阅读说明：本技术 一种钢铝复合列车车轮制造及装配方法 (Manufacturing and assembling method of steel-aluminum composite train wheel ) 是由 郎利辉 张万鹏 于 2021-06-29 设计创作，主要内容包括：本发明公开了一种钢铝复合列车车轮制造及装配方法：(1)切割铝合金厚板得到圆柱形坯料；(2)将铝合金坯料放置在电阻炉中进行加热保温,保温完成后立即对铝合金坯料进行第一次预变形,得到粗坯；将粗坯水冷至室温；(3)对粗坯在室温下进行第二次预变形,第二次预变形为辊轧变形；(4)对粗坯进行二次加热得到液固混合坯料；(5)将液固混合坯料导入模锻成形模具的型腔,开模得到铝合金轮芯；(6)对铝合金轮芯进行T6热处理；(7)将铝合金轮芯进行机加工；(8)将铝合金轮芯与已制备好的钢制轮箍进行装配,得到钢铝复合列车车轮；(9)对钢铝复合列车车轮进行表面处理和无损检测。本发明降低了钢铝复合列车车轮的制造成本。(The invention discloses a method for manufacturing and assembling a steel-aluminum composite train wheel, which comprises the following steps: (1) cutting an aluminum alloy thick plate to obtain a cylindrical blank; (2) placing the aluminum alloy blank in a resistance furnace for heating and heat preservation, and immediately performing primary pre-deformation on the aluminum alloy blank after heat preservation is completed to obtain a rough blank; cooling the rough blank to room temperature by water; (3) carrying out secondary pre-deformation on the rough blank at room temperature, wherein the secondary pre-deformation is rolling deformation; (4) carrying out secondary heating on the rough blank to obtain a liquid-solid mixed blank; (5) introducing the liquid-solid mixed blank into a cavity of a die forging forming die, and opening the die to obtain an aluminum alloy wheel core; (6) carrying out T6 heat treatment on the aluminum alloy wheel core; (7) machining the aluminum alloy wheel core; (8) assembling the aluminum alloy wheel core and the prepared steel wheel rim to obtain a steel-aluminum composite train wheel; (9) and carrying out surface treatment and nondestructive testing on the steel-aluminum composite train wheel. The invention reduces the manufacturing cost of the steel-aluminum composite train wheel.)

1. A manufacturing and assembling method of a steel-aluminum composite train wheel is characterized by comprising the following steps: the steel-aluminum composite train wheel comprises a steel wheel rim and an aluminum alloy wheel core, wherein a groove is formed between the outer wall of the aluminum alloy wheel core and the steel wheel rim, and a clamping ring is fixedly arranged in the groove; the manufacturing and assembly method comprises the following steps:

(1) cutting an aluminum alloy thick plate to obtain a cylindrical blank, and removing oil stains on the surface of the cylindrical blank;

(2) placing the aluminum alloy blank in a resistance furnace for heating and heat preservation, wherein the temperature range of the heat preservation is 430-470 ℃, immediately placing the aluminum alloy blank in a pre-forging die for primary pre-deformation after the heat preservation is finished, and controlling the pre-deformation amount to be 30-50% to obtain a rough blank; cooling the rough blank to room temperature by water;

(3) carrying out secondary pre-deformation on the rough blank at room temperature, wherein the secondary pre-deformation is rolling deformation, the deformation amount is 5% -10%, and right-angle edges of the rough blank are rolled into round corners;

(4) carrying out secondary heating on the rough blank to obtain a liquid-solid mixed blank; the secondary heating is divided into three stages: in the first stage, the heating rate is 10 ℃/min, and the heat preservation range is reached: keeping the temperature at 300-330 ℃ for 0.5-1 h; in the second stage, the heating rate is 10 ℃/min, and the heat preservation range is reached: keeping the temperature at 470-500 ℃ for 0.5-1 h; in the third stage, the temperature rise rate is 5 ℃/min, and the heat preservation range is reached: the temperature is kept at 570-660 ℃ for 0.5-2 h;

(5) introducing the liquid-solid mixed blank into a cavity of a die forging forming die, solidifying and forming the liquid-solid mixed blank under pressure, wherein the forming pressure is 10-100 MPa, the pressing speed is 5-10 mm/s, and the die is opened after the pressure is maintained for 10-35 s to obtain the aluminum alloy wheel core;

(6) carrying out T6 heat treatment on the aluminum alloy wheel core, wherein the solution heat treatment temperature is 430-470 ℃, the heat preservation time is 1-4 h, and soaking the aluminum alloy wheel core in water for rapid cooling within 20s after heat preservation; the subsequent aging heat treatment temperature is 120-170 ℃, and the heat preservation time is 8-12 h;

(7) machining the aluminum alloy wheel core, and ensuring that the dimensional tolerance and the wheel axle assembly precision after machining meet the subsequent assembly requirements;

(8) assembling the aluminum alloy wheel core and the prepared steel wheel rim, and installing the snap ring in a groove between the aluminum alloy wheel core and the steel wheel rim to enable the aluminum alloy wheel core to be in interference fit with the steel wheel rim, so as to obtain the steel-aluminum composite train wheel;

(9) and carrying out surface treatment and nondestructive testing on the steel-aluminum composite train wheel.

2. The method for manufacturing and assembling a steel-aluminum composite train wheel according to claim 1, wherein the method comprises the following steps: before the liquid-solid mixed blank is introduced into the cavity of the die forging forming die in the step (5), a scale removing step is required: and removing the surface scale of the liquid-solid mixed blank during discharging through a blank transfer tool.

3. The method for manufacturing and assembling a steel-aluminum composite train wheel according to claim 2, wherein the method comprises the following steps: a mold preheating step is also required before the scale removing step: preheating the die forging forming die to 300-350 ℃.

4. The method for manufacturing and assembling a steel-aluminum composite train wheel according to claim 3, wherein the method comprises the following steps: the method also comprises a mould spraying step before the mould preheating step: before the die forging forming die is preheated, a coating is uniformly sprayed on the inner wall of a cavity of the die forging forming die, and the coating is made of a boron nitride high-temperature inert high-temperature inorganic lubricating material.

5. The method for manufacturing and assembling a steel-aluminum composite train wheel according to claim 1, wherein the method comprises the following steps: in step (6): and the rapid cooling is carried out after the solution heat treatment is finished so as to obtain a supersaturated solid solution required by aging, and the rapid cooling is carried out by adopting brine, wherein the water temperature of the brine is 80 +/-5 ℃.

6. The method for manufacturing and assembling the steel-aluminum composite train wheel according to claim 1, wherein the method for assembling the aluminum alloy wheel core and the steel wheel rim comprises the following steps: and carrying out liquid nitrogen precooling treatment on the aluminum alloy wheel core to realize the cold assembly of the aluminum alloy wheel core and the steel wheel band, wherein the temperature range of the precooling treatment is-110 ℃ to-60 ℃, and the time of the precooling treatment is 2h to 6 h.

7. The method for manufacturing and assembling the steel-aluminum composite train wheel according to claim 1, wherein the method for assembling the aluminum alloy wheel core and the steel wheel rim comprises the following steps: and preheating the steel wheel rim to realize the hot assembly of the steel wheel rim and the aluminum alloy wheel core, wherein the preheating temperature is 350-450 ℃, and the preheating time is 2-4 h.

8. The method for manufacturing and assembling a steel-aluminum composite train wheel according to claim 1, wherein the method comprises the following steps: the surface treatment comprises conductive oxidation treatment; the nondestructive testing comprises ultrasonic testing and X-ray testing.

Technical Field

The invention relates to the technical field of wheel manufacturing, in particular to a manufacturing and assembling method of a steel-aluminum composite train wheel.

Background

In recent years, the high-speed and heavy-load degree of railway vehicles in China is continuously improved, the requirements of people on environmental protection and safety are increasingly strict, the further improvement of the energy efficiency of the railway vehicles is particularly important, and particularly the light weight problem of a vehicle bogie system is solved. However, the research on the weight reduction of the vehicle bogie system is subject to the development of materials and safety considerations, and is at a relatively late stage, and the weight reduction technology of the vehicle body bearing structure, the interior trim and the like is saturated, and the weight reduction of the bogie system becomes a new direction to be countered, particularly the weight reduction of the wheel set which accounts for 30% to 40% of the total weight of the bogie system. Rail train wheels are an important component of rail vehicles and are a vital component of rail vehicles.

The wheel supports the weight of the entire vehicle body, and therefore, it is impossible to design the wheel with spare or protected parts, and it is important to design the wheel with absolute reliability, particularly, the strength of the wheel. In the case of taking strength as a basic guarantee, from the viewpoint of performance optimization, the wear resistance, the thermal crack resistance, and the noise/vibration resistance are also of great concern. In addition, the wheel is a wear part, so its service life and maintenance costs determine the economy of production costs. In order to improve the characteristics, related research and technical development are carried out at home and abroad at present. At present, in the high-speed railway field, the train wheels of most countries adopt the whole steel wheel that grinds, mainly includes: the method comprises the following process steps of saw cutting, billet heating, dephosphorization, preforming, forming, rolling, bending and punching, heat treatment, rough machining, finish machining, flaw detection, oil hole machining, surface treatment and the like, and the process is complex.

With the increase in the speed of trains, there is a demand for an increase in the traction power of locomotives and a demand for a reduction in the weight of trains. The application of light structural materials and the optimal design of part structures are the most effective way for lightening the bogie system and are one of the most important key technologies for developing high-speed trains. The light weight of the train wheels can meet the requirements of composite functions of weight reduction, noise reduction, vibration reduction and the like. The wheels are used as main parts of a railway vehicle bogie system, play a role in transmitting vertical force and transverse force between wheel rails and providing adhesion for vehicle operation, and have the characteristics of ultrahigh cycle fatigue, extreme impact load, low noise, high abrasion, high heat and the like, so that the wheels have higher requirements on materials. In addition to sufficient strength, toughness, and wear resistance, it is necessary to have scratch and peel resistance and low running noise. In order to reduce the weight of the wheel, the wheel diameter can be reduced, but with the reduction of the wheel diameter, the contact stress of the wheel rail is increased, the abrasion of the wheel rail is increased, and the fatigue damage of the wheel shaft and the bearing is accelerated under the condition of the same running mileage.

Patent CN207683235U proposes a split type train wheel, adopts boss inclined plane structure, including steel rim and aluminum alloy tire, and single wheel subtracts heavy 13.2%. The technical drawback of the above design is that the bolt is subjected to a large shear force in the manner of bolting. Is the concentrated point of fatigue failure occurrence in the service process. Moreover, as shown in fig. 1, the existing wheel has complicated manufacturing process, too high production cost, too high energy consumption and pollution, and is not suitable for the current concept of green development.

Disclosure of Invention

The invention aims to provide a manufacturing and assembling method of a steel-aluminum composite train wheel, which aims to solve the problems in the prior art and reduce the production cost of the wheel.

In order to achieve the purpose, the invention provides the following scheme:

the invention provides a manufacturing and assembling method of a steel-aluminum composite train wheel, wherein the steel-aluminum composite train wheel comprises a steel wheel rim and an aluminum alloy wheel core, a groove is formed between the outer wall of the aluminum alloy wheel core and the steel wheel rim, and a clamping ring is fixedly arranged in the groove; the manufacturing and assembly method comprises the following steps:

(1) cutting an aluminum alloy thick plate to obtain a cylindrical blank, and removing oil stains on the surface of the cylindrical blank;

(2) placing the aluminum alloy blank in a resistance furnace for heating and heat preservation, wherein the temperature range of the heat preservation is 430-470 ℃, immediately placing the aluminum alloy blank in a pre-forging die for primary pre-deformation after the heat preservation is finished, and controlling the pre-deformation amount to be 30-50% to obtain a rough blank; cooling the rough blank to room temperature by water;

(3) carrying out secondary pre-deformation on the rough blank at room temperature, wherein the secondary pre-deformation is rolling deformation, the deformation amount is 5% -10%, and right-angle edges of the rough blank are rolled into round corners;

(4) carrying out secondary heating on the rough blank to obtain a liquid-solid mixed blank; the secondary heating is divided into three stages: in the first stage, the heating rate is 10 ℃/min, and the heat preservation range is reached: keeping the temperature at 300-330 ℃ for 0.5-1 h; in the second stage, the heating rate is 10 ℃/min, and the heat preservation range is reached: keeping the temperature at 470-500 ℃ for 0.5-1 h; in the third stage, the temperature rise rate is 5 ℃/min, and the heat preservation range is reached: the temperature is kept at 570-660 ℃ for 0.5-2 h;

(5) introducing the liquid-solid mixed blank into a cavity of a die forging forming die, solidifying and forming the liquid-solid mixed blank under pressure, wherein the forming pressure is 10-100 MPa, the pressing speed is 5-10 mm/s, and the die is opened after the pressure is maintained for 10-35 s to obtain the aluminum alloy wheel core;

(6) carrying out T6 heat treatment on the aluminum alloy wheel core, wherein the solution heat treatment temperature is 430-470 ℃, the heat preservation time is 1-4 h, and soaking the aluminum alloy wheel core in water for rapid cooling within 20s after heat preservation; the subsequent aging heat treatment temperature is 120-170 ℃, and the heat preservation time is 8-12 h;

(7) machining the aluminum alloy wheel core, and ensuring that the dimensional tolerance and the wheel axle assembly precision after machining meet the subsequent assembly requirements;

(8) assembling the aluminum alloy wheel core and the prepared steel wheel rim, and installing the snap ring in a groove between the aluminum alloy wheel core and the steel wheel rim to enable the aluminum alloy wheel core to be in interference fit with the steel wheel rim, so as to obtain the steel-aluminum composite train wheel;

(9) and carrying out surface treatment and nondestructive testing on the steel-aluminum composite train wheel.

Preferably, before the liquid-solid mixed billet is introduced into the cavity of the die forging forming die in the step (5), a scale removing step is further performed: and removing the surface scale of the liquid-solid mixed blank during discharging through a blank transfer tool.

Preferably, a mold preheating step is further performed before the scale removing step: preheating the die forging forming die to 300-350 ℃.

Preferably, the method further comprises a die spraying step before the die preheating step: before the die forging forming die is preheated, a coating is uniformly sprayed on the inner wall of a cavity of the die forging forming die, and the coating is made of a boron nitride high-temperature inert high-temperature inorganic lubricating material.

Preferably, in step (6): and the rapid cooling is carried out after the solution heat treatment is finished so as to obtain a supersaturated solid solution required by aging, and the rapid cooling is carried out by adopting brine, wherein the water temperature of the brine is 80 +/-5 ℃.

Preferably, the assembling method of the aluminum alloy wheel core and the steel wheel rim comprises the following steps: and carrying out liquid nitrogen precooling treatment on the aluminum alloy wheel core to realize the cold assembly of the aluminum alloy wheel core and the steel wheel band, wherein the temperature range of the precooling treatment is-110 ℃ to-60 ℃, and the time of the precooling treatment is 2h to 6 h.

Preferably, the assembling method of the aluminum alloy wheel core and the steel wheel rim comprises the following steps: and preheating the steel wheel rim to realize the hot assembly of the steel wheel rim and the aluminum alloy wheel core, wherein the preheating temperature is 350-450 ℃, and the preheating time is 2-4 h.

Preferably, the surface treatment comprises a conductive oxidation treatment; the nondestructive testing comprises ultrasonic testing and X-ray testing.

Compared with the prior art, the invention has the following technical effects:

the manufacturing and assembling method of the steel-aluminum composite train wheel reduces the manufacturing cost of the steel-aluminum composite train wheel. The manufacturing and assembling method of the steel-aluminum composite train wheel comprises the steps of cutting, heating, pre-deforming and secondarily heating an aluminum alloy original blank to obtain a liquid-solid mixed deformation blank, then preparing an aluminum alloy wheel core by using a liquid-solid die forging forming technology, carrying out solid solution heat treatment and aging heat treatment after forming, obtaining the aluminum alloy wheel core meeting the assembling requirement through machining after the heat treatment is completed, and assembling the aluminum alloy wheel core and a steel wheel band together after precooling treatment in liquid nitrogen to obtain the expected steel-aluminum composite train wheel, wherein the weight of the manufactured steel-aluminum composite train wheel is reduced by more than 25% compared with that of the existing train wheel, and the application requirement of the integral performance composite train is met. The economical efficiency of the production of the wheels of the railway vehicle and the driving safety and comfort are promoted by utilizing the characteristics of high recovery rate of the aluminum alloy, simplified production process flow and the like while realizing the light weight of the vehicle.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.

FIG. 1 is a flow chart of a conventional method of manufacturing a wheel;

FIG. 2 is a schematic structural diagram of a steel-aluminum composite train wheel in the method for manufacturing and assembling the steel-aluminum composite train wheel according to the present invention;

FIG. 3 is a flow chart of a method of manufacturing and assembling a steel-aluminum composite train wheel according to the present invention;

wherein: 100. steel-aluminum composite train wheels; 1. a steel wheel band; 2. a snap ring; 3. an aluminum alloy wheel core; 4. steel-aluminum interface.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.

The invention aims to provide a manufacturing and assembling method of a steel-aluminum composite train wheel, which aims to solve the problems in the prior art and reduce the production cost of the wheel.

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.

As shown in fig. 2 to 3: the embodiment provides a manufacturing and assembling method of a steel-aluminum composite train wheel, wherein the steel-aluminum composite train wheel 100 comprises a steel wheel rim and an aluminum alloy wheel core 3, a groove is formed between the outer wall of the aluminum alloy wheel core 3 and the steel wheel rim, and a snap ring 2 is fixedly arranged in the groove.

The manufacturing and assembling method of the steel-aluminum composite train wheel comprises the following steps:

(1) cutting an aluminum alloy thick plate to obtain a cylindrical blank, and removing oil stains on the surface of the cylindrical blank;

(2) placing the aluminum alloy blank in a resistance furnace for heating and heat preservation, wherein the temperature range of the heat preservation is 430-470 ℃, immediately placing the aluminum alloy blank in a pre-forging die for primary pre-deformation after the heat preservation is finished, and controlling the pre-deformation amount to be 30-50% to obtain a rough blank; cooling the rough blank to room temperature by water;

(3) carrying out secondary pre-deformation on the rough blank at room temperature, wherein the secondary pre-deformation is rolling deformation, the deformation is 5% -10%, and right-angle edges of the rough blank are rolled into round corners;

(4) carrying out secondary heating on the rough blank to obtain a liquid-solid mixed blank; the secondary heating is divided into three stages: in the first stage, the heating rate is 10 ℃/min, and the heat preservation range is reached: keeping the temperature at 300-330 ℃ for 0.5-1 h; in the second stage, the heating rate is 10 ℃/min, and the heat preservation range is reached: keeping the temperature at 470-500 ℃ for 0.5-1 h; in the third stage, the temperature rise rate is 5 ℃/min, and the heat preservation range is reached: the temperature is kept at 570-660 ℃ for 0.5-2 h;

(5) before preheating the die forging forming die, uniformly spraying a coating on the inner wall of a cavity of the die forging forming die, wherein the coating is made of a boron nitride high-temperature inert high-temperature inorganic lubricating material; preheating a die forging forming die to 300-350 ℃; removing the surface scale of the liquid-solid mixed blank during unloading by using a blank transfer tool; introducing the liquid-solid mixed blank into a cavity of a die forging forming die, solidifying and forming the liquid-solid mixed blank under the pressure of 10-100 MPa, keeping the pressing speed of 5-10 mm/s for 10-35 s, and then opening the die to obtain an aluminum alloy wheel core 3;

(6) carrying out T6 heat treatment on the aluminum alloy wheel core 3, wherein the temperature of the solution heat treatment is 430-470 ℃, the heat preservation time is 1-4 h, and the aluminum alloy wheel core is immersed in water for rapid cooling within 20s after heat preservation, the rapid cooling is also included when the solution heat treatment is finished so as to obtain supersaturated solid solution required by aging, the rapid cooling adopts salt water for cooling, and the water temperature of the salt water is 80 +/-5 ℃; the subsequent aging heat treatment temperature is 120-170 ℃, and the heat preservation time is 8-12 h;

(7) machining the aluminum alloy wheel core 3, and ensuring that the dimensional tolerance and the wheel axle assembly precision after machining meet the subsequent assembly requirements;

(8) assembling the aluminum alloy wheel core 3 and the prepared steel wheel rim 1, namely, realizing interference fit on a bonding interface 4 between the steel wheel rim 1 and the aluminum alloy wheel core 3, and installing a clamping ring 2 in a groove between the aluminum alloy wheel core 3 and the steel wheel rim 1 to obtain the steel-aluminum composite train wheel 100, wherein the clamping ring 2 can block axial sliding between the aluminum alloy wheel core 3 and the steel wheel rim 1, so that the steel wheel rim 1 is prevented from being separated;

an interference fit method of an aluminum alloy wheel core 3 and a steel wheel band 1 comprises the following steps: the aluminum alloy wheel core 3 is subjected to liquid nitrogen precooling treatment, so that the aluminum alloy wheel core 3 and the steel wheel band 1 are subjected to cold assembly, wherein the temperature range of the precooling treatment is-110 ℃ to-60 ℃, and the time of the precooling treatment is 2h to 6 h.

The other interference fit method of the aluminum alloy wheel core 3 and the steel wheel band 1 comprises the following steps: and preheating the steel wheel rim 1 to realize the hot assembly of the steel wheel rim 1 and the aluminum alloy wheel core 3, wherein the preheating temperature is 350-450 ℃, and the preheating time is 2-4 h.

(9) Performing surface treatment and nondestructive testing on the steel-aluminum composite train wheel 100, wherein the surface treatment comprises conductive oxidation treatment; non-destructive testing includes ultrasonic testing and X-ray testing.

The steel wheel band 1 is made of CL60 steel, the aluminum alloy wheel core 3 is made of 7075 aluminum alloy, and the 7075 aluminum alloy comprises the following components in percentage by mass: zn: 5.1-6.1%, Mg:

2.1% -2.9%, Cu: 5.1% -6.1%, Zn: 5.1% -6.1%, Zn: 5.1-6.1 percent, the total amount of other impurity elements is not more than 0.15 percent, the balance is Al, the density is 2.81g/cm3, the weight of a single steel-aluminum composite train wheel 100 is 221kg, compared with the weight of 315kg of a traditional integral rolled steel wheel, the integral weight loss reaches 29.8 percent, compared with an integral all-steel wheel, the integral all-steel wheel is greatly improved, and compared with the single wheel in the published patent [ CN107984962A ], the integral weight loss is 13.2 percent, and the obvious improvement is achieved.

In the description of the present invention, it should be noted that the terms "first" and "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.

The principle and the implementation mode of the present invention are explained by applying specific examples in the present specification, and the above descriptions of the examples are only used to help understanding the method and the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.