CN108804816B - Anti-side-rolling torsion bar shaft upsetting process simulation analysis method for railway vehicle - Google Patents
Anti-side-rolling torsion bar shaft upsetting process simulation analysis method for railway vehicle Download PDFInfo
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Abstract
The invention discloses a simulation analysis method for an upsetting process of an anti-rolling torsion bar shaft for a railway vehicle, which comprises the following implementation steps of: decomposing the upsetting process into three processes of bar heating, upsetting forming and integral cooling in sequence and obtaining a process file, and obtaining size parameters and material marks related to the three processes; establishing a geometric model of the bar, the heating mold, the ejector rod, the heading, the female mold and the fixed mold, and assembling the bar, the heating mold, the female mold and the fixed mold according to parameters in a process file; and respectively simulating three processes of bar heating, upsetting and forming and integral cooling in a forming process simulation analysis software, and judging the rationality after the requirements are met to obtain a final process parameter scheme. The invention replaces the prior empirical design method with a simulation analysis method, and can solve the problems of more trial-manufacture times, long production period and high manufacturing cost of the prior upsetting process.
Description
Technical Field
The invention relates to an upsetting forming production technology of an anti-side-rolling torsion bar shaft for a railway vehicle, in particular to a simulation analysis method of an upsetting process of the anti-side-rolling torsion bar shaft for the railway vehicle.
Background
The application of the air spring greatly improves the vertical vibration performance of the train, but reduces the side roll angle rigidity of the train body. In order to improve the anti-rolling performance of the vehicle, an anti-rolling torsion bar device is widely used. The anti-rolling torsion bar shaft is characterized in that the diameter of the end part of the shaft far exceeds the diameter of the middle section, the structure is realized by an end part upsetting process (a forming process for increasing the diameter of a workpiece by axial extrusion deformation of a die), and the specific process comprises the following steps: and heating the end part of the bar stock through an intermediate frequency furnace, moving the bar stock to upsetting equipment, and placing the heated end part of the bar stock in the cavity of the concave model and positioning. And under the action of a press, the heading axially extrudes the bar until the bar completely fills the whole die cavity, then the die is unloaded, and the bar is placed in a fixed die and cooled to room temperature in the air.
The upsetting process needs to ensure that the upsetting part of the torsion bar shaft meets the size requirement, the defect of underfilling cannot exist, and the streamline distribution is regular; the main parameters of the upsetting process include heating temperature, die size, bar size, equipment load, etc. At present, the research of the torque rod shaft upsetting process is mainly based on an empirical analysis method, a large amount of trial production is carried out on products, the batch production can be carried out after all small batches are qualified, the defects of difficulty in finding defect formation mechanisms, difficulty in controlling trial production times, long setting period of batch production, high trial production test cost and the like exist, the control of the product development period and the development cost is not facilitated, the rapid market promotion of products is not facilitated, and the market competitiveness of the products is influenced by great importance.
Disclosure of Invention
The technical problems to be solved by the invention are as follows: aiming at the problems in the prior art, the method for simulating and analyzing the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle is provided, the existing empirical design method is replaced by the simulating and analyzing method, and the problems that the upsetting process is large in trial-manufacture times, long in production period and high in manufacturing cost can be solved.
In order to solve the technical problems, the invention adopts the technical scheme that:
a simulation analysis method for an upsetting process of an anti-rolling torsion bar shaft for a railway vehicle is characterized by comprising the following implementation steps:
1) the upsetting process is sequentially decomposed into three processes of bar heating, upsetting forming and integral cooling, process files of the three processes are obtained, and size parameters and material marks of a bar, a heating die, a mandril, an upsetting head, a female die and a fixed die related to the three processes are obtained according to the process files;
2) establishing a geometric model of the bar, the heating mold, the ejector rod, the heading, the female mold and the fixed mold, and assembling the bar, the heating mold, the female mold and the fixed mold according to parameters in a process file;
3) newly building a bar heating procedure in molding process simulation analysis software, importing the assembled bar and a geometric model of a heating mould, setting a heating mode, dividing grids, defining streamline and material attributes for the bar, building a bar heating simulation model, and setting process parameters of the bar heating procedure to simulate the bar heating procedure;
4) reading the temperature distribution of the bar during simulation of the bar heating procedure and judging whether the temperature distribution is consistent with the process temperature, if so, deriving a simulation result of the bar heating procedure, and skipping to execute the step 5); otherwise, modifying at least one technological parameter of a bar heating procedure, wherein the technological parameters of the bar heating procedure comprise heating time, heating range, heating temperature control and a heating area, and skipping to execute the step 4);
5) newly building an upsetting forming procedure in forming process simulation analysis software, introducing a geometric model of an assembled ejector rod, an upsetting head and a female die, introducing a geometric model of a bar stock in a heating procedure as a workpiece, setting the equipment motion driving type of the upsetting head as a hydraulic machine, stopping when a specified stroke is reached, adopting a grid simulated by the heating procedure in the last step for the workpiece, defining material properties of the female die and the workpiece, and building an upsetting forming procedure simulation model;
6) performing upsetting forming process simulation, and acquiring various internal characteristics and external characteristics of the workpiece and the female die and the change condition of equipment load along with the stroke of the upset head in the forming process simulated by the upsetting process, wherein the internal characteristics comprise stress strain and a metal streamline, and the external characteristics comprise deformation and temperature; judging whether the metal flow line is disordered or the workpiece is not filled in the female die or the female die is cracked in the forming process simulated by the upsetting procedure, if any problem occurs, modifying the technological parameters of the upsetting procedure, wherein the technological parameters of the upsetting procedure comprise a die cavity, an upsetting head stroke and the diameter of a bar stock, if only one or all of the die cavity and the upsetting head stroke is modified, skipping to execute the step 6), and if the diameter of the bar stock is modified, skipping to execute the step 2); otherwise, deriving the simulation result of the upsetting procedure simulation, and skipping to execute the step 7);
7) newly building an integral cooling procedure in the modeling process simulation analysis software, leading out a torsion bar shaft of the upsetting shaping procedure, leading in a geometric model of a fixed die, setting the unformed ends of the fixed die and the torsion bar shaft as Glue, dividing a grid for the torsion bar shaft, defining material attributes, and building an integral cooling process simulation model;
8) setting technological parameters of an integral cooling process, simulating the integral cooling process, reading the size of the cooled torsion bar shaft, judging whether the size of the cooled torsion bar shaft meets the design requirement, and correcting the technological parameters of the integral cooling process if the size of the cooled torsion bar shaft does not meet the design requirement, wherein the technological parameters of the integral cooling process comprise a cooling tool structure, an air cooling rate and a bar diameter, the technological parameters of the integral cooling process corrected when the size deviation exceeds a preset threshold value comprise the correction of the bar diameter, and the step 2 is skipped to be executed after the technological parameters of the integral cooling process are corrected; when the size deviation does not exceed the preset threshold, the corrected technological parameters of the integral cooling process comprise one or all of a cooling tool structure and an air cooling rate, and after the technological parameters of the integral cooling process are corrected, the step 8) is executed; if the design requirements are met, deriving a simulation result of the whole cooling process, and skipping to execute the step 8);
9) and judging the actual reasonability of the simulation results of the three processes of bar heating, upsetting forming and integral cooling, if the actual reasonability exists, keeping the current technological parameter schemes of the three processes of bar heating, upsetting forming and integral cooling, and if the actual reasonability exists, discarding the current technological parameter schemes of the three processes of bar heating, upsetting forming and integral cooling.
Preferably, the step 8) further includes a step of adding the current process parameter scheme to the process parameter scheme set, and the specific steps include:
s1) adding the current technological parameter scheme and the simulation results of the three procedures of bar heating, upsetting and forming and integral cooling into the technological parameter scheme set;
s2), judging whether the number of the technological parameter schemes in the technological parameter scheme set reaches a preset threshold value, and if so, skipping to execute the step S3); otherwise, skipping to execute the step 2) to continuously obtain a new current process parameter scheme and simulation results of three processes of bar heating, upsetting forming and integral cooling;
s3) aiming at the technological parameter scheme with the centralized technological parameter scheme, comprehensively evaluating stress strain at the end part of the torsion bar shaft, metal flow lines, geometric dimension, die stress and equipment load in the simulation results of the three processes of bar heating, upsetting forming and integral cooling, and carrying out comparative analysis, thereby selecting the optimal technological parameter scheme as the final optimized technological parameter scheme for output.
Preferably, the heating mode set in step 3) is a short-distance heat radiation mode.
Preferably, the type of the mesh used in the mesh division in step 3) is Overlay Hex.
The method for simulating and analyzing the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle realizes the simulation and reproduction of the whole process of the upsetting process of the anti-rolling torsion bar, and reproduces the change conditions of various internal characteristics (such as stress strain, metal flow line and the like) and external characteristics (such as deformation of a rod head) of the torsion bar shaft, mold stress, equipment load and the like in the upsetting process. Compared with the prior art, the method for carrying out simulation analysis on the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle has the advantages that:
1. the simulation reappearance of the whole process of the upsetting process of the anti-side rolling torsion bar is realized. And various internal characteristics (such as stress strain, metal flow line and the like) and external characteristics (such as rod head deformation) of the torsion bar shaft and the change conditions of die stress, equipment load and the like are reproduced in the upsetting process, and the defect forming mechanism in the upsetting process is intuitively analyzed.
2. The invention can adjust different technological parameter schemes based on the model, comprehensively evaluate and contrastively analyze stress strain at the end part of the torsion bar shaft, metal streamline, geometric dimension, die stress and equipment load, and realize the optimal design of technological parameters.
3. The invention can effectively reduce the trial-production times of the process, shorten the trial-production period, reduce the process cost and improve the trial-production efficiency of the product process.
4. The invention can provide support for the selection of the upsetting process equipment.
5. The invention can provide support for the design of the upsetting process die and the selection of materials.
Drawings
FIG. 1 is a schematic diagram of a basic flow of a method according to an embodiment of the present invention.
Detailed Description
As shown in fig. 1, the implementation steps of the method for performing the upsetting process simulation analysis on the anti-rolling torsion bar shaft for the railway vehicle in the embodiment include:
1) decomposing an upsetting process into three processes of bar Heating (Heating), upsetting forming (forming) and integral Cooling (Cooling) in sequence and obtaining process files of the three processes, and obtaining size parameters and material marks of a bar, a Heating die, an ejector rod, an upset head, a concave die and a fixed die related to the three processes according to the process files;
2) establishing a geometric model of the bar, the heating mold, the ejector rod, the heading, the female mold and the fixed mold, and assembling the bar, the heating mold, the female mold and the fixed mold according to parameters in a process file;
3) newly building a bar heating procedure in molding process simulation analysis software, importing the assembled bar and a geometric model of a heating mould, setting a heating mode, dividing grids, defining streamline and material attributes for the bar, building a bar heating simulation model, and setting process parameters of the bar heating procedure to simulate the bar heating procedure; in the embodiment, the heating mode set in the step 3) is a short-distance heat radiation mode; the type of the adopted grid when the grid is divided in the step 3) is Overlay Hex;
4) reading the temperature distribution of the bar during simulation of the bar heating procedure and judging whether the temperature distribution is consistent with the process temperature, if so, deriving a simulation result of the bar heating procedure, and skipping to execute the step 5); otherwise, modifying at least one technological parameter of a bar heating procedure, wherein the technological parameters of the bar heating procedure comprise heating time, heating range, heating temperature control and a heating area, and skipping to execute the step 4);
5) newly building an upsetting forming procedure in forming process simulation analysis software, introducing a geometric model of an assembled ejector rod, an upsetting head and a female die, introducing a geometric model of a bar stock in a heating procedure as a workpiece, setting the equipment motion driving type of the upsetting head as a hydraulic machine, stopping when a specified stroke is reached, adopting a grid simulated by the heating procedure in the last step for the workpiece, defining material properties of the female die and the workpiece, and building an upsetting forming procedure simulation model; in this embodiment, the molding process simulation analysis software specifically adopts simulact software;
6) performing upsetting forming process simulation, and acquiring various internal characteristics and external characteristics of the workpiece and the female die and the change condition of equipment load along with the stroke of the upset head in the forming process simulated by the upsetting process, wherein the internal characteristics comprise stress strain and a metal streamline, and the external characteristics comprise deformation and temperature; judging whether the metal flow line is disordered or the workpiece is not filled in the female die or the female die is cracked in the forming process simulated by the upsetting procedure, if any problem occurs, modifying the technological parameters of the upsetting procedure, wherein the technological parameters of the upsetting procedure comprise a die cavity, an upsetting head stroke and the diameter of a bar stock, if only one or all of the die cavity and the upsetting head stroke is modified, skipping to execute the step 6), and if the diameter of the bar stock is modified, skipping to execute the step 2); otherwise, deriving the simulation result of the upsetting procedure simulation, and skipping to execute the step 7);
7) newly building an integral cooling procedure in the modeling process simulation analysis software, leading out a torsion bar shaft of the upsetting shaping procedure, leading in a geometric model of a fixed die, setting the unformed ends of the fixed die and the torsion bar shaft as Glue, dividing a grid for the torsion bar shaft, defining material attributes, and building an integral cooling process simulation model;
8) setting technological parameters of an integral cooling process, simulating the integral cooling process, reading the size of the cooled torsion bar shaft, judging whether the size of the cooled torsion bar shaft meets the design requirement, and correcting the technological parameters of the integral cooling process if the size of the cooled torsion bar shaft does not meet the design requirement, wherein the technological parameters of the integral cooling process comprise a cooling tool structure, an air cooling rate and a bar diameter, the technological parameters of the integral cooling process corrected when the size deviation exceeds a preset threshold value comprise the correction of the bar diameter, and the step 2 is skipped to be executed after the technological parameters of the integral cooling process are corrected; when the size deviation does not exceed the preset threshold, the corrected technological parameters of the integral cooling process comprise one or all of a cooling tool structure and an air cooling rate, and after the technological parameters of the integral cooling process are corrected, the step 8) is executed; if the design requirements are met, deriving a simulation result of the whole cooling process, and skipping to execute the step 8);
9) and judging the actual reasonability of the simulation results of the three processes of bar heating, upsetting forming and integral cooling, if the actual reasonability exists, keeping the current technological parameter schemes of the three processes of bar heating, upsetting forming and integral cooling, and if the actual reasonability exists, discarding the current technological parameter schemes of the three processes of bar heating, upsetting forming and integral cooling.
In this embodiment, step 8) further includes a step of adding the current process parameter scheme to the process parameter scheme set, and the specific steps include:
s1) adding the current technological parameter scheme and the simulation results of the three processes of bar heating, upsetting and forming and integral cooling into the technological parameter scheme set;
s2) judging whether the number of the process parameter schemes in the process parameter scheme set reaches a preset threshold value, and if so, skipping to execute the step S3); otherwise, skipping to execute the step 2) to continuously obtain a new current process parameter scheme and simulation results of three processes of bar heating, upsetting forming and integral cooling;
s3) aiming at the technological parameter scheme with the centralized technological parameter scheme, comprehensively evaluating stress strain at the end part of the torsion bar shaft, metal flow lines, geometric dimension, die stress and equipment load in the simulation results of the three processes of bar heating, upsetting forming and integral cooling, and carrying out comparative analysis, thereby selecting the optimal technological parameter scheme as the final optimized technological parameter scheme for output.
Through the steps S1) to S3), iterative optimization based on the steps 1) to 9) of the method for simulating and analyzing the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle is realized, so that the optimal process parameter scheme is selected as the final optimized process parameter scheme to be output.
In summary, the anti-rolling torsion bar shaft upsetting process simulation analysis method for the railway vehicle in the embodiment realizes the simulation of the whole process of the torsion bar shaft upsetting process by means of the plastic mechanics theory and the forming process finite element simulation software. The method has the advantages that the change conditions of various internal characteristics (such as stress strain, metal flow line and the like) and external characteristics (such as rod head deformation) of the torsion bar shaft in the upsetting process are reproduced, the forming mechanism of defects in the upsetting process of the torsion bar shaft can be intuitively analyzed through the characteristics, the optimal design of process parameters is realized through the comparative analysis under different process parameters, the problems of multiple trial-manufacturing times, long production period and high manufacturing cost of the existing upsetting process can be solved, the risk of the trial-manufacturing test is effectively reduced, the period for determining the upsetting process parameters is greatly shortened, the production cost of the torsion bar shaft is greatly reduced, and the torsion bar shaft product is rapidly pushed to the market.
The above description is only a preferred embodiment of the present invention, and the scope of the present invention is not limited to the above embodiments, and all technical solutions that belong to the idea of the present invention belong to the scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.
Claims (4)
1. A simulation analysis method for an upsetting process of an anti-rolling torsion bar shaft for a railway vehicle is characterized by comprising the following implementation steps:
1) the upsetting process is sequentially decomposed into three processes of bar heating, upsetting forming and integral cooling, process files of the three processes are obtained, and size parameters and material marks of a bar, a heating die, a mandril, an upsetting head, a female die and a fixed die related to the three processes are obtained according to the process files;
2) establishing a geometric model of the bar, the heating mold, the ejector rod, the heading, the female mold and the fixed mold, and assembling the bar, the heating mold, the female mold and the fixed mold according to parameters in a process file;
3) newly building a bar heating procedure in molding process simulation analysis software, importing the assembled bar and a geometric model of a heating mould, setting a heating mode, dividing grids, defining streamline and material attributes for the bar, building a bar heating simulation model, and setting process parameters of the bar heating procedure to simulate the bar heating procedure;
4) reading the temperature distribution of the bar during simulation of the bar heating procedure and judging whether the temperature distribution is consistent with the process temperature, if so, deriving a simulation result of the bar heating procedure, and skipping to execute the step 5); otherwise, modifying at least one technological parameter of a bar heating procedure, wherein the technological parameters of the bar heating procedure comprise heating time, heating range, heating temperature control and a heating area, and skipping to execute the step 4);
5) newly building an upsetting forming procedure in forming process simulation analysis software, introducing a geometric model of an assembled ejector rod, an upsetting head and a female die, introducing a geometric model of a bar stock in a heating procedure as a workpiece, setting the equipment motion driving type of the upsetting head as a hydraulic machine, stopping when a specified stroke is reached, adopting a grid simulated by the heating procedure in the last step for the workpiece, defining material properties of the female die and the workpiece, and building an upsetting forming procedure simulation model;
6) performing upsetting forming process simulation, and acquiring various internal characteristics and external characteristics of the workpiece and the female die and the change condition of equipment load along with the stroke of the upset head in the forming process simulated by the upsetting process, wherein the internal characteristics comprise stress strain and a metal streamline, and the external characteristics comprise deformation and temperature; judging whether the metal flow line is disordered or the workpiece is not filled in the female die or the female die is cracked in the forming process simulated by the upsetting procedure, if any problem occurs, modifying the technological parameters of the upsetting procedure, wherein the technological parameters of the upsetting procedure comprise a die cavity, an upsetting head stroke and the diameter of a bar stock, if only one or all of the die cavity and the upsetting head stroke is modified, skipping to execute the step 6), and if the diameter of the bar stock is modified, skipping to execute the step 2); otherwise, deriving the simulation result of the upsetting procedure simulation, and skipping to execute the step 7);
7) newly building an integral cooling procedure in the modeling process simulation analysis software, leading out a torsion bar shaft of the upsetting shaping procedure, leading in a geometric model of a fixed die, setting the unformed ends of the fixed die and the torsion bar shaft as Glue, dividing a grid for the torsion bar shaft, defining material attributes, and building an integral cooling process simulation model;
8) setting technological parameters of an integral cooling process, simulating the integral cooling process, reading the size of the cooled torsion bar shaft, judging whether the size of the cooled torsion bar shaft meets the design requirement, and correcting the technological parameters of the integral cooling process if the size of the cooled torsion bar shaft does not meet the design requirement, wherein the technological parameters of the integral cooling process comprise a cooling tool structure, an air cooling rate and a bar diameter, the technological parameters of the integral cooling process corrected when the size deviation exceeds a preset threshold value comprise the correction of the bar diameter, and the step 2 is skipped to be executed after the technological parameters of the integral cooling process are corrected; when the size deviation does not exceed the preset threshold, the corrected technological parameters of the integral cooling process comprise one or all of a cooling tool structure and an air cooling rate, and after the technological parameters of the integral cooling process are corrected, the step 8) is executed; if the design requirements are met, deriving a simulation result of the whole cooling process, and skipping to execute the step 9);
9) and judging the actual reasonability of simulation results of the three processes of bar heating, upsetting forming and integral cooling, if the actual reasonability is realized, keeping the current technological parameter schemes of the three processes of bar heating, upsetting forming and integral cooling, and otherwise, discarding the current technological parameter schemes of the three processes of bar heating, upsetting forming and integral cooling.
2. The method for the simulated analysis of the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle as claimed in claim 1, wherein the step 9) further comprises the step of adding the current process parameter scheme into the process parameter scheme set, and the specific steps comprise:
s1) adding the current technological parameter scheme and the simulation results of the three procedures of bar heating, upsetting and forming and integral cooling into the technological parameter scheme set;
s2), judging whether the number of the technological parameter schemes in the technological parameter scheme set reaches a preset threshold value, and if so, skipping to execute the step S3); otherwise, skipping to execute the step 2) to continuously obtain a new current process parameter scheme and simulation results of three processes of bar heating, upsetting forming and integral cooling;
s3) aiming at the technological parameter scheme with the centralized technological parameter scheme, comprehensively evaluating stress strain at the end part of the torsion bar shaft, metal flow lines, geometric dimension, die stress and equipment load in the simulation results of the three processes of bar heating, upsetting forming and integral cooling, and carrying out comparative analysis, thereby selecting the optimal technological parameter scheme as the final optimized technological parameter scheme for output.
3. The method for simulating and analyzing the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle as claimed in claim 1, wherein the heating mode set in the step 3) is a short-distance heat radiation mode.
4. The method for performing the simulation analysis on the upsetting process of the anti-rolling torsion bar shaft for the railway vehicle as claimed in claim 1, wherein the type of the grid adopted in the step 3) is Overlay Hex.
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