锻钢制动盘结构与成形工艺协同设计研究

发布时间：2018-04-30 20:12

  本文选题：制动盘 + 结构设计　； 参考：《北京交通大学》2016年硕士论文

【摘要】：制动盘是列车制动系统的重要组成部件,其服役可靠性取决于制动盘的材料、结构、成型质量及服役条件。本文基于数值模拟技术,针对选定的材料和服役条件,探讨了动车组制动盘的结构特征与设计要素对制动过程的热应力、锻造成形工艺性的影响,基于有限元模拟结果,完成了锻钢制动盘结构及其成形工艺协同设计。本文的主要研究内容及结论如下：(1) 基于ANSYS瞬态热应力分析技术和QForm锻造成形模拟技术,对我国动车组锻钢制动盘结构设计进行了深入的解读,阐明了制动盘结构设计要素,包括摩擦环厚度、散热筋形状及分布、螺栓孔数量、装配方式、整体结构及盘毂之间的连接方法等对其制动热应力和锻造成形工艺性的影响。(2)针对ZDPH材料,结合动车组制动盘的实际服役工况,完成了锻钢制动盘结构设计,该结构在满足制动过程热容量要求的基础上,同时具有防止制动盘发生翘曲变形的结构和良好的通风散热性能。(3)针对锻钢制动盘的结构特点,参照锻造工艺手册及相关标准完成了制动盘的模锻件设计及模型锻造的模具设计。(4)基于QForm锻造成形模拟技术开展锻钢制动盘的锻造成形仿真,确定了压力机型号、坯料尺寸、工艺参数等信息。研究表明,制动盘模锻最佳始锻温度为1230℃-1250℃；在上下模具预热温度为200℃,锻造设备最小吨位为8000t(J53-8000型),对应的环状坯料尺寸为(?)520mm-(?)316mm×70mm;或选用吨位为10000t的锻造设备(J53-10000型)、且对应的环状坯料尺寸满足(?)580mmD外 径(?)600mm,0306mmd内径(?)312mm,45mmh50mm时,均可获得成形质量良好的制动盘盘坯。本文取得的研究成果具有自主知识产权,对我国动车组制动盘自主研发的进程具有一定推动作用。
[Abstract]:Brake disc is an important component of train braking system. Its service reliability depends on the material, structure, forming quality and service conditions of brake disc. Based on the numerical simulation technology, this paper discusses the influence of the structural characteristics and design elements of the brake disc on the thermal stress and forging forming process of the EMU brake disc according to the selected materials and service conditions, based on the results of finite element simulation. The structure of forging steel brake disc and its forming process are designed in cooperation. The main contents and conclusions of this paper are as follows: (1) based on ANSYS transient thermal stress analysis technology and QForm forging simulation technology, the structural design of forged steel brake disc of EMU in China is deeply interpreted, and the design elements of brake disc structure are expounded. Including the thickness of friction ring, the shape and distribution of heat dissipation bars, the number of bolt holes, the assembly mode, the overall structure and the connecting method between the hub and other factors affecting the braking thermal stress and forging forming process of the friction ring, etc., for the ZDPH material, Combined with the actual service condition of the brake disc of the EMU, the structural design of the forged steel brake disc is completed. The structure meets the requirements of the heat capacity of the braking process. At the same time, it has the structure of preventing the warping deformation of the brake disc and good ventilation and heat dissipation performance. It aims at the structural characteristics of the forged steel brake disc. According to the forging technology manual and related standards, the die forging design of brake disc and die design of model forging have been completed. Based on QForm forging simulation technology, forging simulation of forging steel brake disc has been carried out, and the type of press and blank size have been determined. Process parameters and other information. The results show that the optimum starting forging temperature of brake disc die forging is 1230 鈩，

本文编号：1826039