Inlaid frog wing rail insert

Abstract

The utility model provides an embedded frog wing rail insert. The insert is made of a blank; the blank comprises an embedded frog wing rail insert local die forging blank and an embedded frog wing rail insert machining blank; the local die forging blank of the embedded frog wing rail insert is cast by a casting forming process; the machining blank of the embedded frog wing rail insert is prepared by carrying out local die forging on an area of the local die forging blank of the embedded frog wing rail insert from the throat of a frog to the section range with the width of 50mm of a point rail and then carrying out water toughening treatment at 1000-1100 DEG C; the inlaid frog wing rail insert is manufactured by machining the inlaid frog wing rail insert machining blank and removing the allowance. According to the utility model, the later machining amount can be effectively reduced, the manufacturing period is shortened, the cost is reduced, the insert has good service performance, the practical value and the application prospect are higher, the service life of a finished product is prolonged, and the safety performance of the finished product is improved.

Description

Technical Field

[0001] This utility model belongs to the field of forging technology of inlaid frog wing rail inserts, specifically relating to an inlaid frog wing rail insert. Background Technology

[0002] Traditional methods for manufacturing inlaid frog rail inserts typically involve forging square blanks using free forging, followed by machining. While this method produces rail inserts with good service performance, it results in a large amount of machining, a long manufacturing cycle, and high costs. Therefore, the following improved technical solution is proposed. Utility Model Content

[0003] The technical problem solved by this utility model is to provide an inlaid frog wing rail insert, which solves the technical problems of huge machining volume, long manufacturing cycle and high cost of the existing insert blank manufacturing.

[0004] The technical solution adopted in this utility model is as follows: an inlaid frog wing rail insert, the insert being made from a blank; the blank includes a partially forged blank for the inlaid frog wing rail insert and a machined blank for the inlaid frog wing rail insert; the partially forged blank for the inlaid frog wing rail insert is cast by a casting process; the machined blank for the inlaid frog wing rail insert is obtained by partially forging the area within a 50mm section from the frog throat to the center rail of the partially forged blank for the inlaid frog wing rail insert, followed by water quenching at 1000-1100℃; the inlaid frog wing rail insert is obtained by machining the machined blank for the inlaid frog wing rail insert after removing the excess material.

[0005] In the above technical solution, the preferred technical solution of this utility model is as follows: the machined blank of the inlaid frog wing rail insert is divided into three regions along the longitudinal direction, including a local forging zone I, a transition zone I, and a non-forging zone I; the local forging zone I is located within a 50mm cross-sectional area from the frog throat to the center rail; the local forging zone I is provided with transition zones I on both sides, and the local forging zone I is smoothly connected to the non-forging zone I through the transition zones I.

[0006] In the above technical solutions, the preferred technical solution of this utility model is: the machining allowance of the machined blank of the inlaid frog wing rail insert is 6-8mm.

[0007] In the above technical solution, the preferred technical solution of this utility model is as follows: the two sides of the local forging zone I have different draft angles, the draft angle of the side of the local forging zone I with the step is 3°, and the draft angle of the side of the local forging zone I without the step is 1°; the parting surface height is not higher than the step height.

[0008] In the above technical solutions, the preferred technical solution of this utility model is: the length of the transition zone I is 0.25 to 1.5 times the height of the machined blank of the inlaid frog wing rail insert.

[0009] In the above technical solution, the preferred technical solution of this utility model is as follows: the locally forged blank of the inlaid frog wing rail insert is divided into three regions along the longitudinal direction, including the locally forged region II, the transition region II and the non-forged region II respectively; the locally forged region II is located within a 50mm cross-sectional area from the frog throat to the center rail; the transition region II is provided on both sides of the locally forged region II, and the locally forged region II is smoothly connected to the non-forged region II through the transition region II.

[0010] In the above technical solution, the preferred technical solution of this utility model is as follows: the height of the local forging zone II of the inlaid frog wing rail insert blank is 40-80mm higher than the upper end face of the corresponding position of the machined blank of the inlaid frog wing rail insert. The height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local forging zone II is not less than 0.5; the top of the local forging zone II is a rounded corner tangent to both sides, and the radius of the rounded corner is 8-10mm.

[0011] In the above technical solution, the preferred technical solution of this utility model is as follows: the shape of the non-forging area II of the partially forged blank of the inlaid frog wing rail insert is consistent with the shape and size of the non-forging area I of the machined blank of the inlaid frog wing rail insert.

[0012] In the above technical solutions, the preferred technical solution of this utility model is as follows: the shape and length of the transition zone II of the partially forged blank of the inlaid frog wing rail insert are consistent with the shape and length of the transition zone I of the machined blank of the inlaid frog wing rail insert.

[0013] In the above technical solutions, the preferred technical solution of this utility model is as follows: the cross-section of the partially forged blank of the inlaid frog wing rail insert is designed in three sections from top to bottom; the three sections of the partially forged blank of the inlaid frog wing rail insert are respectively the large deformation zone, the small deformation zone and the non-deformation zone.

[0014] In the above technical solutions, the preferred technical solution of this utility model is as follows: the shape of the large deformation zone is approximately an isosceles triangle; the shape of the small deformation zone is approximately an isosceles trapezoid; and the shape of the non-deformation zone is the same as the shape of the corresponding part of the bottom of the blank of the machined blank for the inlaid frog wing rail insert.

[0015] Advantages of this utility model compared to the prior art:

[0016] 1. This utility model can produce machined blanks of inlaid frog wing rail inserts that meet the requirements, which can effectively reduce the amount of subsequent machining, shorten the manufacturing cycle, and reduce costs.

[0017] 2. In this utility model, the presence of local die forging in the inlaid frog wing rail insert ensures sufficient deformation in key areas due to the presence of local die forging, thereby guaranteeing good service performance of the insert. This method is applicable to the manufacturing of inlaid frog wing rail inserts and has high practical value and application prospects.

[0018] 3. This utility model is designed based on the principle of ensuring sufficient deformation in the key parts of the insert, while also ensuring good service performance of the insert, thereby improving the service life and safety performance of the finished insert. Attached Figure Description

[0019] Figure 1 This is an assembly drawing of the inlaid frog wing rail insert of this utility model;

[0020] Figure 2 This is an enlarged perspective view of the inlaid frog wing rail insert of this utility model;

[0021] Figure 3 This is a perspective view of the machined blank for the inlaid frog wing rail insert of this utility model;

[0022] Figure 4 for Figure 3 A schematic front view of the local forging area;

[0023] Figure 5 This utility model Figure 3 , Figure 4 Enlarged detail of the BB cross section;

[0024] Figure 6 This is a three-dimensional view of a partial die-forged blank for the inlaid frog wing rail insert of this utility model;

[0025] Figure 7 for Figure 6 Enlarged detail of the BB cross section;

[0026] In the figure: 1- Partially forged blank of inlaid frog wing rail insert, 1-1 Partially forged zone II, 1-2 Transition zone II, 1-3 Non-forged zone II; 2- Machining blank of inlaid frog wing rail insert, 2-1 Partially forged zone I, 2-2 Transition zone I, 2-3 Non-forged zone I, 3- Large deformation zone, 4- Small deformation zone, 5- No deformation zone. Detailed Implementation

[0027] The following will refer to the appendix in the embodiments of this utility model. Figure 1-7The 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.

[0028] This utility model claims protection for an inlaid frog wing rail insert, the insert being made from a blank; the blank includes a partially forged blank 1 and a machined blank 2; the partially forged blank 1 is cast using a casting process; the machined blank 2 is obtained by partially forging a 50mm section from the frog throat to the center rail of the partially forged blank 1, followed by water quenching at 1000-1100℃; the inlaid frog wing rail insert (e.g.) Figure 2 (As shown) is obtained by machining the blank 2 of the embedded frog wing rail insert after removing the excess material.

[0029] Specifically: the area within a 50mm section from the billet frog throat to the center rail width is located in the range of 172mm to 772mm from the maximum section of the billet.

[0030] It should be noted that partial forging can effectively improve the mechanical properties of the frog wing rail insert material. Forging can eliminate defects such as shrinkage cavities and porosity that may occur during casting, resulting in a denser material structure and thus improving its strength, toughness, and wear resistance. Forging also refines the grain size, improving the overall mechanical properties of the material and making it better suited to the complex operating conditions of the frog. Due to the improved material properties, partially forged frog wing rail inserts can significantly extend the service life of the frog. This advantage is particularly pronounced on heavy-load and high-speed railway lines. Forging also reduces cracks and spalling during frog service, improving its reliability and stability. Partially forged frog wing rail inserts have more precise shapes and dimensions, facilitating subsequent machining and assembly. The partial forging method allows for flexible adjustment of forging process parameters and mold design according to the specific operating conditions and requirements of the frog, meeting the needs of different lines and vehicles.

[0031] Furthermore, water toughening is a process that heats the material to the austenitic single-phase region and then rapidly cools it to obtain a uniform austenitic structure. This process significantly improves the material's mechanical properties, such as increasing its hardness, strength, and toughness, giving the frog wing rail insert better fatigue resistance and durability when subjected to the impact and wear of passing trains. During local forging, the material is subjected to large deformation forces, which easily generate internal stress. Water toughening can effectively eliminate these internal stresses, preventing cracks and fractures caused by stress concentration during use. Local forging ensures that the shape and dimensions of the frog wing rail insert meet design requirements, especially in critical areas such as the transition zone and local forging zone, enabling high-precision forming. Local forging reduces the workload of subsequent machining, lowers processing costs and time, and improves production efficiency. Local forging allows for precise control of the material's shape and dimensions, avoiding excessive waste during forming and improving material utilization. High material utilization helps conserve raw material resources, meeting the requirements of sustainable development. The frog wing rail inserts, after partial die forging and water toughening, exhibit improved machinability, such as machinability and weldability, which facilitates subsequent processing. Partial die forging and water toughening enhance the structural strength of the frog wing rail inserts, enabling them to better withstand various loads and impacts during use.

[0032] (like Figure 3 , Figure 4 As shown in the above embodiment, as a preferred embodiment of this utility model: the machined blank 2 of the inlaid frog wing rail insert is divided into three regions along the longitudinal direction, including a local forging region I2-1, a transition region I2-2, and a non-forging region I2-3; the local forging region I2-1 is located within a 50mm width section from the frog throat to the center rail; transition regions I2-2 are provided on both sides of the local forging region I2-1, and the local forging region I2-1 is smoothly connected to the non-forging region I2-3 through the transition regions I2-2. The advantages have been described above and will not be repeated here.

[0033] The local forging zone I2-1 is precisely positioned within a 50mm cross-section from the frog throat to the center rail, which is the area where the frog experiences the greatest impact and wear during operation. Local forging significantly improves the material properties of this area, such as strength, hardness, and wear resistance, thereby extending the overall service life of the frog. Dividing the machined blank into three zones—local forging zone I2-1, transition zone I2-2, and non-forging zone I2-3—achieves efficient material utilization. The non-forging zone I2-3 maintains lower processing costs, while the local forging zone I2-1 is strengthened through forging, avoiding the high costs and unnecessary material waste associated with integral forging. The transition zone I2-2 allows for a smooth transition from local forging zone I2-1 to non-forging zone I2-3, reducing processing difficulty and costs caused by abrupt changes in material properties. Simultaneously, the presence of the transition zone I2-2 helps alleviate stress concentration and improve the overall stability of the frog. This clear zone division makes the machining process more orderly and efficient. Machining personnel can select appropriate processing techniques and parameters based on the characteristics of different areas, thereby improving processing accuracy and efficiency. Localized die forging enhances the load-bearing capacity and wear resistance of the frog in critical areas, reducing failures and accidents caused by wear and fatigue, thus improving the reliability and safety of the frog.

[0034] (like Figure 5 As shown in the above embodiments, as a preferred embodiment of this utility model, the machining allowance of the machined blank 2 of the inlaid frog wing rail insert is 6-8mm. The advantages have already been described above and will not be repeated here.

[0035] Specifically, the machined blank 2 of the inlaid frog wing rail insert has a machining allowance of 6mm to facilitate subsequent machining.

[0036] A machining allowance of 6-8mm is precisely reserved according to the shape and size of the finished product to ensure the smooth progress of subsequent machining processes. This allowance is neither too much, which would lead to material waste, nor too little, which would affect the precision and quality of the final product.

[0037] In the above embodiments, as a preferred embodiment of the present invention: the two sides of the local forging zone I2-1 of the machined blank 2 of the inlaid fork rail insert have different draft angles; the draft angle of the side of the local forging zone I2-1 with the step is 3°, and the draft angle of the side of the local forging zone I2-1 without the step 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.

[0038] The partial forging zone I2-1 features different draft angles on both sides: 3° on the stepped side and 1° on the side without a step. This design facilitates smooth demolding during forging, reducing the risk of die wear and billet damage. Simultaneously, different draft angles allow for adjustment of material flowability and formability according to actual needs, ensuring the shape and dimensional accuracy of the forging. The design where the parting surface height does not exceed the step height facilitates die manufacturing and installation, reducing die complexity and cost. This design also reduces stress concentration and deformation during forging, improving the dimensional stability and surface quality of the forging. Draft angle is a crucial parameter in die design, used to reduce the resistance when the part is demolded. In partial forging zone I2-1, the stepped side features a larger draft angle (3°), significantly reducing demolding resistance on that side and allowing for smoother demolding. Different draft angle designs can adapt to the deformation characteristics of different parts of the part. A larger draft angle at the step helps maintain the shape stability of the part during demolding, reducing deformation caused by improper demolding. By precisely controlling the draft angle and parting surface height, it is possible to ensure that the parts maintain high dimensional accuracy after demolding, meeting design requirements. A parting surface height no higher than the step height ensures that the parts can smoothly separate from the mold during demolding, avoiding demolding difficulties caused by an excessively high parting surface. This design helps simplify the mold structure and reduce mold manufacturing difficulty and cost. It also helps improve mold reliability and service life. By precisely designing the shape and dimensions of the local forging zone I2-1 and reserving machining allowances, material waste can be minimized and material utilization improved. Furthermore, a reasonable draft angle and parting surface height design also helps improve production efficiency and reduce production costs.

[0039] (like Figure 4 As shown in the above embodiment, as a preferred embodiment of the present invention: the length of the transition zone I2-2 of the machined blank 2 of the inlaid frog wing rail insert is 0.25 to 1.5 times the height of the machined blank 2. Specifically, the lengths of the transition zone I2-2 are 60 mm and 172 mm, respectively. The height of the machined blank 2 of the inlaid frog wing rail insert is 180 mm.

[0040] First, the design of the transition zone I2-2 allows for a smooth transition and integration between the locally forged zone I2-1 and the non-forged zone I2-3. This smooth connection helps reduce stress concentration caused by abrupt changes in material properties, thereby improving the overall strength and stability of the frog rail insert. Stress concentration is one of the main causes of cracking and fracture during forging and subsequent use. A well-designed transition zone I2-2 can effectively reduce this risk and extend the frog's service life. The presence of the transition zone I2-2 also makes the connection between the locally forged zone and the non-forged zone tighter and more stable, reducing the scrap rate caused by poor connection.

[0041] The length of the 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.

[0042] Furthermore, the transition zone I2-2, as a crucial component connecting the large deformation zone and the small deformation zone (or the non-deformation zone), requires a well-designed length to ensure a smooth stress transition. 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 ensures uniform stress distribution during loading, reducing stress concentration and thus improving the fatigue resistance and durability of the frog wing rail insert. An appropriate length of the transition zone I2-2 enhances the overall load-bearing capacity of the frog wing rail insert. A well-designed length of the transition zone I2-2 also simplifies the machining process. During machining, the presence of the transition zone I2-2 makes the machining path smoother, reducing machining difficulty and costs caused by abrupt shape changes. By precisely controlling the length and shape of the transition zone I2-2, it is possible to ensure that the frog wing rail insert maintains high dimensional accuracy during machining, which is of great significance for improving the overall performance and stability of the frog.

[0043] (like Figure 6 As shown in the above embodiment, as a preferred embodiment of the present invention: the locally forged blank 1 of the inlaid frog wing rail insert is divided into three regions along the longitudinal direction, including a locally forged region II1-1, a transition region II1-2, and a non-forged region II1-3; the locally forged region II1-1 is located within a 50mm width section from the frog throat to the center rail; transition regions II1-2 are provided on both sides of the locally forged region II1-1, and the locally forged region II1-1 is smoothly connected to the non-forged region II1-3 through the transition regions II1-2. The advantages are the same as before and will not be repeated.

[0044] (like Figure 7As shown in the above embodiment, as a preferred embodiment of the present utility model: the height of the local forging zone II1-1 of the inlaid frog wing rail insert 1 is 40-80mm higher than the upper end face of the corresponding position of the machined blank 2 of the inlaid frog wing rail insert. The height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local forging zone II1-1 is not less than 0.5; the top of the local forging zone II1-1 is a rounded corner tangent to both sides, and the radius of the rounded corner is 8-10mm.

[0045] Specifically, the height of the partially forged area II1-1 of the partially forged blank 1 of the inlaid frog wing rail insert is 45mm higher than the upper end face of the corresponding position of the machined blank 2 of the inlaid frog wing rail insert. The top of the partially forged area II1-1 of the partially forged blank 1 of the inlaid frog wing rail insert is a rounded corner tangent to both sides, with a radius of 8mm.

[0046] By designing the local forging zone II1-1 to be 40-80mm higher than the upper end face of the corresponding position on the machined blank 2 of the inlaid frog wing rail insert, this height design ensures that the rail top portion of the local forging zone II1-1 can accumulate sufficient plastic equivalent strain (not less than 0.5) during the forging process. This strain accumulation helps refine the grains and improve the material microstructure, thereby increasing the material's strength, hardness, and wear resistance. The increase in accumulated plastic equivalent strain significantly improves the material properties of the local forging zone II1-1, enabling it to better adapt to the frog's usage requirements under complex working conditions and extend the frog's service life. The top of the local forging zone II1-1 is designed with rounded corners tangent to both sides, with a radius of 8-10mm. This rounded corner design helps reduce stress concentration during the forging process and avoids defects such as cracks. At the same time, the rounded corner design also makes the subsequent machining process smoother, improving machining efficiency and accuracy. Through reasonable shape and size design, the local forging zone Ⅱ1-1 can better fill the mold during the forging process, reduce forging defects, and improve the yield and quality of forgings.

[0047] In the above embodiments, as a preferred embodiment of the present utility model: the shape of the non-forging area II1-3 of the partially forged blank 1 of the inlaid 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 inlaid frog wing rail insert.

[0048] The shape and dimensions of the non-forged zone II1-3 are consistent with those of the non-forged zone I2-3 of the machined blank 2 for the inlaid frog wing rail insert. This design ensures the structural uniformity and coordination of the entire frog wing rail insert. During assembly and installation, it ensures a tight fit between components, reducing assembly problems caused by dimensional differences. The uniformity of the shape and dimensions of the non-forged zone II1-3 facilitates subsequent machining processes. Because the two "non-forged zones" have the same shape and dimensions, the same inspection standards and methods can be used during quality control. This helps ensure the quality stability and consistency of each component of the frog wing rail insert, improving the overall product quality level.

[0049] In the above embodiments, as a preferred embodiment of the present utility model: the shape and length of the transition zone II1-2 of the partially forged blank 1 of the inlaid frog wing rail insert 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.

[0050] First, the design of transition zone II1-2 allows for a smooth transition between the locally forged zone II1-1 and the non-forged zone II1-3, avoiding stress concentration caused by abrupt changes in material properties. This helps reduce the risk of cracks and fractures due to stress concentration during the use of the frog, thus improving its service life. Second, the shape and length dimensions of transition zone II1-2 are consistent with those of transition zone I2-2 in the machined blank 2. This means that the same process parameters and methods can be used during processing, simplifying the process and improving efficiency. By designing the same transition zone shape and dimensions, the structural consistency of frog wing rail inserts from different batches and under different production conditions can be ensured, thereby guaranteeing the stability and reliability of product quality.

[0051] (like Figure 7 As shown in the above embodiment, as a preferred embodiment of the present utility model: the cross section of the inlaid frog wing rail insert partial die forging blank 1 is designed in three sections from top to bottom; the three sections of the inlaid frog wing rail insert partial die forging blank 1 are respectively the large deformation zone 3, the small deformation zone 4 and the non-deformation zone 5.

[0052] The three-section design makes local forging and subsequent processing more orderly and efficient. The clear division between the large deformation zone 3 and the small deformation zone 4 helps determine the processing sequence and parameters, reducing processing difficulty and cost. The presence of the non-deformation zone 5 provides a stable reference surface for the installation of the insert. By precisely controlling the size and shape of the non-deformation zone 5, it can be ensured that the insert closely cooperates with other components of the track system during installation, improving the stability and safety of the entire turnout system.

[0053] In the above embodiments, 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-deformable zone 5 is the same as the shape of the corresponding part of the bottom of the machined blank 2 of the inlaid frog wing rail insert.

[0054] The approximately isosceles triangular shape allows the large deformation zone to effectively disperse and absorb impact energy during forging, reducing stress concentration and improving material toughness. Large deformation helps refine the material's grain structure, increasing strength and hardness, while also improving overall mechanical properties. The isosceles trapezoidal shape, serving as a transition zone between the large deformation and non-deformation zones, gradually reduces deformation, resulting in smoother deformation behavior and fewer internal defects caused by uneven deformation. The trapezoidal structure also provides good stability, enhancing the overall insert's resistance to deformation and fatigue. The non-deformation zone's shape corresponds to the bottom of the machined blank, ensuring a stable reference surface during machining and assembly, improving assembly accuracy and reliability. As the stabilizing part of the insert, the non-deformation zone enhances its overall performance, ensuring stable resistance to various loads and impacts during use.

[0055] This utility model relates to a method for partial forging of an inlaid frog wing rail insert. First, a partial die-forged blank 1 for the inlaid frog wing rail insert is cast using a casting process. Then, a portion of the cross-section within a 50mm width from the frog throat to the center rail of the inlaid frog wing rail insert partial die-forged blank 1 is partially die-forged. After partial die-forging, the blank is subjected to water quenching at 1000-1100℃ to obtain a machined blank 2 for the inlaid frog wing rail insert.

[0056] This utility model relates to a method for partial forging of an inlaid frog wing rail insert, which includes the following steps:

[0057] (like Figure 3 (As shown) Step 1: Determine the local forging zone 2-1 of the machined blank 2 for the inlaid frog wing rail insert: Divide the machined blank 2 for the inlaid frog wing rail insert into three areas along the longitudinal direction, namely the local forging zone I2-1, the transition zone I2-2, and the non-forging zone I2-3; the local forging zone I2-1 is located within a 50mm section from the frog throat to the center rail; the transition zone I2-2 is provided on both sides of the local forging zone I2-1, and the local forging zone I2-1 is connected to the non-forging zone I2-3 through the transition zone I2-2.

[0058] (like Figure 5(As shown) Step 2: Design the shape and dimensions of the machined blank 2 for the inlaid frog wing rail insert 2 and the local forging zone I2-1: Design the shape and dimensions of the machined blank 2 for the inlaid frog wing rail insert 2 according to the shape and dimensions of the finished product and reserve machining allowance. The machining allowance of the machined blank 2 for the inlaid frog wing rail insert 2 is 6-8mm. The two sides of the local forging zone I2-1 have different draft angles. The draft angle of the side of the local forging zone I2-1 with the step is 3°, and the draft angle of the side of the local forging zone I2-1 without the step is 1°. The parting surface height is not higher than the step height.

[0059] (like Figure 3 (As shown) Step 3: Design the shape and dimensions of the transition zone I2-2 of the machined blank 2 for the inlaid frog wing rail insert: The transition zone I2-2 smoothly connects the local forging zone I2-1 and the non-forging zone I2-3 into one unit. The length of the transition zone I2-2 is 0.25 to 1.5 times the height of the machined blank 2 for the inlaid frog wing rail insert.

[0060] Step 4: Design the shape and dimensions of the non-forged zone I2-3 of the machined blank 2 for the inlaid fork rail insert: The non-forged zone I2-3 does not require forging. Based on the shape and size of the finished product and combined with the sand casting process, the machining allowance of each part of the non-forged zone I2-3 is determined to be 6-8mm.

[0061] In this step, the non-forging zone I2-3 does not require forging, which directly reduces the use of forging processes and related equipment, thereby lowering production costs. Based on the finished product shape and dimensions, and combined with sand casting technology, the machining allowances for each part of the non-forging zone I2-3 are precisely determined, avoiding unnecessary material waste and improving material utilization efficiency. Eliminating the forging step in the non-forging zone I2-3 simplifies the production process, reduces the production cycle, and improves overall production efficiency. Although sand casting is not as effective as forging in refining grains and improving material properties, it can meet the basic strength and dimensional requirements for the non-forging zone, while avoiding internal defects that may occur during forging, such as cracks and shrinkage cavities. By precisely controlling the machining allowance of each part of the non-forging zone I2-3 to 6–8 mm, it ensures that excess material can be smoothly removed in subsequent processing, achieving the expected finished product dimensions and shape accuracy.

[0062] (like Figure 7 (As shown) Step 5: Design the shape and dimensions of the local forging area II1-1 of the inlaid frog wing rail insert 1: The height of the local forging area II1-1 is 40-80mm higher than the upper end face of the corresponding position of the machined blank 2 of the inlaid frog wing rail insert. The height is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local forging area II1-1 is not less than 0.5. The top of the local forging area II1-1 is a rounded corner tangent to both sides, and the radius of the rounded corner is 8-10mm.

[0063] (like Figure 7 (As shown) Step 6: Design the shape and dimensions of the non-forged area II1-3 of the local die-forged blank 1 of the inlaid frog wing rail insert: The shape and dimensions of the non-forged area II1-3 are consistent with the shape and dimensions of the non-forged area I2-3 of the machined blank 2 of the inlaid frog wing rail insert.

[0064] (like Figure 6 (As shown) Step 7: Design the shape and dimensions of the transition zone II1-2 of the local die-forged blank 1 of the inlaid frog wing rail insert: The transition zone II1-2 smoothly connects the local die-forged zone II1-1 and the non-forged zone II1-3 of the local die-forged blank 1 of the inlaid frog wing rail insert into one piece. The length and shape of the transition zone II1-2 are consistent with the shape and length dimensions of the transition zone I2-2 of the machined blank 2 of the inlaid frog wing rail insert.

[0065] Step 8: According to the shape and size of the designed inlaid frog wing rail insert partial die forging blank 1, prepare the inlaid frog wing rail insert partial die forging blank 1 by casting process.

[0066] In this step, the casting process can precisely manufacture billets according to the designed shape and size, ensuring that the dimensions and shapes of the local forging zone II1-1, transition zone II1-2, and non-forging zone II1-3 meet the design requirements, thus improving product precision and consistency. Precise casting reduces the workload of subsequent machining, lowers processing costs and time, and improves production efficiency. During the casting process, reasonable pouring and heat treatment processes can make the material structure denser, reduce internal defects, and improve the material's strength and toughness. The cast billets have more uniform material properties, which is beneficial for maintaining and utilizing material properties during subsequent forging and machining. The casting process has strong adaptability and can be adjusted and optimized according to different design requirements and material characteristics to meet the preparation needs of locally forged billets for turnout wing rail inserts of various complex shapes and sizes. Precise casting can reduce material waste and improve material utilization. Precise casting can ensure a smooth transition in the transition zone, reduce stress concentration, and improve the product's fatigue resistance and durability.

[0067] Step 9: Partially forge the prepared inlaid frog wing rail insert blank 1, and then water toughen it at 1000-1100℃ to finally obtain the machined blank 2 of the inlaid frog wing rail insert.

[0068] As can be seen from the above description, this utility model can produce machined blanks of inlaid frog wing rail inserts that meet the requirements, which can effectively reduce the amount of subsequent machining, shorten the manufacturing cycle, and reduce costs.

[0069] Due to the presence of localized die forging, the key parts of this invention have sufficient deformation, thereby ensuring that the insert has good service performance. This method is applicable to the manufacturing of inlaid frog wing rail inserts and has high practical value and application prospects.

[0070] This invention is designed to ensure that the key parts of the wing rail insert have sufficient deformation capacity, while also ensuring that the wing rail insert has good service performance, thereby improving the service life and safety performance of the finished insert.

[0071] It should be understood that although this specification describes one embodiment, it does not mean that the embodiment contains only one independent technical solution. This way of describing the specification is only for 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 embodiments that can be understood by those skilled in the art.

[0072] The above preferred embodiments are not intended to limit the scope of this utility model. Therefore, all equivalent changes made to the content described in the claims of this utility model should be included within the scope of the claims of this utility model. It should be noted that, unless otherwise specified, the components and materials used in the above embodiments are commercially available.

Claims

1. An inlaid frog wing rail insert, characterized in that: The insert is made from a blank; the blank includes a partially forged blank (1) for the inlaid frog wing rail insert and a machined blank (2) for the inlaid frog wing rail insert; the partially forged blank (1) for the inlaid frog wing rail insert is cast by a casting process; the machined blank (2) for the inlaid frog wing rail insert is made by partially forging the area within a 50mm section from the frog throat to the center rail of the partially forged blank (1) and then water-toughening treatment at 1000-1100℃; the inlaid frog wing rail insert is made by machining the machined blank (2) for the inlaid frog wing rail insert after removing the excess material.

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

3. The inlaid frog wing rail insert according to claim 1 or 2, characterized in that: The machining allowance of the machined blank (2) for the inlaid frog wing rail insert is 6-8 mm.

4. The inlaid frog wing rail insert according to claim 2, characterized in that: The two sides of the local forging zone I (2-1) have different draft angles. The draft angle of the side of the local forging zone I (2-1) with the step is 3°, and the draft angle of the side of the local forging zone I (2-1) without the step is 1°. The parting surface height is not higher than the step height.

5. The inlaid frog wing rail insert according to claim 2, 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 inlaid frog wing rail insert.

6. The inlaid frog wing rail insert according to claim 1, characterized in that: The inlaid frog wing rail insert partially forged blank (1) is divided into three regions along the longitudinal direction, including partially forged region II (1-1), transition region II (1-2) and non-forged region II (1-3); the partially forged region II (1-1) is located within a 50mm width section from the frog throat to the center rail; the partially forged region II (1-1) is provided with transition regions II (1-2) on both sides, and the partially forged region II (1-1) is smoothly connected to the non-forged region II (1-3) through the transition regions II (1-2).

7. The inlaid frog wing rail insert according to claim 6, characterized in that: The height of the local forging zone II (1-1) of the inlaid frog wing rail insert (1) is 40-80mm higher than the upper end face of the corresponding position of the machined blank (2) of the inlaid frog wing rail insert. The height difference is used to ensure that the cumulative plastic equivalent strain of the rail top part of the local forging zone II (1-1) is not less than 0.

5. The top of the local forging zone II (1-1) is a rounded corner tangent to both sides, and the radius of the rounded corner is 8-10mm.

8. The inlaid frog wing rail insert according to claim 6, characterized in that: The shape of the non-forged area II (1-3) of the partially forged blank (1) of the inlaid frog wing rail insert is consistent with the shape and size of the non-forged area I (2-3) of the machined blank (2) of the inlaid frog wing rail insert.

9. The inlaid frog wing rail insert according to claim 6, characterized in that: The shape and length of the transition zone II (1-2) of the partially forged blank (1) of the inlaid 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 inlaid frog wing rail insert.

10. The inlaid frog wing rail insert according to claim 6, characterized in that: The cross section of the inlaid frog wing rail insert partial die forging blank (1) is designed in three sections from top to bottom; the three sections of the inlaid frog wing rail insert partial die forging blank (1) are respectively the large deformation zone (3), the small deformation zone (4) and the non-deformation zone (5).

11. The inlaid frog wing rail insert according to claim 10, characterized in that: The large deformation zone (3) is approximately an isosceles triangle; the small deformation zone (4) is approximately an isosceles trapezoid; and the non-deformable zone (5) has the same shape as the corresponding part of the bottom of the machined blank (2) of the inlaid frog wing rail insert.

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