阅读说明：本技术 一种钢铝复合列车车轮一体化制造方法 (Integrated manufacturing 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一体化制造方法：(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)在模锻成形模具的下模型腔中放置已制备好的钢制轮箍,并通过压圈固定钢制轮箍,然后将液固混合坯料导入模锻成形模具的型腔,模锻成形得到钢铝复合一体式车轮；(6)对钢铝复合一体式车轮整体进行T6热处理；(7)进行局部压力加工；(8)对钢铝复合一体式车轮进行机加工。本发明降低了车轮的生产成本。(The invention discloses an integrated manufacturing method of 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) placing the prepared steel wheel band in a lower die cavity of a die forging forming die, fixing the steel wheel band through a pressing ring, introducing the liquid-solid mixed blank into the die cavity of the die forging forming die, and performing die forging forming to obtain the steel-aluminum composite integrated wheel; (6) carrying out T6 heat treatment on the whole steel-aluminum composite integrated wheel; (7) carrying out local pressure processing; (8) and machining the steel-aluminum composite integrated wheel. The invention reduces the production cost of the wheel.)

1. The integrated manufacturing method of the steel-aluminum composite train wheel is characterized by comprising the following steps of: the steel-aluminum composite train wheel comprises a steel wheel band and an aluminum alloy wheel core, wherein the steel wheel band and the aluminum alloy wheel core are integrally formed; the manufacturing 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) placing the prepared steel wheel band in a lower die cavity of a die forging forming die, fixing the steel wheel band through a pressing ring, then introducing the liquid-solid mixed blank into a die cavity of the 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 pressure is maintained for 10-35 s, and then opening the die to obtain the steel-aluminum composite integrated wheel;

(6) carrying out T6 heat treatment on the whole steel-aluminum composite integrated wheel, wherein the solution heat treatment temperature is 430-470 ℃, the heat preservation time is 1-4 h, and soaking the whole steel-aluminum composite integrated wheel 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) directly carrying out local pressure processing on a steel-aluminum combination part and a wheel core hole part of the steel-aluminum composite integrated wheel at a heat treatment temperature;

(8) and machining the steel-aluminum composite integrated wheel to obtain the steel-aluminum composite train wheel meeting the requirements of dimensional tolerance and axle assembly precision, and performing surface protection treatment on the steel-aluminum composite interface joint, namely performing corrosion protection on the steel-aluminum composite train wheel.

2. The integrated manufacturing method of the steel-aluminum composite train wheel according to claim 1, characterized in that: 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 integrated manufacturing method of the steel-aluminum composite train wheel according to claim 2, characterized in that: a mold preheating step is also required before the scale removing step: preheating the die forging forming die to 300-350 ℃.

4. The integrated manufacturing method of the steel-aluminum composite train wheel according to claim 3, characterized in that: 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 integrated manufacturing method of the steel-aluminum composite train wheel according to claim 1, characterized in that: in step (6): after the artificial aging heat treatment, the steel-aluminum composite integrated wheel immediately utilizes liquid forging forming equipment to perform local warm grinding processing on a steel-aluminum joint part, wherein the temperature is 120-170 ℃, and the pressure is 10-30 MPa.

6. The integrated manufacturing method of the steel-aluminum composite train wheel according to claim 5, characterized in that: 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 ℃.

7. The integrated manufacturing method of the steel-aluminum composite train wheel according to claim 1, characterized in that: and (4) after the step (8), carrying out nondestructive testing on the steel-aluminum composite train wheel.

8. The integrated manufacturing method of the steel-aluminum composite train wheel according to claim 1, characterized in that: the inner wall of the steel wheel rim is provided with an annular groove corresponding to the aluminum alloy wheel core, and the edge of the aluminum alloy wheel core is directly formed in the annular groove.

Technical Field

The invention relates to the technical field of wheels, in particular to an integrated manufacturing 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, people have increasingly strict requirements on environmental protection and safety, the further improvement of the running energy efficiency of the railway vehicles is particularly important, and the light weight of a vehicle bogie system is particularly important. However, the research on the weight reduction of the vehicle bogie system is limited by the development of the material forming technology and the consideration of safety, 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, especially 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.

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 running, and have the characteristics of ultrahigh cycle fatigue, extreme impact load, low noise, high abrasion, high heat and the like, so the wheels have high requirements on materials, and have the characteristics of enough strength, toughness and abrasion resistance, and also have the characteristics of abrasion resistance, stripping 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. Therefore, the present invention is based on the concept of replacing part of the steel structure with aluminum alloy to reduce the mass of the wheel while maintaining the wheel diameter, and therefore, it is necessary to realize the optimized design of the wheel finite element and the application of the light material in the bogie component, wherein the material must have higher strength, modulus, toughness, wear resistance, fatigue resistance, aging resistance and the like besides the requirement of light weight.

Patent CN207683235U proposes a split type train wheel, which adopts a boss inclined plane structure, and uses bolts to connect a rim and a wheel band, and the weight of a single wheel is reduced by 13.2%. The technical defect of the design is that the bolt in the bolt connection mode is subjected to larger shearing force and is a concentrated point for fatigue failure in the service process. Moreover, the traditional manufacturing process of the integrally rolled steel wheel is quite complex (refer to fig. 1), the production cost of the wheel is too high, and the energy consumption and pollution are also too high, so that the traditional integrally rolled steel wheel is not suitable for the current concept of green development.

Disclosure of Invention

The invention aims to provide an integrated manufacturing 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 an integrated manufacturing method of a steel-aluminum composite train wheel, which comprises a steel wheel band and an aluminum alloy wheel core, wherein the steel wheel band and the aluminum alloy wheel core are integrally formed; the manufacturing 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) placing the prepared steel wheel band in a lower die cavity of a die forging forming die, fixing the steel wheel band through a pressing ring, then introducing the liquid-solid mixed blank into a die cavity of the 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 pressure is maintained for 10-35 s, and then opening the die to obtain the steel-aluminum composite integrated wheel;

(6) carrying out T6 heat treatment on the whole steel-aluminum composite integrated wheel, wherein the solution heat treatment temperature is 430-470 ℃, the heat preservation time is 1-4 h, and soaking the whole steel-aluminum composite integrated wheel 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) directly carrying out local pressure processing on a steel-aluminum combination part and a wheel core hole part of the steel-aluminum composite integrated wheel at a heat treatment temperature;

(8) and machining the steel-aluminum composite integrated wheel to obtain the steel-aluminum composite train wheel meeting the requirements of dimensional tolerance and axle assembly precision, and performing surface protection treatment on the steel-aluminum composite interface joint, namely performing corrosion protection 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 also required 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): after the artificial aging heat treatment, the steel-aluminum composite integrated wheel immediately utilizes liquid forging forming equipment to perform local warm grinding processing on a steel-aluminum joint part, wherein the temperature is 120-170 ℃, and the pressure is 10-30 MPa.

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, after the step (8), nondestructive testing is carried out on the steel-aluminum composite train wheel.

Preferably, the inner wall of the steel wheel rim is provided with an annular groove corresponding to the aluminum alloy wheel core, and the edge of the aluminum alloy wheel core is directly formed in the annular groove.

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

the integrated manufacturing method of the steel-aluminum composite train wheel reduces the production cost of the steel-aluminum composite train wheel. The invention discloses an integrated manufacturing method of a steel-aluminum composite train wheel, which is characterized in that an aluminum alloy original blank is cut, heated, pre-deformed and secondarily heated to obtain a liquid-solid mixed deformation blank, then liquid-solid die forging forming is carried out, solid solution heat treatment and aging heat treatment are carried out after forming, swing-rolling local forming process is carried out at the temperature of the aging heat treatment, and finally, machining and surface treatment are carried out to obtain the steel-aluminum composite integrated wheel, so that the weight of the whole wheel manufactured by the method is reduced by more than 25%, and the application requirements of the vehicle are 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 integrated manufacturing method of the steel-aluminum composite train wheel according to the present invention;

FIG. 3 is a flow chart of the integrated manufacturing method of the steel-aluminum composite train wheel of the invention;

wherein: 100. steel-aluminum composite train wheels; 1. a steel wheel band; 2. an aluminum alloy wheel core; 3. and (6) combining the interfaces.

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 an integrated manufacturing 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 an integrated manufacturing method of a steel-aluminum composite train wheel, the steel-aluminum composite train wheel comprises a steel wheel band and an aluminum alloy wheel core, the steel wheel band and the aluminum alloy wheel core are integrally formed, an annular groove is formed in the inner wall of the steel wheel band corresponding to the aluminum alloy wheel core, and the edge of the aluminum alloy wheel core is directly formed in the annular groove.

The integrated manufacturing 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) placing the prepared steel wheel rim in a lower die cavity of a die forging forming die, and fixing the steel wheel rim through a pressing ring; uniformly spraying a coating on the inner wall of a cavity of a die forging forming die, wherein the coating is made of a boron nitride high-temperature inert high-temperature inorganic lubricating material; then preheating a die forging forming die to 300-350 ℃; then, the crucible is assisted by a mechanical arm to transfer the blank, and the surface oxide skin of the liquid-solid mixed blank is removed during unloading;

then 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 the steel-aluminum composite integrated wheel;

(6) carrying out T6 heat treatment on the whole steel-aluminum composite integrated wheel, wherein the temperature of the solution heat treatment is 430-470 ℃, the heat preservation time is 1-4 h, and immersing the whole steel-aluminum composite integrated wheel in water for rapid cooling within 20s after heat preservation; the method also comprises the steps of rapidly cooling to obtain a supersaturated solid solution required by aging after the solution heat treatment is finished, wherein the rapid cooling is carried out by adopting brine, and the water temperature of the brine is 80 +/-5 ℃;

the subsequent aging heat treatment temperature is 120-170 ℃, and the heat preservation time is 8-12 h; after the artificial aging heat treatment, the local warm grinding processing is immediately carried out on the steel-aluminum combination part of the steel-aluminum composite integrated wheel by using liquid forging forming equipment, the temperature is 120-170 ℃, and the pressure is 10-30 MPa;

(7) directly carrying out local pressure processing on a steel-aluminum combination part and a wheel core hole part of the steel-aluminum composite integrated wheel at a heat treatment temperature;

(8) the steel-aluminum composite integrated wheel is machined to obtain the steel-aluminum composite train wheel meeting the requirements of dimensional tolerance and axle assembly precision, and surface protection treatment is carried out on the steel-aluminum composite interface joint, namely corrosion protection is carried out on the steel-aluminum composite train wheel.

And then carrying out nondestructive testing on the steel-aluminum composite train wheel.

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.