The Influence Rules of Stress about Technical Parameters on Synchronous Rolling Railway Axis with Multi-Wedge Cross-Wedge Rolling

Shu, Xinyu; Wei, Xin Hong; Li, Chuan Min; Zheng, Huayan

doi:10.4028/www.scientific.net/amm.37-38.1482

Cited by 34 publications

(29 citation statements)

References 3 publications

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“…However, the conducted research works [8,9] showed that realization of this rolling case would require constructing a rolling machine of large dimensions (wedge diameter would be 1.6 m) and power. Hence, searching for new, effective ways of rail axles forming, which are nowadays manufactured from free forged forgings, is still up-to-date issue.…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the Skew Rolling Process for Rail Axles

Pater¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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The paper describes a new method for producing stepped rail axles. The method is based on the skew rolling process. With this method, the product is formed by three tapered rolls located every 120• on the perimeter of the billet. Positioned askew to the centerline of the billet, the rolls rotate in the same direction and with the same velocity. At the same time, they get closer together or go apart depending on the desired cross sectional reduction of an axle step. In addition, the workpiece is shifted lengthwise relative to the rolls by the translational motion of the workpiece-holding chuck. In order to verify the designed method for producing rail axles, a series of numerical simulations were performed using the Simufact.Forming v.12 simulation software. The numerical modeling enabled the determination of maps of the effective strain and temperature in the finished product as well as variations in the loads and torques during rolling. The numerical results unambiguously confirm that the skew rolling method can be applied to form parts of considerable dimensions (the modeled axles had a length of 2146 mm and their maximum diameter was 202 mm).Keywords: Skew rolling, rail axle, FEM W artykule opisano metodę wytwarzania stopniowanej osi wagonowej bazującą na procesie walcowania skośnego. W metodzie tej wyrób kształtowany jest za pomocą trzech rolek stożkowych, rozmieszczonych na obwodzie wsadu co 120• . Rolki te ustawione są skośnie względem osi wsadu, a w trakcie kształtowania obracają się z jednakową prędkością w tę sa-mą stronę oraz jednocześnie zsuwają lub rozsuwają się -w zależności od redukcji przekroju poprzecznego kształtowanego stopnia osi. Dodatkowo, wyrób kształtowany przesuwany jest wzdłużnie względem rolek, w wyniku ruchu postępowego uchwytu utwierdzającego jeden z jego końców. Sprawdzenia poprawności założonej koncepcji kształtowania osi wagonowej dokonano w drodze symulacji numerycznej wykonanej w programie Simufact.Forming v.12. W efekcie wykonanych obliczeń uzyskano mapy intensywności odkształcenia i temperatury w ukształtowanym wyrobie oraz wyznaczono przebiegi sił i momentów w trakcie walcowania. Jednoznacznie potwierdzono możliwość kształtowania wyrobów o dużych gabarytach (długość osi wynosi 2146 mm, a jej średnica maksymalna 202 mm) metodą walcowania skośnego.

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Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the Skew Rolling Process for Rail Axles

Pater¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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“…375 mm) using tools, the maximum length of which could not exceed 1250 mm (their maximum length was due to the machine design). For that reason, we decided to employ multi-wedge rolling that is also used for producing elongated parts such as stepped axes and shafts [16][17][18][19]. To this end, we designed tools with three wedges described by the same forming angles set to 25°.…”

Section: Numerical Modeling Of the Proposed Process For Forming Ballsmentioning

confidence: 99%

An innovative method for producing balls from scrap rail heads

Pater

Tomczak

Bulzak

et al. 2018

Int J Adv Manuf Technol

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The paper describes an innovative technological solution for producing balls from scrap rail heads. The proposed method consists in performing the following operations: the side pressing of a rail head to increase shape compactness, a process for forming a cylindrical rod by cross-wedge rolling (CWR), a CWR process for producing balls that have a diameter which is by 35% larger than that of the billet, quenching of the produced balls. Tools for the above manufacturing operations are designed, and numerical simulations are performed to verify whether the assumptions of the proposed technique are correct. A flat-wedge reversing mill is designed and constructed that enables performing the two abovementioned rolling operations without idle running, which makes the design innovative on a global scale. The implementation of the proposed method would enable producing balls for grinding media used in ball mills.

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“…The research and development works conducted so far have concentrated on the application of this method for producing automotive axle shafts [2,[5][6][7], stepped shafts [4,8] as well as railway axles, both solid [9] and hollow [3]. In addition to this, the method can be used for forming several short parts at one time.…”

Section: Survey Of the Research On Mwcrmentioning

confidence: 99%

Analysis of a cross wedge rolling process for producing drive shafts

Pater

Tomczak

Bulzak

2016

Int J Adv Manuf Technol

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The paper discusses the problems of forming parts such as stepped shafts by cross wedge rolling (CWR). In industrial practice, this rolling process is performed at stages, i.e., in several passes, when large cross-sectional reductions are involved. The same can also be done using a different design of this forming process, namely, multi-wedge cross rolling (MWCR), in which the workpiece is simultaneously formed by several pairs of tools (wedges). This paper compares the above two methods with respect to forming a drive shaft. Wedge tools used in both forming processes are described, and the numerical results of the simulations performed to verify the adopted solutions are reported. The results demonstrate that the MWCR method offers more advantages than the classical CWR technique. Consequently, MWCR is then verified in experimental tests. The experimental results confirm that parts such as stepped shafts can be formed by the MWCR method.

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The Influence Rules of Stress about Technical Parameters on Synchronous Rolling Railway Axis with Multi-Wedge Cross-Wedge Rolling

Cited by 34 publications

References 3 publications

Numerical Analysis of the Skew Rolling Process for Rail Axles

Numerical Analysis of the Skew Rolling Process for Rail Axles

An innovative method for producing balls from scrap rail heads

Analysis of a cross wedge rolling process for producing drive shafts

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