged frog mandrel blank, 2-1 Large deformation zone, 2-2 Small deformation zone, 2-3 No deformation zone, 3-Large arc, 4-Arch, 5-Rail top, 6-Rail bottom. Detailed Implementation

[0021] The following will refer to the appendix in the embodiments of this utility model. Figures 1-6 The technical solutions in the embodiments of this utility model are clearly and completely described herein. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0022] An inlaid forged frog mandrel blank, wherein the cross-sectional area reference value of the inlaid forged frog mandrel blank 2 is the value of the cross-sectional area of ​​the forged portion of the inlaid forged frog mandrel blank 1 multiplied by a coefficient of 1.035 (e.g., ...). Figure 1 , Figure 3 (As shown).

[0023] It is important to note that: First, a representative cross-section should be selected from the forged frog mandrel of the inlaid frog. This cross-section should reflect the key characteristics of the mandrel under stress and operating conditions. Accurately measuring and calculating the area of ​​the selected cross-section is fundamental to subsequent design; ensuring data accuracy is crucial. The calculated cross-sectional area is multiplied by a coefficient of 1.035, which serves as the baseline cross-sectional area for the inlaid frog mandrel blank. This coefficient is determined based on a comprehensive consideration of factors such as the material's deformation characteristics, shrinkage rate, and safety margin during the forging process. By accurately calculating and appropriately enlarging the cross-sectional area, dimensional deviations caused by material shrinkage during forging can be effectively reduced, thereby improving material utilization and reducing production costs. An increased cross-sectional area means improved overall strength of the mandrel after forging, enabling it to better withstand train impacts and wear, and extending the frog's service life. Based on precise cross-sectional shape design, forging process parameters, such as forging temperature and forging pressure, can be optimized, making the forging process more stable and reliable, and improving production efficiency and yield. By precisely controlling the cross-sectional shape and area, the dimensional accuracy and surface quality of the frog point rail after die forging can be ensured, meeting higher usage requirements. Although initial design and calculations require a certain amount of time and effort, in the long run, overall production costs can be significantly reduced by improving material utilization, optimizing manufacturing processes, and enhancing product quality.

[0024] The cross section of the mosaic frog cross swage rail blank 2 is left-right symmetrical, and the swage part is designed in three sections from top to bottom, including a forging area and a transition area; the three-section design of the mosaic frog cross swage rail blank 2 from top to bottom is a large deformation area 2-1, a small deformation area 2-2, and a non-deformation area 2-3 (as shown in Figure 4 ).

[0025] The three-section design enables the rail blank to withstand deformation in stages during swaging. The large deformation area 2-1 first undergoes a large degree of plastic deformation, followed by further deformation of the small deformation area 2-2, and finally the non-deformation area 2-3 remains relatively stable. This design helps to control the deformation amount during the entire swaging process, improving the stability and controllability of the process. Through the setting of different deformation areas 2-3, the rail can form a reasonable organizational structure and performance gradient after swaging. The material in the large deformation area 2-1 is refined after undergoing a large deformation, improving the strength and toughness; the small deformation area 2-2 further adjusts the performance of the material to ensure balanced overall performance; the non-deformation area 2-3 maintains the original excellent performance, providing stable support for the rail. The design of the large deformation area 2-1 and the small deformation area 2-2 enables the rail to have higher hardness and wear resistance at key stress points (such as the contact surface when the wheel passes), thereby prolonging the service life of the frog. At the same time, this design also helps to improve the impact resistance of the frog, reducing damage caused by train impact. The left-right symmetrical design of the cross section makes it easier to position and clamp the rail blank during processing, helping to improve processing precision and efficiency. At the same time, the three-section design also facilitates subsequent assembly work, ensuring accurate connection of the rail with the wing rail, frog heel rail, and other components. The three-section design enables the rail to form a more stable structure after swaging, effectively resisting vibrations and impacts during use. At the same time, the left-right symmetrical cross-sectional shape also helps to improve the overall stability and balance of the frog, ensuring smoothness and safety when the train passes.

[0026] In the above embodiments, as a preferred embodiment of the present utility model: the shape of the large deformation area 2-1 is approximately an isosceles triangle; the shape of the small deformation area 2-2 is an isosceles trapezoid; the shape of the non-deformation area 2-3 is the same as the shape of the bottom of the corresponding part of the frog rail swaging piece 1 rail bottom 6.

[0027] The isosceles triangular shape of the large deformation zone 2-1 allows the large deformation zone 2-1 to effectively bear and distribute the deformation force during the die forging process, which is conducive to the full flow and deformation of the material. The isosceles triangular shape is conducive to guiding the material to plastically deform in the predetermined direction during die forging, reducing uneven deformation and stress concentration. The trapezoidal design of the small deformation zone 2-2 allows the small deformation zone 2-2 to further adjust the deformation amount of the material during the die forging process, maintaining smooth transition with the large deformation zone 2-1. This design helps to form a more uniform microstructure and performance gradient, improving the overall performance of the frog. Due to the reasonable shape design of each deformation zone and the matching with the corresponding part of the die forging part 1, the smoothness and uniformity of the material flow during the die forging process can be ensured, which helps to improve the precision and yield of die forging, and reduces the generation of waste and defective products. The isosceles triangular and isosceles trapezoidal shape design makes the frog form a more stable structure after die forging, which can effectively resist vibration and impact generated during use, improving the overall stability and safety of the frog. At the same time, the non-deformation zone 2-3 has the same bottom shape as the corresponding part of the die forging part 1 rail bottom 6, ensuring the close connection and coordination of the frog with the rail bottom 6, further enhancing the structural strength and stability of the frog. By precisely controlling the shape and size of each deformation zone, the waste caused by material shrinkage and deformation during die forging can be minimized, which helps to improve material utilization and reduce production costs. The reasonable shape design of each deformation zone and the certain regularity make the frog blank easier to operate in the subsequent processing and assembly process, which helps to improve production efficiency and reduce labor intensity.

[0028] In the above embodiment, as a preferred embodiment of the utility model: the included angle between the side and the base of the isosceles triangle of the large deformation zone 2-1 is 75°-85°, the large value is taken when the cross section is narrow, and the small value is taken when the cross section is wide;The top of the isosceles triangle of the large deformation zone 2-1 is circular arc, the radius of the circular arc is 7-15mm, the small value is taken when the cross section is narrow, and the large value is taken when the cross section is wide;(Combining Figure 4 )The bottom width of the isosceles triangle of the large deformation zone 2-1 is 0.8 times the width of the rail top 5 of the embedded frog die forging frog rail die forging part 1 (Combining Figure 2 )The height of the isosceles triangle of the large deformation zone 2-1 is 1.1-1.5 times the height of the rail top 5 of the embedded frog die forging frog rail die forging part 1 (Combining Figure 4 ), the large value is taken when the cross section is narrow, and the small value is taken when the cross section is wide.

[0029] It should be noted that the included angle of 75°-85° is designed to make the material flow more smoothly during the die forging process, reducing the accumulation or uneven stretching of the material caused by excessive or insufficient angle. The larger value is taken when the cross-section is narrower, and the smaller value is taken when the cross-section is wider. This dynamic adjustment helps to adapt to the material deformation characteristics under different cross-sectional widths.

[0030] The design of the circular arc radius of 7-15mm reduces the stress concentration points during die forging, avoiding material cracking or damage caused by sharp corners. At the same time, the circular arc top helps to guide the flow direction of the material during the die forging process, improving the filling and forming properties of the material. The smaller value is taken when the cross-section is narrower, and the larger value is taken when the cross-section is wider. This design further enhances the material adaptability under different cross-sectional widths.

[0031] Precise size design ensures the controllability of material deformation during die forging, reducing waste and defective products caused by inaccurate dimensions. This helps to improve the precision and yield of die forging, reducing production costs.

[0032] The bottom width of the large deformation zone 2-1 is 0.8 times the rail top width of the embedded frog die forging heart rail forging piece 1. This design ensures good connection and support between the heart rail and the rail top. At the same time, it also makes the heart rail have enough strength and stiffness after die forging to withstand various forces and impacts when the train passes.

[0033] The height is 1.1-1.5 times the height of the rail top, and is adjusted according to the cross-sectional width. This design makes the heart rail form a reasonable cross-sectional shape and size after die forging, helping to improve the overall structural strength and stability of the frog.

[0034] By adjusting the side and bottom angle, top circular arc radius, bottom width, and height, etc. parameters, the frog can be flexibly adapted to different working conditions. For example, the frog used on heavy rail or high-speed rail may require larger cross-sectional dimensions and stronger structural strength to meet higher safety and usage requirements. Reasonable size design makes the die forging process more stable and reliable, reducing downtime and production costs caused by mold damage or material waste. At the same time, it also improves production efficiency and product quality, bringing better economic benefits to the enterprise.

[0035] In the above embodiment, as a preferred embodiment of the present utility model: the top of the small deformation zone 2-2 and the bottom of the large deformation zone 2-1 are equal in width; the bottom of the small deformation zone 2-2 and the top of the non-deformation zone 2-3 are equal in width; the height of the small deformation zone 2-2 corresponds to the cross-sectional area reference value calculated by multiplying the area of the embedded frog die forging heart rail blank 2 by the coefficient.

[0036] It should be noted that the top of the small deformation area 2-2 is equal in width to the bottom of the large deformation area 2-1, and the bottom is equal in width to the top of the non-deformation area 2-3. This design ensures smooth transition of the center rail from the large deformation area to the small deformation area, and then to the non-deformation area during the die forging process. It avoids stress concentration and uneven deformation caused by sudden changes in width, improves the overall structural strength and stability of the frog, and is beneficial to optimizing material deformation, improving die forging precision, enhancing structural strength, adapting to different specifications, and improving production efficiency.

[0037] In the above embodiment, as a preferred embodiment of the utility model: the height of the non-deformation area 2-3 is equal to the height of the parting surface corresponding to the rail bottom 6 of the inlaid frog die forging center rail die forging piece 1.

[0038] It should be noted that the height of the non-deformation area 2-3 is consistent with the parting surface height of the die forging piece 1 rail bottom 6, which can ensure that the center rail is connected closely and stably with the rail bottom during the die forging process. This structural consistency helps to reduce stress concentration and deformation problems caused by height mismatch, and improves the overall structural strength of the frog. By directly using the same height as the parting surface of the rail bottom 6 as the size of the non-deformation area 2-3, the size control and manufacturing process during die forging can be simplified, which helps to reduce production difficulty and cost, improve production efficiency and yield. Maintaining the consistency of the height of the non-deformation area 2-3 and the parting surface of the rail bottom 6 helps to more accurately control the flow and deformation of the material during die forging, which helps to improve the size accuracy and shape accuracy of the die forging piece, ensuring that the frog can meet the design requirements and use requirements. When the size of the non-deformation area 2-3 matches the height of the parting surface of the rail bottom 6, the interchangeability and universality between the frog and other track components can be enhanced, which helps to reduce maintenance and replacement costs, and improve the overall operating efficiency of the railway system. The stable structure and accurate size of the non-deformation area 2-3 helps to ensure that the frog can withstand various forces and impacts when the train passes, maintaining its stability and reliability, which is of great significance to the safety and smoothness of railway operation.

[0039] In the above embodiment, as a further improvement of the utility model: the side wall of the large deformation area 2-1 and the small deformation area 2-2 is transitioned through a large circular arc 3, and the circular arc radius of the large circular arc 3 is ≥50mm; the side wall of the small deformation area 2-2 and the non-deformation area 2-3 is transitioned through a circular arc 4, and the radius of the circular arc 4 is ≥10mm.

[0040] It should be noted that the design of the transition arc can effectively disperse the stress generated during the die forging process. When the material transitions from the large deformation zone to the small deformation zone, and from the small deformation zone to the non-deformation zone, due to the change in cross-sectional size and shape, a large stress concentration often occurs. The presence of the transition arc can make the stress distribution more uniform, reducing the phenomenon of stress concentration, thereby improving the overall strength and durability of the frog. A larger arc radius (such as the radius of large arc 3 ≥ 50mm) can reduce the cracks caused by sudden changes in cross-sectional size during die forging. Cracks are one of the common defects of die forgings, which not only reduce the performance of the product, but also may cause the product to fail during use. By reasonably designing the radius of the transition arc, the risk of crack generation can be significantly reduced. The design of the transition arc also helps to improve the surface quality of the frog. If the cross-sectional size changes too drastically during die forging, it may cause defects such as folding and scratches on the surface of the forged part. The presence of the transition arc can make the surface of the forged part smoother and more uniform, reducing the occurrence of defects. The design of the transition arc also helps to optimize the flow of materials. The design of the transition arc enhances the structural continuity between different deformation zones. The presence of the transition arc also facilitates subsequent processing and installation of the frog.

[0041] In the above embodiment, the ratio of the cross-sectional area of the inlaid frog die forged center rail blank 2 to the cross-sectional area of the inlaid frog die forged center rail forged part 1 is ≤1.05.

[0042] When the ratio is ≤1.05, it means that the center rail blank can be close to completely filling the die cavity after die forging, reducing waste or defects caused by too much or too little material. This helps to reduce production costs and improve economic benefits. Proper material filling is crucial to the quality of the die forging. If there is too much material, it may cause defects such as folding and cracking during die forging; if there is too little material, it may not be able to form a complete die forging structure.

[0043] Specifically: select a certain cross-section of the inlaid frog die forged center rail forged part 1 die forging part, i.e. the forging zone, as 17889mm 2 , multiplied by the coefficient 1.035 as 18515mm 2 , which is taken as the reference value of the cross-sectional area of the blank.

[0044] (Combined Figure 5 , Figure 6 ) First, determine the shape and size of the large deformation zone 2-1: the shape of the large deformation zone 2-1 is approximately an isosceles triangle; since the cross-sectional area of the large deformation zone 2-1 is moderate, the angle between the side and the base of the isosceles triangle of the large deformation zone 2-1 is set to 80°, the radius of the arc at the top of the large deformation zone 2-1 is set to 10mm, since the width of the top of the forged part is 58mm, the width of the bottom of the large deformation zone is set to 45mm, the height of the top of the rail is 52mm, and therefore the height of the large deformation zone is set to 79mm.

[0045] Then, the shape and size of the non-deformation area 2-3 are determined: the shape of the non-deformation area 2-3 is the same as the bottom of the corresponding part of the rail bottom 6 of the mosaic cross module forging heart rail forging 1, and the height and width of the non-deformation area 2-3 are equal to the part below the parting surface of the forging. Therefore, its height is 90mm, and the width is 110mm.

[0046] Then, the shape and size of the small deformation area 2-2 are determined: the shape of the small deformation area 2-2 is isosceles trapezoidal; the top of the small deformation area 2-2 is equal in width to the bottom of the large deformation area 2-1, and the bottom of the small deformation area 2-2 is equal in width to the top of the bottom of the non-deformation area 2-3. The height of the small deformation area 2-2 is determined according to the area of the blank being equal to the reference value of the area of the blank.

[0047] Then, the transition arcs between the large deformation area 2-1, the small deformation area 2-2 and the non-deformation area 2-3 are determined. The side wall between the large deformation area 2-1 and the small deformation area 2-2 is transitioned through a large arc 3, and the arc radius of the large arc 3 is 60mm; the side wall between the small deformation area 2-2 and the non-deformation area 2-3 also needs to be transitioned through an arc 4, and the radius of the arc 4 is 10mm.

[0048] Finally, the cross section of the obtained mosaic cross module forging heart rail blank 2 is checked for area, and the area is about 18640mm 2 , which is 1.042 times the cross-sectional area of the mosaic cross module forging heart rail forging 1, and the ratio of the cross-sectional areas is ≤1.05, which meets the size requirement, and finally the blank cross section diagram as shown in Figure 6 is obtained, the design result is accepted, and the design scheme is determined.

[0049] The utility model relates to a kind of cross-sectional shape design method of mosaic cross module forging heart rail blank, (as shown in Figure 1 It selects the cross section of mosaic cross module forging heart rail forging 1 forging part, and calculates the cross-sectional area, and the cross-sectional area value obtained by calculation is multiplied by coefficient 1.035, to be used as the cross-sectional area reference value of mosaic cross module forging heart rail blank 2 (as shown in Figure 3 ).

[0050] The cross section of the mosaic cross module forging heart rail blank 2 is left-right symmetrical, and is designed in three sections from top to bottom; the three sections of the mosaic cross module forging heart rail blank 2 from top to bottom are large deformation area 2-1, small deformation area 2-2 and non-deformation area 2-3 (as shown in Figure 4 ).

[0051] The shape of the large deformation area 2-1 is approximately isosceles triangular; the shape of the small deformation area 2-2 is isosceles trapezoidal; the shape of the non-deformation area 2-3 is the same as the shape of the bottom of the corresponding part of the rail bottom 6 of the mosaic cross module forging heart rail forging 1.

[0052] The method related to the utility model further comprises the following steps:

[0053] Step 1, the size of the large deformation area 2-1 is determined: the included angle of the side and the base of the isosceles triangle of the large deformation area 2-1 is 75°-85°, the large value is taken when the section is narrow, and the small value is taken when the section is wide; the top of the isosceles triangle of the large deformation area 2-1 is in the shape of a circular arc, the radius of the circular arc is 7-15 mm, the small value is taken when the section is narrow, and the large value is taken when the section is wide; (combine Figure 4 ) the base width of the isosceles triangle of the large deformation area 2-1 is 0.8 times the width of the rail top 5 of the inlaid frog die forging rail die forging piece 1 (combine Figure 2 ); the height of the isosceles triangle of the large deformation area 2-1 is 1.1-1.5 times the height of the rail top 5 of the inlaid frog die forging rail die forging piece 1 (combine Figure 4 ), the large value is taken when the section is narrow, and the small value is taken when the section is wide.

[0054] Step 2, the size of the undeformed area 2-3 is determined: the height of the undeformed area 2-3 (as shown in Figure 4 ) is equal to the height of the parting surface of the rail bottom 6 (combine Figure 2 ) of the inlaid frog die forging rail die forging piece 1.

[0055] Step 3, the size of the small deformation area 2-2 is determined: the top of the small deformation area 2-2 is equal in width to the bottom of the large deformation area 2-1; the bottom of the small deformation area 2-2 is equal in width to the top of the undeformed area 2-3; the height of the small deformation area 2-2 is determined according to the area of the inlaid frog die forging rail blank 2, so that the area of the inlaid frog die forging rail blank 2 corresponds to the calculated cross-sectional area reference value of the inlaid frog die forging rail blank 2.

[0056] Step 4, the transition circular arc between the large deformation area, the small deformation area and the undeformed area is determined: the side wall of the large deformation area 2-1 and the small deformation area 2-2 is transitioned through a large circular arc 3; the radius of the large circular arc 3 is ≥50 mm; the side wall of the small deformation area 2-2 and the undeformed area 2-3 is transitioned through a circular arc 4, and the radius of the circular arc 4 is ≥10 mm.

[0057] Step 5, the cross-sectional area of the inlaid frog die forging rail blank 2 is checked: the cross-sectional area of the inlaid frog die forging rail blank 2 in steps 1-3 is calculated, if the ratio of the cross-sectional area of the inlaid frog die forging rail blank 2 to the cross-sectional area of the inlaid frog die forging rail blank 2 is ≤1.05, then the design result is accepted, otherwise the transition circular arc radius of step 4 is adjusted appropriately until the ratio of the cross-sectional area of the inlaid frog die forging rail blank 2 to the cross-sectional area of the inlaid frog die forging rail blank 2 is ≤1.05.

[0058] It should be noted that by checking the cross-sectional area ratio, the material utilization rate in the die forging process can be ensured to reach a high level. The adjustment of the transition arc radius is a key link in the checking process. Through continuous iteration and adjustment, the optimal transition arc radius can be found, so that the heart rail blank can flow and deform smoothly in the die forging process, while reducing the risk of stress concentration and crack generation. This helps to further improve the structural strength and durability of the die forging. The checking process allows designers to adjust the transition arc radius according to actual needs to adapt to different specifications and sizes of frog requirements. This flexibility and adaptability makes the design process more efficient and reliable, and can quickly respond to market changes and customer needs. Through checking and adjustment, the stability and reliability of the die forging process can be ensured. Stable process parameters and procedures help to improve production efficiency, reduce waste and defective rates. At the same time, it also helps to reduce production delays and cost increases due to process fluctuations. The final die forging needs to meet strict quality and safety requirements. Through the checking and adjustment process, the die forging can meet the design requirements in terms of structural strength, dimensional accuracy and surface quality. This helps to ensure the safe and stable operation of the railway system.

[0059] In summary, the embedded frog die forging heart rail blank of the utility model has simple cross-sectional shape, is convenient to manufacture and has high material utilization rate. The embedded frog die forging heart rail blank of the utility model is not prone to defects such as folding and meat loss in the forging process, can ensure that the plastic equivalent strain of the key part of the embedded frog die forging heart rail reaches more than 0.5, and the deformation amount presents a gradient distribution from top to bottom, and the deformation amount is greater closer to the rail top, thereby ensuring that the embedded frog heart rail manufactured by using the blank has good service performance.

[0060] It should be understood that although the present specification is described in one embodiment, the embodiment does not contain only one independent technical solution, and the description manner of the specification is only for clarity, and those skilled in the art should consider the specification as a whole, and the technical solutions in the embodiment can also be appropriately arranged and combined to form other embodiments that can be understood by those skilled in the art.

[0061] The above preferred embodiments are not intended to limit the scope of the utility model, so any equivalent changes made in accordance with the contents of the utility model claims should be included within the scope of the utility model claims; it should be noted that the components and materials used in the above embodiments, such as those without special instructions, are commercially available.

Claims

1. A mosaic frog-ironing swage rail blank, characterized by: The cross-sectional area reference value of the mosaic frog cross forging rail blank (2) is the cross-sectional area value of the mosaic frog cross forging rail forging part (1) multiplied by the coefficient 1.

035. The cross section of the mosaic frog cross forging rail blank (2) is left-right symmetrical, and is designed in three sections from top to bottom. The three sections of the mosaic frog cross forging rail blank (2) from top to bottom are the large deformation zone (2-1), the small deformation zone (2-2) and the non-deformation zone (2-3).

2. The mosaic frog-ironing heart rail blank of claim 1, wherein: The shape of the large deformation zone (2-1) is approximately an isosceles triangle. The shape of the small deformation zone (2-2) is an isosceles trapezoid. The shape of the non-deformation zone (2-3) is the same as the shape of the bottom of the corresponding part of the frog cross forging rail forging part (1).

3. The mosaic frog-ironing heart rail blank of claim 2, wherein: The included angle between the side and the base of the isosceles triangle of the large deformation zone (2-1) is 75°-85°, and the large value is taken when the cross section is narrow, and the small value is taken when the cross section is wide. The top of the isosceles triangle of the large deformation zone (2-1) is in the shape of a circular arc, and the radius of the circular arc is 7-15 mm, the small value is taken when the cross section is narrow, and the large value is taken when the cross section is wide. The width of the bottom of the isosceles triangle of the large deformation zone (2-1) is 0.8 times the width of the top of the frog cross forging rail forging part (1). The height of the isosceles triangle of the large deformation zone (2-1) is 1.1-1.5 times the height of the top of the frog cross forging rail forging part (1), and the large value is taken when the cross section is narrow, and the small value is taken when the cross section is wide.

4. The mosaic frog-peg blank according to claim 2, characterized in that: The top of the small deformation zone (2-2) is the same width as the bottom of the large deformation zone (2-1). The bottom of the small deformation zone (2-2) is the same width as the top of the non-deformation zone (2-3). The height of the small deformation zone (2-2) is determined according to the area of the mosaic frog cross forging rail blank (2), so that the area of the mosaic frog cross forging rail blank (2) corresponds to the cross-sectional area reference value calculated by multiplying the area of the frog cross forging rail forging part (1) by a coefficient.

5. The mosaic frog-peg blank of claim 2 wherein: The height of the non-deformation zone (2-3) is equal to the height of the parting surface of the corresponding part of the frog cross forging rail forging part (1).

6. The mosaic frog-peg swage rail billet according to claim 2, wherein: The side wall of the large deformation zone (2-1) and the small deformation zone (2-2) is transitioned by a large circular arc (3), and the radius of the large circular arc (3) is ≥50 mm. The side wall of the small deformation zone (2-2) and the non-deformation zone (2-3) is transitioned by a circular arc (4), and the radius of the circular arc (4) is ≥10 mm.

7. The mosaic frog-peg swage rail billet according to claim 1, wherein: The ratio of the cross-sectional area of the mosaic frog cross forging rail blank (2) to the cross-sectional area of the mosaic frog cross forging rail forging part (1) is ≤1.05.

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