The hollow axle is the key basic component of high-speed trains. How to realize its production with short process and high-quality precision plastic forming is the frontier of current research and a major problem to be solved. On the basis of analyzing the advantages and disadvantages of the existing forging process of the hollow axle, this paper expounds the principles and characteristics of multi-wedge synchrostep cross-wedge rolling (MSCWR) technology, multi-roll cross-wedge rolling (MCWR) technology, three-roll skew rolling (TRSR) technology, and tandem flexible skew rolling (TFSR) technology in detail, and discusses the feasibility and key technical problems of these technologies to form the hollow axle. It is concluded that tandem flexible skew rolling (TFSR) technology has the advantages of short process, high quality, high efficiency, energy saving, and material saving, and this technology is the development direction of precision plastic forming of the hollow axle. The research results provide technical guidance and research directions for promoting global high-speed rail development.
This paper innovatively puts forward the integrated forming of shape and hole of hollow axle. For verifying the feasibility of this method, the integrated forming of hollow axle is simulated by finite element method, and the hollow axle with good forming quality is obtained. On this basis, the effects of feed angle of the disc roll on the wall thickness uniformity of the middle long shaft section are explored. In order to characterize the wall thickness uniformity of each shaft, eight longitudinal sections are taken on each long shaft section, the wall thickness variance of the longitudinal section is calculated, and then the average value of the wall thickness variance of the eight longitudinal sections is used to represent the uniformity of the long shaft section wall thickness. The simulation results show that with the increase of the feed angle of the disc roll, the wall thickness of the long shaft section becomes more uneven, but the increase of the feed angle of the disc roll will improve the rolling efficiency; This paper expounds the influence law of feed angle on the wall thickness uniformity of hollow axle with integrated forming, which provides a theoretical basis for realizing the short and accurate forming of hollow axle.
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