With the rapid development of urbanization in China, many cities have begun to establish urban light rail lines to alleviate the phenomenon of traffic congestion. A domestic company and Bombardier of Canada are cooperating in research and development of faster and more efficient light rail locomotives. Bearing housing is one of the representative forgings. The projected area is large and most of the forgings are very thin. During the forging process of the bearing seat, there will be various technical problems, such as difficult forming at the ends of the head and tail and deformation of the trimming edge. It is difficult to achieve the technical requirements of low cost and high yield through conventional forging process and die design.
The steel casting bearing housing manufacturer introduced the forging process and die design, and successfully solved the difficult forging process of thin forgings.
Analysis of forging process of bearing housing
The forging has a large projection surface, a thin web, and a large change in section. The size of the forging body is 437.2mm × 248.9mm × 60mm, and the projected area is 751.20cm2. The overall shape of the forging is exactly like a "brachiosaurus", with a head length of 510mm from the spine to the tail and a thickness of only 18mm. The thickness of the feet and belly of the "Brachiosaurus" changed dramatically from 18mm to 60mm. The cross-sectional area of the head and tail ends changed from 450mm2 to 542mm2, and the maximum cross-sectional area in the middle was 11,206mm2.
During the forging process, the abdomen is thin, the projection surface is too large, and the cooling speed is too fast during the metal flow process, which makes the metal flow difficult and the cavity is not easy to fill, especially the distance between the ends of the head and tail is prone to lack of meat.
The shape of the cross section in the direction of the main axis of the bearing seat changes dramatically, which is prone to problems such as dissatisfaction, folding, and low utilization. It is necessary to reasonably select the blank specifications and design the mold structure, reasonably distribute the blanks, reduce the forming force of the forging, and improve the qualification rate and material utilization rate of the forging.
(3) Forging process.
Blanking → Medium Frequency Induction Heating → Free Forging Billet → Die Forging (Bending-Die Forging) → Hot Edge Cutting → Thermal Calibration of Hydraulic Press → Shot Peening → Heat Treatment (Normalizing) → Shot Peening → Final Inspection , Flaw detection, etc.).
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