非对称断面钢轨局部镦粗技术开发与应用

为解决非对称断面钢轨镦粗时的波浪变形问题,设计了局部镦粗成套装置,利用已有的锻造生产线,有效地控制了非对称断面钢轨镦粗时产生的失稳和轨肢波浪变形,减少了模具更换次数;同时,设计的镦粗测量和显示装置,可精确控制镦粗量,保证镦粗成形质量稳定。经实物验证,采用本装置及工艺,单根镦粗时间由原工艺的60 min降低至8 min,效率提高了7倍以上;镦粗钢轨一次合格率达100%,较原工艺合格率提高了3倍以上。利用已有的锻造生产线,减少了设备投入,降低了投资成本,在工艺布局上可以减少镦粗工序的生产区域,优化了车间的工艺布局。最后,通过实物验证了方案可行性,并确定了工艺参数,可用于指导实际生产。

Development and application on partial upsetting technology of asymmetrical section rail

For solving the technical problem of wave deformation for asymmetrical section rail in upsetting,a complete set of partial upsetting device was designed,and the instability and wave deformation of rail during the upsetting of asymmetrical section rails were effectively controlled by the existing forging production line. Then,the number of mold changes was reduced,and at the same time,the designed measurement and display device for upsetting amount could accurately control the upsetting amount and ensure the quality of upsetting. The physical verification shows that using this device and process,the upsetting time of single part is reduced from 60 min in the original process to 8 min,and the efficiency is increased by more than 7 times. Furthermore,the pass rate of the upsetting steel rail is 100%,which is more than three times higher than that of the original process. Therefore,using the existing forging production line,this device and process reduces equipment investment and investment cost,and the production area of upsetting process is reduced in the process layout to optimize the process layout of workshop. Finally,the feasibility of the scheme is verified and the process parameters are determined to guide the actual production.