CN112975284A - Manufacturing method of special-shaped rail - Google Patents

Manufacturing method of special-shaped rail Download PDF

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Publication number
CN112975284A
CN112975284A CN202110193678.6A CN202110193678A CN112975284A CN 112975284 A CN112975284 A CN 112975284A CN 202110193678 A CN202110193678 A CN 202110193678A CN 112975284 A CN112975284 A CN 112975284A
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rail
shaped
transition
manufacturing
welding
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CN202110193678.6A
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Inventor
蒋荣国
张大伟
唐丽
蒋红亮
盘国壬
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China Railway Construction Heavy Industry Group Co Ltd
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China Railway Construction Heavy Industry Group Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

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  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

The invention provides a manufacturing method of a special-shaped rail, which comprises a groove-shaped rail, a transition rail and a standard I-shaped steel rail which are sequentially connected, wherein the end surface of one end of the transition rail is matched with the end surface of the standard I-shaped steel rail, and the end surface of the other end of the transition rail is matched with the end surface of the groove-shaped rail; the manufacturing method comprises the following steps: step 1, fixing a forging stock by adopting a five-axis linkage numerical control machining center and machining the forging stock into the transition rail by a numerical control profiling forming cutter; step 2, aligning and attaching end faces of two ends of the transition rail with the end faces of the groove rail and the standard I-shaped steel rail after pretreatment respectively, and then welding by using a flash welding machine; and 3, carrying out post-treatment on welding seams of the groove-shaped rail, the standard I-shaped steel rail and the transition rail after flash welding. The manufacturing method of the profiled rail overcomes the problems of die forging forming and mass manual welding of the profiled rail in the prior art.

Description

Manufacturing method of special-shaped rail
Technical Field
The invention relates to the technical field of railway turnout manufacturing, in particular to a manufacturing method of a special-shaped rail.
Background
In the domestic tramcar, 50kg/m standard I-shaped steel rails are mostly used in a station yard, and 59R2 groove-shaped rails are mostly used in a front line. At the joint of a standard I-shaped steel rail and a groove-shaped rail, two different types of steel rails with height difference are connected together in a field direct butt welding mode, and then a special-shaped fishtail reinforcing plate is welded at the staggered weak position of a rail web joint. Because the size difference of the welding face is great, can only weld under the smooth-going circumstances in assurance work limit, the other parts all produce great wrong tooth, and joint strength is low, and toughness is poor, and stress concentration effect is obvious, is unfavorable for tram operating speed's promotion. Therefore, the special-shaped rail is designed, the special-shaped rail comprises a standard I-shaped steel rail, a transition rail and a groove-shaped rail, one end face of the transition rail is matched with the end face of the standard I-shaped steel rail, the other end face of the transition rail is matched with the end face of the groove-shaped rail, the transition rail is connected to the joint of the standard I-shaped steel rail and the groove-shaped rail to realize the connection of the standard I-shaped steel rail and the groove-shaped rail, and the special-shaped rail is vital to the elimination of wrong teeth.
The existing profiled rails have differences in structure and manufacturing method. For example, the invention with the patent number CN104452486A discloses a 59R2 deformed rail and a forming method thereof, and particularly discloses that the deformed rail is a combined die for designing and manufacturing a forging movable block according to the section characteristics and requirements of two steel rails of a 50kg/m standard I-shaped steel rail and a 59R2 groove-shaped steel rail respectively, a 50kg/m standard I-shaped steel rail is adopted, the 59R2 groove-shaped deformed rail is formed by forging the full section of the 50kg/m steel rail through a movable block die in two parts, the forging transition section and the forming section of the heel end of the groove-shaped deformed rail are respectively 150mm and 450mm long, wherein the shape of the head of the forming section is consistent with the 59R2 groove-shaped rail head without a rail lip, the thickness of the waist of the forming section is the same, the width of a rail limb is 150mm, and finally the forging heel end of the groove-shaped deformed rail and the 59R2 groove-shaped rail with a section with a. Although the special-shaped rail has the advantages of good appearance quality and high mechanical strength of the joint, the special-shaped rail has the defects of high forging forming difficulty, high manufacturing cost, long period and unstable quality.
The invention with the patent number of CN108842525A discloses a special-shaped transition steel rail for connecting a groove-shaped rail and an I-shaped rail, and particularly discloses that the special-shaped transition steel rail comprises a groove-shaped rail section, a transition section and an I-shaped rail connecting section which are connected into a whole, the end surface shape of the groove-shaped rail section is the same as that of the groove-shaped rail to be connected, the end part of the I-shaped rail connecting section is welded with the end part of the I-shaped rail, the depth of the rail bottom of the I-shaped rail connecting section is the same as that of the I-shaped rail to be connected and smaller than that of the groove-shaped rail section, the rail bottom of the transition section is an inclined rail bottom connecting the groove-shaped rail section to the I-shaped rail connecting section, the special-shaped transition steel rail is formed by forging and pressing a section of groove-. The I-shaped rail connecting section is characterized in that a reinforcing plate is welded on the side face of the rail waist of the connecting end of the I-shaped rail connecting section, and the end face of the reinforcing plate is welded with the end face of the rail waist of the connected I-shaped rail. The length of the stiffening plate is equal to the sum of the lengths of the transition section and the I-shaped rail connecting section. The shape of the reinforcing plate is matched with the shapes of the transition section and the side surface of the rail web of the connecting section of the I-shaped rail, and the upper side and the lower side of the reinforcing plate are welded to the rail head bottom surface and the rail bottom top surface of the special-shaped transition rail in an attaching mode. Although the special-shaped transition steel rail has the advantages of simple forging process and low cost, the special-shaped transition steel rail has the following defects: need manual week welding stiffening plate when the stiffening plate welding, cause manual welding position and weak link many for it is poor to connect intensity low and appearance quality. In addition, the unsmooth place needs a large amount of manual smooth-going of polishing behind the stiffening plate welding, and is consuming time hard.
In view of the above, there is a need for a manufacturing method of a profiled rail to solve the problems of the prior art in the process of die forging profiled rail and welding stiffening plates to the profiled rail.
Disclosure of Invention
The invention aims to provide a manufacturing method of a special-shaped rail, which has the following specific technical scheme:
a manufacturing method of a special-shaped rail comprises a groove-shaped rail, a transition rail and a standard I-shaped steel rail which are sequentially connected, wherein one end face of the transition rail is matched with the end face of the standard I-shaped steel rail, and the other end face of the transition rail is matched with the end face of the groove-shaped rail;
the manufacturing method comprises the following steps:
step 1, fixing a forging stock by adopting a five-axis linkage numerical control machining center and machining the forging stock into the transition rail by a numerical control profiling forming cutter;
step 2, aligning and attaching end faces of two ends of the transition rail with the end faces of the groove rail and the standard I-shaped steel rail after pretreatment respectively, and then welding by using a flash welding machine;
and 3, carrying out post-treatment on welding seams of the groove-shaped rail, the standard I-shaped steel rail and the transition rail after welding.
Preferably, before the step 1, the method further comprises the step of machining the groove-shaped rail, and removing a rail lip from one end, close to the transition rail, of the groove-shaped rail through a numerical control profiling cutter.
Preferably, in the step 1, the forging stock is in an i-shaped structure, the processing of the forging stock into the transition rail is completed by multiple passes, and the operation parameters of the numerical control profiling cutter are that the diameter of a cutter head is 150-.
Preferably, the rail head, the rail web and the rail limb which are positioned at the connecting end of the groove-shaped rail on the transition rail are processed into shapes matched with the groove-shaped rail, the rail head, the rail web and the rail limb which are positioned at the connecting end of the standard I-shaped rail are processed into shapes matched with the standard I-shaped rail, and the middle part of the transition rail is trimmed and ground into a smooth transition section by a numerical control profiling forming cutter.
Preferably, in step 2, the pretreatment is to polish and remove rust on the end surfaces of the channel rail and the standard i-shaped steel rail.
Preferably, in step 2, during the operation of the flash welding machine, the position to be welded is arranged under the copper electrode of the flash welding machine, and then the welding machine is energized under pressure, so that part of the metal at the position to be welded is melted and the welding operation is completed through the processes of flash leveling, preheating, flash leveling sintering, upsetting and the like.
Preferably, in step 2, the process parameters of the flash welding machine during operation are as follows: the flash voltage is 650-900KV, the preheating voltage is 450-550KV, the preheating time is 3-6s, the preheating frequency is 5-9 times, the flash flat burning secondary voltage is 880-1000KV, the burning speed is 0.9-3.0mm/s, the upsetting force is 450-520KN, the upsetting voltage is 400-500KV, the upsetting speed is 45-55mm/s, and the upsetting amount is 25-30 mm.
Preferably, in step 3, the post-processing includes projecting and polishing the weld joint, specifically: and after the hydraulic projection pushing machine is adopted to clamp two ends of the special-shaped rail, redundant metal welding slag on the position of the welding line is removed along the length direction of the special-shaped rail by using a profiling projection pushing knife, and the welding line is polished after the slag is removed.
Preferably, in step 3, the post-processing further comprises flaw detection and heat treatment of the weld joint, the polished weld joint is subjected to coloring and magnetic particle flaw detection, and then the seam is subjected to normalizing heat treatment by using a profiling heating induction coil.
Preferably, the length dimension of the transition rail is 100-150 mm.
The technical scheme of the invention has the following beneficial effects:
according to the manufacturing method of the special-shaped rail, the transition rail is processed through the profiling forming tool, a manufacturing die and forging are not needed, the processing cost is low, the technical difficulty is low, a reinforcing plate is not needed after subsequent seam flash welding, the appearance quality of a welding seam is good, the strength is high, and the problems of die forging forming and mass manual welding of the special-shaped rail in the prior art are directly solved. The special-shaped rail is welded by adopting flash, does not need a reinforcing plate and manual welding, does not need cutting processing, has high welding strength, small quantity of welding seams and weak links, simple process operation and stable and reliable quality, and effectively solves the problem of welding the reinforcing plate of the special-shaped rail in the prior art. The special-shaped rail comprises a groove-shaped rail, a transition rail and a standard I-shaped steel rail which are sequentially connected, each section of structure is independently processed and manufactured, the transition rail can be independently selected from materials and processed and manufactured, the structural length and the material strength of the transition rail are flexibly selected, the size is small, automation and modular production are easily realized, and the processing quality is stable and easy to control. The invention can reduce the processing technical difficulty and the manufacturing cost of the transition rail, has the advantages of stable quality, high strength of the special-shaped rail joint, good appearance quality, simple process and convenient manufacturing, and can meet the requirement of effective and reliable connection between different lines of the tramcar.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
fig. 1 is a front view of the structure of a profile rail according to embodiment 1 of the present invention;
fig. 2 is a structural plan view of a profile rail according to example 1 of the present invention;
FIG. 3 is a cross-sectional view taken along line A-A of FIG. 1 (i.e., a cross-section of the grooved rail with the lip portion removed);
FIG. 4 is a cross-sectional view taken at B-B of FIG. 1 (i.e., a cross-section of a portion of a standard I-rail);
FIG. 5 is a cross-sectional view taken at section C-C of FIG. 1 (i.e., a cross-section of the channel rail including the rail lip portion);
the steel rail comprises a groove rail 1, a transition rail 2, a standard I-shaped steel rail 3, a welding seam 4, a rail lip 6, a rail head 7, a rail waist 8 and rail limbs.
Detailed Description
Embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways, which are defined and covered by the claims.
Example 1:
referring to fig. 1-5, a manufacturing method of a special-shaped rail comprises a groove-shaped rail 1, a transition rail 2 and a standard i-shaped steel rail 3 which are connected in sequence, wherein one end face of the transition rail 2 is matched with the end face of the standard i-shaped steel rail 3, and the other end face is matched with the end face of the groove-shaped rail 1;
the manufacturing method comprises the following steps:
step 1, fixing a forging stock by adopting a five-axis linkage numerical control machining center and machining the forging stock into the transition rail 2 by a numerical control profiling forming cutter;
step 2, aligning and attaching the end surfaces of the two ends of the transition rail 2 with the end surfaces of the groove rail 1 and the standard I-shaped steel rail 3 after pretreatment respectively, and then welding by using a flash welding machine;
and 3, post-processing the welding seams 4 of the groove-shaped rail 1, the standard I-shaped steel rail 3 and the transition rail 2 after welding.
Referring to fig. 1-3 and 5, before step 1, the groove-shaped rail 1 is further processed, and a rail lip 5 is removed from one end, close to the transition rail 2, of the groove-shaped rail 1 through a numerical control profiling cutter, so that the rail lip 5 is prevented from being processed when the transition rail 2 and the groove-shaped rail 1 are matched and processed, and the processing steps are greatly simplified. While the rail lip 5 at the end of the channel rail 1 remote from the transition rail 2 is not removed.
In the step 1, the forging stock is in an I-shaped structure, the forging stock is processed into the transition rail 2 and is finished by multiple feeding, and the operation parameters of the numerical control profiling cutter are that the diameter of a cutter head is 150-.
Referring to fig. 2-5, the rail head 6, the rail web 7 and the rail limb 8 which are positioned at the connecting end of the groove-shaped rail 1 on the transition rail 2 are processed into a shape matched with the groove-shaped rail 1 through a numerical control profiling forming tool, the rail head 6, the rail web 7 and the rail limb 8 which are positioned at the connecting end of the standard i-shaped steel rail 3 are processed into a shape matched with the standard i-shaped steel rail 3 through a numerical control profiling forming tool, and the middle part of the transition rail 2 is trimmed into a smooth transition section through the numerical control profiling forming tool.
In the step 2, the pretreatment is to polish and remove rust on the end surfaces of the groove rail 1 and the standard I-shaped steel rail 3.
In step 2, when the flash welding machine works, the ends of two rail ends to be welded are respectively clamped by an upper copper electrode and a lower copper electrode of the flash welding machine, after the end surfaces to be welded are aligned and attached, a power supply is switched on, and in the process of power-on welding, the rail ends are clamped by the upper copper electrode and the lower copper electrode to move oppositely, so that part of metal at the position to be welded is subjected to subsequent flash leveling, preheating melting and upset forging welding.
In step 2, the technological parameters of the flash welding machine during operation are as follows: the flash voltage is 650-900KV, the preheating voltage is 450-550KV, the preheating time is 3-6s, the preheating frequency is 5-9 times, the flash flat burning secondary voltage is 880-1000KV, the burning speed is 0.9-3.0mm/s, the upsetting force is 450-520KN, the upsetting voltage is 400-500KV, the upsetting speed is 50mm/s, and the upsetting amount is 29 mm.
In step 3, the post-processing comprises the steps of carrying out projection pushing and polishing on the welding seam 4, and specifically comprises the following steps: and (3) clamping two ends of the irregular rail by adopting a hydraulic projection pushing machine (the model can be selected to be YTT-200 hydraulic clamping projection pushing machine), removing redundant metal welding slag at the position of the welding line 4 along the length direction of the irregular rail by utilizing a profiling projection pushing knife, and polishing the welding line 4 after removing slag.
In step 3, the post-processing further comprises flaw detection and heat treatment of the welding seam 4, the polished welding seam 4 is subjected to coloring and magnetic particle flaw detection, whether the welding seam 4 has welding defects such as cracks or the like is observed, and then the normalizing heat treatment is carried out on the welding seam 4 by adopting a profiling heating induction coil, so that the welding stress of the welding seam 4 is reduced, the structure of the welding seam 4 is homogenized and refined, and the comprehensive mechanical property of the welding seam 4 is improved. The coloring treatment mode is as follows: firstly, grinding and polishing the welding seam 4, then cleaning scrap iron, oil stains and the like on the surface to be detected by using a cleaning agent, wiping the surface of the welding seam 4, then spraying a penetrating agent on the surface of the welding seam 4, determining that the flaw detection part on the surface of the welding seam 4 is fully wetted by the penetrating agent, after the penetrating time is 10 minutes, using clear water and the like to scrub redundant penetrating agent on the surface, finally spraying a developer on the surface of the welding seam 4, and observing the defect part after a moment.
The length dimension of the transition rail 2 is 150 mm.
According to the manufacturing method of the special-shaped rail, the transition rail 2 is processed through the profiling forming tool, a manufacturing die and forging are not needed, the processing cost is low, the technical difficulty is low, a reinforcing plate is not needed after subsequent seam flash welding, the appearance quality of a welding seam is good, the strength is high, and the problems of die forging forming and mass manual welding of the special-shaped rail in the prior art are directly solved. The special-shaped rail is welded by adopting flash, a reinforcing plate and manual welding are not needed, cutting machining is not needed, the welding strength is high, the number of welding seams 4 and weak links is small, the process operation is simple, the quality is stable and reliable, and the problem that the reinforcing plate is welded by the special-shaped rail in the prior art is effectively solved. The special-shaped rail comprises a groove-shaped rail 1, a transition rail 2 and a standard I-shaped steel rail 3 which are sequentially connected, each section of structure is independently processed and manufactured, the transition rail 2 can be independently selected from materials and processed and manufactured, the structural length and the material strength of the special-shaped rail are flexibly selected, the special-shaped rail is small in size, automation and modular production are easily realized, and the processing quality is stable and easy to control. The invention can reduce the processing technical difficulty and the manufacturing cost of the transition rail 2, has the advantages of stable quality, high strength of the special-shaped rail joint, good appearance quality, simple process and convenient manufacturing, and can meet the requirement of effective and reliable connection between different lines of the tramcar.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (10)

1. The manufacturing method of the special-shaped rail is characterized in that the special-shaped rail comprises a groove-shaped rail, a transition rail and a standard I-shaped steel rail which are sequentially connected, wherein the end face of one end of the transition rail is matched with the end face of the standard I-shaped steel rail, and the end face of the other end of the transition rail is matched with the end face of the groove-shaped rail;
the manufacturing method comprises the following steps:
step 1, fixing a forging stock by adopting a five-axis linkage numerical control machining center and machining the forging stock into the transition rail by a numerical control profiling forming cutter;
step 2, aligning and attaching end faces of two ends of the transition rail with the end faces of the groove rail and the standard I-shaped steel rail after pretreatment respectively, and then welding by using a flash welding machine;
and 3, carrying out post-treatment on welding seams of the groove-shaped rail, the standard I-shaped steel rail and the transition rail after welding.
2. A method of manufacturing a profiled rail according to claim 1, further comprising machining the grooved rail prior to step 1 by removing a rail lip from an end of the grooved rail adjacent the transition rail by means of a numerically controlled profiling tool.
3. A method for manufacturing a profiled rail according to claim 2, wherein in step 1, the forging stock is i-shaped, the process of the forging stock into the transition rail is completed by multiple passes, and the operating parameters of the numerical control profiling tool include a tool disc diameter of 150-.
4. A method of manufacturing a profiled rail as claimed in claim 3, wherein the head, web and limbs of the transition rail at the connecting end of the channel rail are shaped to fit the channel rail, and the head, web and limbs at the connecting end of the standard I-rail are shaped to fit the standard I-rail, and the middle portion of the transition rail is finished to a smooth transition section by a numerically controlled profiling tool.
5. A method of manufacturing a profiled rail as claimed in claim 4, wherein in step 2, the pre-treatment is grinding to remove rust on the end faces of the channel rail and standard I-rail.
6. A method of manufacturing a profiled rail according to claim 5, wherein in step 2, the flash welding machine is operated to dispose the position to be welded under the copper electrode of the flash welding machine, and then the flash welding machine is energized under pressure to melt part of the metal at the position to be welded and complete the welding operation through the processes of flash leveling, preheating, flash leveling burning and upsetting.
7. A method of manufacturing a profiled rail according to claim 6, wherein in step 2, the flash welder is operated with the following process parameters: the flash voltage is 650-900KV, the preheating voltage is 450-550KV, the preheating time is 3-6s, the preheating frequency is 5-9 times, the flash flat burning secondary voltage is 880-1000KV, the burning speed is 0.9-3.0mm/s, the upsetting force is 450-520KN, the upsetting voltage is 400-500KV, the upsetting speed is 45-55mm/s, and the upsetting amount is 25-30 mm.
8. A method of manufacturing a profiled rail according to any one of claims 1 to 7, wherein in step 3, the post-treatment comprises embossing and grinding the weld joint, in particular: and after the hydraulic projection pushing machine is adopted to clamp two ends of the special-shaped rail, redundant metal welding slag on the position of the welding line is removed along the length direction of the special-shaped rail by using a profiling projection pushing knife, and the welding line is polished after the slag is removed.
9. A method of manufacturing a profiled rail according to claim 8 wherein in step 3, the post-treatment further comprises flaw detection and heat treatment of the weld, the polished weld is colour tested and magnetic particle tested, and the weld is subjected to normalizing heat treatment using a profiling heating induction coil.
10. A method of manufacturing a profile rail according to claim 9, wherein the length dimension of the transition rail is 100-150 mm.
CN202110193678.6A 2021-02-20 2021-02-20 Manufacturing method of special-shaped rail Pending CN112975284A (en)

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CN115488482A (en) * 2022-11-03 2022-12-20 攀钢集团攀枝花钢铁研究院有限公司 Method for reducing width of heat affected zone of high-strength pearlite steel rail flash welding head

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Publication number Priority date Publication date Assignee Title
CN115488482A (en) * 2022-11-03 2022-12-20 攀钢集团攀枝花钢铁研究院有限公司 Method for reducing width of heat affected zone of high-strength pearlite steel rail flash welding head
CN115488482B (en) * 2022-11-03 2023-12-22 攀钢集团攀枝花钢铁研究院有限公司 Method for reducing width of heat affected zone of high-strength pearlitic steel rail flash welding head

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Application publication date: 20210618