CN109894819B - Manufacturing process of energy-absorbing steel cylinder - Google Patents
Manufacturing process of energy-absorbing steel cylinder Download PDFInfo
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Abstract
The invention relates to a manufacturing process of an energy-absorbing steel cylinder, which mainly comprises the steps of material selection, heat treatment and precision machining forming. According to the technical specification requirement of the energy absorption device of the alternating current transmission electric locomotive, the invention takes the existing hollow energy absorption steel cylinder structure as the basic steel cylinder structure, combines the material selection, the heat treatment technology and the precision machining technology, designs the heat treatment technology with different four grades and the precision machining technology with different four grades corresponding to the mechanical property difference of the selected materials, and finally achieves the purpose of meeting the technical parameters of the static pressure of the energy absorption device. The invention not only simplifies the appearance structure of the key part energy-absorbing steel cylinder of the energy-absorbing device of the electric locomotive, but also has simpler material selection and process and greatly improves the product percent of pass.
Description
Technical Field
The invention relates to the technical field of rail vehicle collision safety, in particular to a manufacturing process of an energy-absorbing steel cylinder.
Background
The energy absorption device is a high and new technology product introduced by the original Ministry of railways when German Siemens DJ1 type high-power alternating current electric power vehicles are introduced. The energy absorbing device is arranged behind the coupler buffering device of the alternating current transmission electric locomotive and is fixed in the coupler box, when the locomotive bears static pressure which is larger than the design regulation during running, the energy absorbing device generates plastic deformation, transmits impact force and compression force which are received by the locomotive during running to the underframe, absorbs impact energy through the action and deformation of the energy absorbing device, provides overload protection for the locomotive running, and ensures the safe and stable running of the locomotive. The most important component of the device is an energy-absorbing steel cylinder which can generate plastic deformation in the stress process.
The energy absorption device produced by Siemens achieves the purpose of deformation energy absorption mainly through a high-quality material technology and a complex appearance structure, and along with different impact forces, the deformation degree of the steel cylinder is different, and the energy absorption amount is also different. The energy-absorbing steel cylinder designed by Siemens meets two problems in the localization process: 1. the energy-absorbing steel cylinder has a complex appearance structure, the outer circle of the steel cylinder is provided with a rib, the mechanical processing technology has high technical requirement, the cost is huge, and processing traces can be seen; 2. the requirements on the mechanical properties of the material are particularly high, the parameter ranges of tensile strength, yield strength and elongation after fracture are narrow, and the raw material rolled by the domestic general technical standard cannot meet the technical requirements of the energy-absorbing steel cylinder on the raw material.
Manufacturing enterprises in the field also select raw materials in the national standard range produced by domestic steel mills to process and produce the energy-absorbing steel cylinder, but a large number of test results show that the energy-absorbing steel cylinder which is mechanically processed by domestic steel cannot meet the requirement of qualified batch of the static pressure value of the energy-absorbing device, and the energy-absorbing steel cylinder which occasionally meets the requirement in numerous tests has the test qualification rate of less than 10 percent and cannot be put into batch production. Therefore, the energy absorption device is dependent on import at the first stage, and step-off is given by reducing the technical quality standard of the locomotive.
Disclosure of Invention
The invention aims to improve and innovate the defects and problems in the background art and provides a manufacturing process of an energy-absorbing steel cylinder.
The invention mainly comprises material selection, heat treatment and precision processing molding, and specifically comprises the following steps:
1. selecting materials: a steel billet having the following chemical composition was selected as a raw material.
2. Rolling the raw materials into a steel pipe, detecting the mechanical property of the steel pipe material, and entering the next procedure according with the following requirements.
| Tensile strength (N/mm)2) | Yield strength (N/mm)2) | Elongation after Break (%) |
| 490～650 | 310～450 | Greater than 16 |
3. And (4) performing heat treatment on the semi-finished steel cylinder after rough machining.
4. And (5) detecting the mechanical property, wherein the mechanical property of the steel cylinder after heat treatment meets the following mechanical parameter range, and entering the next procedure.
| Tensile strength (N/mm)2) | Yield strength (N/mm)2) | Elongation after Break (%) |
| 460～550 | 270～360 | Greater than 30 |
5. And (5) performing precision machining and forming.
Designing a hollow basic steel cylinder according to the structure of the energy-absorbing steel cylinder, and then finely adjusting the size of an inner circular hole of the basic steel cylinder to form the energy-absorbing steel cylinder product process design, wherein d0 represents the diameters of different positions of the inner hole of the basic steel cylinder.
And (4) carrying out numerical control programming and processing according to the steel cylinder product process after the size of the inner hole is adjusted, and obtaining the deformed energy-absorbing steel cylinder after the finished product is inspected to be qualified, and warehousing the deformed energy-absorbing steel cylinder for later use.
In one embodiment, the base steel cylinder is an integrally formed hollow cylinder body and comprises a cylinder body, an upper connecting end and a lower connecting end, wherein the upper connecting end and the lower connecting end are respectively positioned at two ends of the cylinder body, the upper connecting end is in a horn mouth shape which is horizontally unfolded outwards, and the wall thickness of the lower connecting end is greater than that of the cylinder body and the upper connecting end. The upper connecting end of the scheme is a stressed front end, and the lower connecting end is a stressed rear end, so that the structural design can further ensure that the stress is uniformly deformed from front to back step by step.
The invention has the advantages and beneficial effects that:
according to the technical specification requirement of the energy absorption device of the alternating current transmission electric locomotive, the invention takes the existing hollow energy absorption steel cylinder structure as the basic steel cylinder structure, combines the material selection, the heat treatment technology and the precision machining technology, designs the heat treatment technology with different four grades and the precision machining technology with different four grades corresponding to the mechanical property difference of the selected materials, and finally achieves the purpose of meeting the technical parameters of the static pressure of the energy absorption device. The invention not only simplifies the appearance structure of the key part energy-absorbing steel cylinder of the energy-absorbing device of the electric locomotive, but also has simpler material selection and process and greatly improves the product percent of pass.
The method specifically comprises the following technical and economic effects:
1. the requirements on the energy absorption steel cylinder material are relaxed, the raw material can be selected within the range of national universal standard, and then the corresponding heat treatment technology and precision machining technology are adopted to meet the final requirements.
2. The energy-absorbing steel cylinder has a simplified appearance structure, and the batch processing efficiency is improved by more than 60%.
3. The cost is greatly reduced, and the energy absorption device with the same technical effect is imported into Siemens products and is about 12000 yuan in terms of RMB single piece; selecting a product manufactured by Siemens approximate materials and processes, wherein the manufacturing cost of a single piece is more than 8000 yuan; according to the energy absorption device manufactured by the patent technology, the manufacturing cost of a single piece is within 3000 yuan.
Drawings
FIG. 1 is a schematic structural view of an energy absorbing steel cylinder of the present invention.
Fig. 2 is an enlarged view of fig. 1I.
FIG. 3 is a schematic view of an energy absorber according to the present invention.
FIG. 4 is a schematic top view of an energy absorber according to the present invention.
FIG. 5 is a pictorial representation of an end product of an energy absorbing device of the present invention.
FIG. 6 is a graph showing a static pressure test in accordance with example 1.
FIG. 7 is a second graph of the static pressure test of the embodiment 1.
FIG. 8 is a graph of the full pressure test of example 1.
FIG. 9 is a state diagram after a full compression test of an energy absorber of the present invention.
FIG. 10 is a graph of the static pressure test of example 2.
FIG. 11 is a second graph of the static pressure test of example 2.
FIG. 12 is a graph of the static pressure test of example 3.
FIG. 13 is a second graph of the hydrostatic test of example 3.
Detailed Description
To facilitate an understanding of the invention, the invention will now be described more fully with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
It will be understood that when an element is referred to as being "disposed" or "connected" to another element, it can be directly disposed or connected to the other element or intervening elements may also be present.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
Example 1:
firstly, material processing.
1. A batch of steel billets are selected as raw materials, and the steel billets are rolled into steel pipe workpieces. The steel billet can be specially selected in a steel billet warehouse of a universal standard of a steel mill, and the independent furnace opening smelting is not needed. The German Siemens energy absorption steel cylinder raw material needs to be independently smelted due to special requirements. The selected material is detected by the detection center in a physicochemical way, and the chemical components and the mechanical properties of the selected material are as follows:
2. selecting a corresponding heat treatment process according to the detected tensile strength of the material, wherein the specific process comprises the following steps:
the heat treatment of the steel cylinder is to obtain the mechanical property meeting the technical specification requirement of the final product and eliminate the circumferential property segregation of the steel cylinder.
3. After the heat treatment is finished, the test bar is sent to a material inspection center for detection, and the mechanical properties are as follows:
and secondly, producing the energy-absorbing steel cylinder.
1. Forming a base steel cylinder:
the design drawing of the basic steel cylinder of the hollow structure is formed according to the size of the energy-absorbing steel cylinder of the existing electric locomotive, the upper connecting end at one end of the cylinder body is designed into a horn mouth shape which is horizontally unfolded outwards, and the wall thickness of the lower connecting end at the other end is greater than that of the cylinder body and the upper connecting end. In this example, the structural dimensions of the base steel cylinder are as follows: the cylinder height is 270mm, the outer diameter of the upper connecting end is 100mm, the outer diameter of the cylinder body is 86mm, the outer diameter of the lower connecting end is 89mm, the inner diameter of the steel cylinder is 74mm, the coaxiality of the inner conical surface and the outer conical surface of the steel cylinder is phi 0.05mm, and the specific structure is shown in figures 1 and 2.
2. Adjusting and finish machining the inner hole of the foundation steel cylinder to form:
according to the mechanical property detection data after heat treatment, on the basis of the basic steel cylinder, the inner hole is subjected to numerical control programming and machining forming according to the d0-0.2 (namely, according to the minus 20 threads of the reference drawing). After finishing, the method does not allow cracks, slag inclusions, looseness, shrinkage cavities and other defects to exist, and does not allow any form of repair. And coating an antirust oil layer on the outer wall of the finished energy-absorbing steel cylinder product after finish machining. And (5) obtaining the energy-absorbing steel cylinder finished product after the energy-absorbing steel cylinder is qualified through inspection, and warehousing the finished product for later use.
And thirdly, assembling an energy absorption device.
The energy absorption devices are correspondingly arranged on two groups of car body underframe car coupler boxes in a mirror image mode, namely a left deformation energy absorption device and a right deformation energy absorption device, as shown in figure 5. Each group of energy absorption devices comprises a lower supporting plate 3 and two steel cylinders 2 symmetrically arranged on the lower supporting plate 3 (the two steel cylinders are arranged on the lower supporting plate in parallel and are separated by a certain distance), and the other ends of the two steel cylinders 2 are fixedly connected with an upper supporting plate 1, as shown in fig. 3 and 4.
And fourthly, testing the energy absorption device.
1. The energy absorption device has the following technical specification requirements:
the technical parameters of the single group of energy absorption devices are given below, and the technical parameters of the left and right groups of energy absorption devices are equal to the technical parameters of the single group of energy absorption devices multiplied by 2:
a) the energy absorption device must safely bear 1500kN static pressure without plastic deformation in the bearing direction.
b) And when the static pressure is 1500-1650 kN, the energy absorption device reliably begins to deform.
c) The maximum pressure at final deformation was 1897.5 kN.
d) The minimum static energy absorption at which the maximum deformation displacement occurs is 225 kJ.
2. Static pressure test (routine test) of energy absorber:
the two groups of energy absorption devices are subjected to static pressure test on a 200-ton microcomputer control pressure testing machine, and the test results are as follows:
| numbering | Prepressure value (kN) | Displacement (mm) | |
| 1 | 1586.85 | 2.22 | Qualified |
The static compression plot is shown in fig. 6.
| Numbering | Prepressure value (kN) | Displacement (mm) | |
| 2 | 1598.42 | 2.54 | Qualified |
The static compression plot is shown in fig. 7.
3. Full compression test of energy absorber (sample test):
the energy absorption devices of each material batch need to be randomly extracted, a left group of energy absorption devices and a right group of energy absorption devices are symmetrically placed on a 400t pressure testing machine to be subjected to a full-compression folding test, the generated plastic deformation is in a regular axisymmetric folding ripple form, no fracture, drop, adhesion, abnormal bending deformation, crushing damage and the like are generated, the surface is smooth after deformation, and the test data meet the requirements of related technical specifications.
If the two groups of energy absorption devices which are randomly extracted are unqualified in the full compression test, two groups of energy absorption devices must be extracted for the second time to perform the full compression test, and the like, and when the third group of energy absorption devices is extracted to perform the full compression test and is still unqualified, all the energy absorption steel cylinders of the batch are judged to be unqualified.
The deformation energy absorption device is used for carrying out a full-compression folding test, and parameters of compression height, folding wave quantity and deformation area diameter are as follows: full compression deformation zone parameters
The sample full compression test data for this example is as follows:
the full compression curve is shown in fig. 8 and meets the technical specification requirement.
The energy absorbing device after full compression is a physical product, and is shown in figure 9.
And mounting the qualified energy absorption device on a car body underframe car coupler box. When the energy absorption element is used, the energy absorption element deforms (folds or is unstable) in the collision process, the deformation is uniform, the diameter of a deformation area does not exceed 120mm, and the crushed energy absorption element cannot be stuck to the installation space of a locomotive underframe, so that the crushed energy absorption element can be conveniently replaced, parts of the crushed energy absorption element cannot fall off, and the application safety is ensured.
Example 2:
firstly, material processing.
1. A batch of raw materials are selected, and the chemical components and the mechanical properties of the raw materials are as follows through physical and chemical detection of a material detection center:
2. selecting a corresponding heat treatment process according to the tensile strength of the material, wherein the specific process comprises the following steps:
the heat treatment of the steel cylinder is to obtain the mechanical property meeting the technical specification requirement of the final product and eliminate the circumferential property segregation of the steel cylinder.
3. After the heat treatment is finished, the test bar is sent to a new material inspection center for detection, and the mechanical properties are as follows:
and secondly, producing a deformation energy-absorbing steel cylinder.
1. Forming a base steel cylinder:
the specific structure is basically the same as that of example 1, but is omitted.
2. Adjusting and finish machining the inner hole of the foundation steel cylinder to form:
according to the mechanical property detection data after heat treatment, on the basis of the basic steel cylinder, the inner hole is subjected to numerical control programming and machining according to the d0 (namely according to the reference drawing). After finishing, the method does not allow cracks, slag inclusions, looseness, shrinkage cavities and other defects to exist, and does not allow any form of repair. And coating an antirust oil layer on the outer wall of the finished deformation energy-absorbing steel cylinder product after finish machining. And (5) obtaining a finished product of the deformation energy-absorbing steel cylinder after the steel cylinder is qualified through inspection, and warehousing the finished product for later use.
And thirdly, assembling a deformation energy absorption device.
The specific structure is basically the same as that of example 1, but is omitted.
The two groups of energy absorption devices are respectively subjected to static pressure tests on a 200-ton microcomputer control pressure testing machine, and the test results are as follows:
| numbering | Prepressure value (KN) | Displacement (mm) | |
| 1 | 1553.88 | 1.89 | Qualified |
The static compression plot is shown in fig. 10.
| Numbering | Prepressure value (KN) | Displacement (mm) | |
| 2 | 1594.04 | 2.46 | Qualified |
The static compression plot is shown in fig. 11.
Other detection methods are basically the same as the embodiment 1, the detection structures are all qualified, and the specific detection is omitted.
Example 3:
firstly, material processing.
1. A batch of raw materials are purchased, and the chemical components and the mechanical properties of the raw materials are as follows through the physical and chemical detection of a material detection center:
2. selecting a corresponding heat treatment process according to the tensile strength of the material, wherein the specific process comprises the following steps:
the heat treatment of the steel cylinder is to obtain the mechanical property meeting the technical specification requirement of the final product and eliminate the circumferential property segregation of the steel cylinder.
3. After the heat treatment is finished, the test bar is sent to a new material inspection center for detection, and the mechanical properties are as follows:
and secondly, producing a deformation energy-absorbing steel cylinder.
1. Forming a base steel cylinder:
the specific structure is basically the same as that of example 1, but is omitted.
2. Adjusting and finish machining the inner hole of the foundation steel cylinder to form:
according to the mechanical property detection data after heat treatment, on the basis of the basic steel cylinder, the inner hole is subjected to numerical control programming and machining according to the d0+0.1 (namely, according to the positive 10 wires of the reference drawing). After finishing, the method does not allow cracks, slag inclusions, looseness, shrinkage cavities and other defects to exist, and does not allow any form of repair. And coating an antirust oil layer on the outer wall of the finished deformation energy-absorbing steel cylinder product after finish machining. And (5) obtaining a finished product of the deformation energy-absorbing steel cylinder after the steel cylinder is qualified through inspection, and warehousing the finished product for later use.
And thirdly, assembling a deformation energy absorption device.
The specific structure is basically the same as that of example 1, but is omitted.
After two energy-absorbing steel cylinders are welded and assembled, a static pressure test is carried out twice after a 200-ton microcomputer control pressure tester, and the test results are as follows:
| numbering | Prepressure value (KN) | Displacement (mm) | |
| 1 | 1578.06 | 2.06 | Qualified |
The static compression plot is shown in fig. 12.
| Numbering | Prepressure value (KN) | Displacement (mm) | |
| 2 | 1564.50 | 2.42 | Qualified |
The static compression plot is shown in fig. 13.
Other detection methods are basically the same as the embodiment 1, the detection structures are all qualified, and the specific detection is omitted.
The energy-absorbing steel cylinder and the energy-absorbing device which are manufactured by the process technology are sequentially arranged on HXD1 series high-power alternating-current transmission electric locomotives manufactured by Zhongzhui electric locomotive Limited and Guangzhou electric locomotive Limited, and the self-inspection qualified rate of the energy-absorbing steel cylinder product reaches more than 95%. In the full-compression test inspection performed by the Zhongzhu Taizhou electric locomotive Co.
The embodiments of the present invention are described only for the preferred embodiments of the present invention, and not for the limitation of the concept and scope of the present invention, and various modifications and improvements made to the technical solution of the present invention by the skilled in the art without departing from the design concept of the present invention shall fall into the protection scope of the present invention, and the technical content of the present invention which is claimed is fully set forth in the claims.
Claims (2)
1. The manufacturing process of the energy-absorbing steel cylinder is characterized by mainly comprising material selection, heat treatment and precision machining forming, and comprises the following steps:
1) selecting materials: selecting a steel billet with the following chemical components as a raw material:
chemical components: 0.15-0.22% of C, 0.18-0.35% of Si, 1.1-1.5% of Mn, less than or equal to 0.035% of P and less than or equal to 0.015% of S;
2) rolling the raw materials into a steel pipe, detecting the mechanical property of the steel pipe material, and entering the next procedure according with the following requirements:
tensile strength of 490-650N/mm2Yield strength of 310 to 450N/mm2Elongation after break is greater than 16%;
3) heat treatment of semi-finished steel cylinder after rough machining:
4) and (3) detecting the mechanical property, wherein the mechanical property of the steel cylinder after heat treatment meets the following mechanical parameter range, and entering the next procedure:
tensile strength of 460-550N/mm2Yield strength of 270-360N/mm2Elongation after break is greater than 30%;
5) precision machining and forming:
designing a hollow basic steel cylinder according to the structure of the energy-absorbing steel cylinder, and then finely adjusting the size of an inner circular hole of the basic steel cylinder to form the energy-absorbing steel cylinder product design, wherein d0 represents the diameters of different positions of the inner hole of the basic steel cylinder;
and (4) carrying out numerical control programming and processing according to the steel cylinder product with the size of the inner hole adjusted, and obtaining the deformed energy-absorbing steel cylinder after the finished product is inspected to be qualified, and warehousing the deformed energy-absorbing steel cylinder for later use.
2. The manufacturing process of the energy-absorbing steel cylinder as claimed in claim 1, wherein the base steel cylinder is an integrally formed hollow cylinder body, and comprises a cylinder body, and an upper connecting end and a lower connecting end which are respectively arranged at two ends of the cylinder body, wherein the upper connecting end is in a flared shape which is horizontally unfolded outwards, and the wall thickness of the lower connecting end is greater than that of the cylinder body and the upper connecting end.
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0910153B1 (en) * | 1997-10-08 | 2002-12-18 | Siemens VDO Automotive Inc. | An end cap for an ultra quiet electric motor |
| CN201089461Y (en) * | 2007-10-15 | 2008-07-23 | 株洲九方制动设备有限公司 | Deformation unit for electric locomotives |
| CN202147649U (en) * | 2011-07-08 | 2012-02-22 | 苏州市职业大学 | Automobile collision energy absorber |
| CN102862537A (en) * | 2012-09-25 | 2013-01-09 | 浙江工业大学 | Shrinkage-type automobile energy absorption beam |
| CN202656979U (en) * | 2012-04-23 | 2013-01-09 | 中国电力科学研究院 | Thin-wall circular tube energy absorption device |
| CN106994982A (en) * | 2017-04-27 | 2017-08-01 | 西南交通大学 | A kind of pressurized type energy absorption device |
-
2019
- 2019-03-25 CN CN201910225705.6A patent/CN109894819B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0910153B1 (en) * | 1997-10-08 | 2002-12-18 | Siemens VDO Automotive Inc. | An end cap for an ultra quiet electric motor |
| CN201089461Y (en) * | 2007-10-15 | 2008-07-23 | 株洲九方制动设备有限公司 | Deformation unit for electric locomotives |
| CN202147649U (en) * | 2011-07-08 | 2012-02-22 | 苏州市职业大学 | Automobile collision energy absorber |
| CN202656979U (en) * | 2012-04-23 | 2013-01-09 | 中国电力科学研究院 | Thin-wall circular tube energy absorption device |
| CN102862537A (en) * | 2012-09-25 | 2013-01-09 | 浙江工业大学 | Shrinkage-type automobile energy absorption beam |
| CN106994982A (en) * | 2017-04-27 | 2017-08-01 | 西南交通大学 | A kind of pressurized type energy absorption device |
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Address after: Room B, building 5, power components Park, Xinma power independent innovation park, Tianyuan District, Zhuzhou City, Hunan Province 412000 Patentee after: Zhuzhou Dongrun Technology Development Co., Ltd Address before: 412000 Zhuzhou, Hunan, Shifeng Tong metal building 903 Patentee before: ZHUZHOU DONGRUN XINGDA TECHNOLOGY DEVELOPMENT Co.,Ltd. |