CN212443050U

CN212443050U - Forging die assembly for manufacturing steel wheel for track

Info

Publication number: CN212443050U
Application number: CN201922144221.7U
Authority: CN
Inventors: 侯沛云; 李树林; 张磊; 魏华成; 张鹏; 刘华堂; 白辉东; 刘伟亮
Original assignee: Taiyuan Heavy Industry Railway Traffic Equipment Co ltd
Current assignee: Taiyuan Heavy Industry Railway Traffic Equipment Co ltd
Priority date: 2019-12-04
Filing date: 2019-12-04
Publication date: 2021-02-02
Anticipated expiration: 2029-12-04

Abstract

The utility model discloses a forge mould assembly for making track steel wheel, wherein, forge mould assembly and include because of forming the base contact with the steel wheel and wearing and tearing relatively more consumptive nature mould and wearing and tearing relatively less general structure nature mould, wherein, consumptive nature mould and general structure nature mould are all dismantled and assembled, wherein, general structure nature mould design is for having the general series mould of different specifications, with the steel wheel product that is applicable to the different specifications of manufacturing, wherein, general structure nature mould includes single-stage general structure nature mould and doublestage general structure nature mould, doublestage general structure nature mould includes first order general structure nature mould and second level general structure nature mould, wherein, second level general structure nature mould carries out the design of stepping according to first order general structure nature mould. The utility model discloses can reduce mould manufacturing cost by a wide margin on satisfying assembly requirement and performance's basis.

Description

Forging die assembly for manufacturing steel wheel for track

Technical Field

The utility model relates to a track technical field especially relates to a forge mould assembly for making steel wheel for track.

Background

The steel wheel for the track can be widely applied to various fields of railway rolling stocks, high-speed trains, urban rail trains, industrial and mining metallurgy and hoisting equipment thereof, port machinery and the like. The combined process of die forging and rolling is the most commonly used hot forming mode for steel wheels for rails. Because steel wheel products are various in types, different in specifications and large in ordered batch, the demand of the die for forging the steel wheel is large; meanwhile, because the steel wheel production process has the characteristics of continuity and high efficiency, the working condition of a die for manufacturing the steel wheel is relatively severe, the die is strongly extruded and rubbed by the plastic flow of high-temperature steel billets, and is cooled by water spraying during unloading, the die is repeatedly quenched and heated rapidly under a relatively fast production rhythm, and the die is usually subjected to failure in various forms such as collapse, thermal abrasion, thermal fatigue crack (crazing) and the like due to thermal softening or circulating thermal stress and the like, so that the consumption of the die is very high. How to reduce the cost of the steel wheel die is an urgent need for controlling the product cost of steel wheel manufacturing enterprises.

Fig. 1 shows a steel wheel forging die assembly 1 for a rail typically used in a conventional forging apparatus, which includes an upper die unit 2 and a lower die unit 3 for manufacturing a steel wheel-formed blank 4, wherein a die cavity for manufacturing the steel wheel-formed blank 4 is formed between the upper die unit 2 and the lower die unit 3 when the upper die unit 2 and the lower die unit 3 are fitted together.

As shown in FIG. 1, the steel wheel blank 4 may include a core material at its center, a hub surrounding the core material, a rim located at the radially outermost side, and a web connecting the hub and rim.

The upper mold unit 2 may include: an upper die base 21 located on the axially and radially outermost side of the upper die unit 2; an upper pressing disc 22 mounted to a first side portion of the upper die holder 21 facing the steel wheel formed blank 4 and located at a radially outermost side of the upper die holder 21; an upper adapter ring 23 clamped between the upper die holder 21 and the upper pressing disc 22 and positioned on the radial inner side of the upper pressing disc 22; an upper pad 24 mounted to a first side of the upper die holder 21 and located radially inward of the upper adaptor ring 23; a clamping sleeve 29 mounted to a first side of the upper die holder 21 and radially inward of the upper backing plate 24; an upper looper 25 located radially inside the clamping collar 29 and having one end mounted to a first side of the upper die base 21 and the other end for contacting a first annular end surface 41 of the wheel hub of the steel wheel shaped blank 4 facing the upper die unit 2; an upper core rod 26 nested inside the upper loop 25 and extending from the inside of the upper loop 25 by a portion, one end of which is mounted to a first side of the upper die base 21 and the other end of which is adapted to contact a first concave surface 42 of the core material of the steel wheel shaped blank 4 facing the upper die unit 2; an upper forming die 27 sandwiched between the upper saucer 24 and the upper looper 25, one end of which is adapted to contact a first annular concave surface 43 of the web of the steel wheel shaped blank 4 facing the upper die unit 2 and the opposite end of which is adapted to abut against the clamping sleeve 29 and the upper saucer 24; and a forming ring 28 sandwiched between the upper adapter ring 23, the upper saucer 24, and the upper forming die 27 for contacting a rim first end surface 44 of the steel wheel blank 4 facing the upper die unit 2.

The lower mold unit 3 may include: a cylindrical lower die holder 31 located at the axially and radially outermost side of the lower die unit 3; a lower pressing disc 32 which is arranged on the second side part of the lower die holder 31 facing the steel wheel forming blank 4 and is positioned on the outermost side in the radial direction of the lower die holder 31; a lower adapter ring 33 clamped between the lower die holder 31 and the lower pressing disc 32 and positioned at the radial inner side of the lower pressing disc 32; a lower pad 34 mounted to a second side of the lower die holder 31 and located radially inward of the lower adaptor ring 33; a lower forming die 35 located radially inwardly of the lower adaptor ring 33 and between the lower backing plate 34 and the steel wheel shaped blank 4 for contacting a second annular surface 45 of the steel wheel shaped blank 4 facing the lower die unit 3, wherein the second annular surface 45 includes a second rim end surface where the rim faces the lower die unit 3 and a second annular concave surface where the web faces the lower die unit 3; a lower pocket 36 located radially inwardly of the lower saucer 34 and the lower forming die 35 and having one end mounted to a second side portion of the lower die base 31 and the other end for contacting a hub second annular end surface 46 of the steel wheel blank 4 facing the lower die unit 3; a lower mandrel 37, which is nested inside the lower loop 36 and extends from the inside of the lower loop 36, has one end mounted to a second side of the lower die bed 31 and the other end for contacting a second concave core 47 of the steel wheel blank 4 facing the lower die unit 3. In addition, a lower loop washer 38 may be provided axially and a bushing 39 may be provided radially between the lower loop 36 and the second side of the lower die bed 31.

The major disadvantages of the forging die assembly described above include: firstly, when a blank is formed, a consumable die contacting the blank is large in size and heavy in weight, and is inconvenient to transport and install in the using process; in the manufacturing process of the die, the cost of raw materials is high, the forging, heat treatment and processing costs are high, and the manufacturing period is long. Second, the upper and lower consumable dies are each comprised of multiple dies to collectively complete the forming of the blank. In the working process, because the friction force of the metal flow of each die is different from the extrusion force of the forming die, the abrasion degree or the consumption speed can be greatly different, so that the condition that any die in the same combination has a use defect and needs to be repaired, and the surfaces of other related dies need to be processed with the same repair amount even if the surface of the other related dies has no defect so as to ensure the normal shape and size of the steel wheel forging, thereby shortening the service life of the normal die and increasing the repair cost; meanwhile, because the volume and the appearance of the die are large, even if the die is used to be scrapped normally, the weight of the rest part of the die still accounts for a large proportion of the original weight of the die, and the utilization rate of the die material is low. The phenomena can cause the manufacturing cost of the die of the steel wheel manufacturing enterprise to be high.

Accordingly, there is a need in the art for an improved forging die assembly for manufacturing steel wheels for rails that eliminates or at least alleviates some or all of the above-mentioned deficiencies of prior art forging die assemblies.

SUMMERY OF THE UTILITY MODEL

To the above-mentioned technical problem that exists among the prior art, the utility model aims to provide a forging mould subassembly that modified is used for making steel wheel for track, on satisfying assembly requirement and performance, furthest reduces mould manufacturing cost.

The general concept of an improved forging die assembly for manufacturing steel wheels for rails according to the present invention is as follows:

firstly, according to whether the die is worn relatively more in the blank forming process and whether the shape and the size of a specific product forging are determined, the die is divided into two types, namely a consumable die which is worn relatively more due to contact with a steel wheel forming blank and a general structural die which is worn relatively less, and the general structural die is further divided into a single-stage general structural die and a two-stage general structural die, wherein the two-stage general structural die comprises a first-stage general structural die and a second-stage general structural die.

Secondly, the existing product consumable mould is disassembled, so that the easy-to-wear part and the few and no-to-wear parts are mutually independent parts, the sizes of the consumable mould in the diameter and height directions are effectively reduced as much as possible, and the weight of the product consumable mould is obviously reduced; the parts with less wear and no wear are graded according to the size and designed into universal series dies with different specifications so as to be suitable for long-term use of steel wheel products with different specifications.

Therefore, after the die is worn or loses efficacy, only the easy-to-wear special part contacting the blank needs to be repaired or scrapped, and other parts can be normally used, so that the material utilization rate of the die is obviously improved; meanwhile, the height of the large-size die is adjusted and designed to realize the independent repairability of the die, and the whole set of die is not repaired and processed due to the defect of one or some dies in the die assembly.

After the optimization design, the manufacturing cost of the steel wheel forging die assembly for the track can be greatly reduced, so that the economic benefit can be improved.

It is emphasized that, unless otherwise indicated, the terms used herein correspond to the ordinary meanings of the various technical and scientific terms in the art, and the meanings of the technical terms defined in the various technical dictionaries, textbooks, etc.

Note that the term "target steel wheel product shaped blank" refers to a steel wheel shaped blank to be manufactured in a particular manufacturing process.

According to the utility model provides an embodiment provides a forge mould assembly for making steel wheel for track, wherein, include because of wearing and tearing more relatively consumptive nature mould and the general structure nature mould that wearing and tearing are less relatively with the contact of steel wheel shaping base, wherein, consumptive nature mould and general structure nature mould are all dismantled and assembled, wherein, general structure nature mould design is the general series mould that has different specifications, in order to be applicable to the steel wheel product of making different specifications, wherein, general structure nature mould includes single-stage general structure nature mould and doublestage general structure nature mould, doublestage general structure nature mould includes first order general structure nature mould and second level general structure nature mould, wherein, second level general structure nature mould carries out the design of stepping according to first order general structure nature mould.

The forging die assembly can be structurally divided into an upper die unit and a lower die unit which are independent from each other, wherein when the upper die unit and the lower die unit are matched together, a die cavity for manufacturing a steel wheel forming blank can be formed between the upper die unit and the lower die unit;

wherein the upper mold unit may include at least one expendable mold and at least one general structural mold, and the lower mold unit may also include at least one expendable mold and at least one general structural mold;

preferably, the steel wheel shaped blank may include a core material at the center thereof, a hub surrounding the core material, a rim located at the outermost side in the radial direction, and a web connecting the hub and the rim, wherein the rim has a first outer diameter D1 and a second inner diameter D2 at a first side rim end surface facing the upper mold unit, the hub has a third outer diameter D3 and a fourth inner diameter D4 at a first side hub end surface facing the upper mold unit, and the rim has an eighth outer diameter D8 and a seventh inner diameter D7 at a second side rim end surface facing the lower mold unit, and the hub has a sixth outer diameter D6 and a fifth inner diameter D5 at a second side hub end surface facing the lower mold unit, wherein the steel wheel shaped blank may have various specifications as needed.

Further, the upper mold unit may include: an upper die holder which can be located at the axially and radially outermost side of the upper die unit; the upper pressing disc can be detachably mounted on a first side part of the upper die base, which faces the steel wheel forming blank, and is positioned on the outermost side in the radial direction of the upper die base; a first-stage upper adaptor ring which may be connected to a first side of the upper die holder and the upper pressing disk, respectively, in an axial direction and a radial direction, and may be located radially inside the upper pressing disk; the upper padding plate can be axially installed on a first side part of the upper die holder and is arranged on the radial inner side of the first-stage upper adapter ring; the first-stage upper adapter ring can be designed into a first-stage universal structural die in a two-stage universal structural die, preferably, the radial outer size of the first-stage upper adapter ring matched with the upper die holder and the upper pressing disc can be a fixed size, the radial inner size can be a stepped size changed according to the specification of a steel wheel product, the radial inner size can be m grades according to the conventional size statistic value of the first outer diameter D1 of the steel wheel forming blank, and m is a natural number greater than 1; according to the grading of the first-stage upper adapter ring, the radial outer side and the radial inner side of the upper pad disc can be designed to be m grades correspondingly.

Further, the upper mold unit may further include: the forming ring can be positioned on the radial inner side of the first-stage upper adapter ring and comprises a step-shaped connecting part and a conical curved surface part which are integrally formed, wherein the step-shaped connecting part can be respectively connected to the upper pad disc and the first-stage upper adapter ring in the axial direction and the radial direction and is provided with a step adjacent to the end face of the first side rim of the rim, and the conical curved surface part can be used for being in contact with the radial outer part of the steel wheel forming blank; a second-stage upper adaptor ring fittable at a step of the stepped connecting portion of the forming ring and adapted to be brought into contact with the rim first-side rim end face; wherein the forming ring may be designed as a consumable mold, preferably, the minimum inner diameter of the forming ring at the conical curved surface portion thereof may be set to a ninth inner diameter D9, and the ninth inner diameter D9 coincides with the first outer diameter D1 of the target steel wheel preform, and the radially outer dimension of the forming ring may be adapted to the selected first-stage adaptor ring, and preferably, the inner diameter dimension of the stepped connection portion of the forming ring may be stepped and stepped to m steps according to the first-stage adaptor ring; wherein the second stage upper adapter ring can be designed as a second stage universal structural mold of the first stage upper adapter ring, preferably, the outer diameter of the second stage upper adapter ring can be consistent with the inner diameter of the step for embedding the second stage upper adapter ring, the outer diameter of the second stage upper adapter ring can also be graded according to the first stage upper adapter ring and correspondingly graded into m grades, the inner diameter of each grade of the second stage upper adapter ring is determined according to the conventional size statistic of the second inner diameter D2 of the steel wheel forming blank of the selected grade, and the step and the second stage upper adapter ring can have the same third axial height H3, preferably, the third axial height H3 of the step and the second stage upper adapter ring can be determined according to the conventional size value of the first hub rim distance H1 of the steel wheel forming blank on the first side, the mold use strength of the forging mold assembly, and the maintenance regulation.

Further, the upper mold unit may further include: the upper forming die comprises an upper forming die connecting part and an upper forming die curved surface part which are integrally formed, wherein the upper forming die connecting part is connected to the radial inner side of the upper backing plate in the radial direction and is positioned on the radial inner side of the second-stage upper adapting ring, and the upper forming die curved surface part is used for being in contact with the first side radial inner side surface of the rim of the steel wheel forming blank, the first side surface of the wheel disk and the first side radial outer side surface of the hub; an upper height adjusting shim plate axially installed between the upper shim plate and the upper forming die; wherein the upper forming die is designed as a consumable die, preferably, a fifth axial thickness H5 of the upper forming die from a joint of the upper forming die and the upper height adjusting shim plate to a contact part of the upper forming die and a rim first side rim end surface is determined according to conventional size statistics of a first hub rim distance H1 of the steel wheel forming blank, die use strength of a forging die assembly and maintenance regulations, and the upper height adjusting shim plate is designed as a single-stage universal structural die with a series of thicknesses, preferably, a sixth axial thickness H6 of the upper height adjusting shim plate is determined according to single processing amount and maintenance regulations of the upper forming die, so that a first effective height dimension H7 of the sum of the fifth axial thickness H5 of the upper forming die and the sixth axial thickness H6 of the upper height adjusting shim plate is constant; preferably, the radial inner side size of the upper forming die is determined according to the third outer diameter D3 of the target steel wheel product formed blank, the radial outer side size is determined according to the conventional size statistical maximum value of the second inner diameter D2 of the steel wheel formed blank of the selected grade, and the steel wheel formed blank is divided into m grades according to the grading of the first-grade upper adapter ring; and the radial outer side dimension of the upper height adjusting shim plate is determined according to the radial inner side dimension of the upper shim plate, and is also graded according to the first-stage upper adapter ring and is graded into m grades correspondingly, and the radial inner side dimension of the upper height adjusting shim plate is determined according to the conventional dimension statistical maximum value of the third outer diameter D3 of the steel wheel forming blank of the selected grade and is graded into m grades correspondingly based on the grading of the outer diameter.

Further, the upper mold unit may further include: the upper loop is positioned on the radial inner side of the upper forming die and provided with an upper loop first end facing the steel wheel forming blank and an upper loop second end deviating from the steel wheel forming blank, wherein the upper loop first end is used for contacting with a first side hub end face of the hub; an upper looper base with a first flange located radially inward of the upper backing plate and having a first end connected to the upper looper second end of the upper looper and a second end with a first flange extending toward the first side of the upper die base such that the upper looper is coaxial with the upper looper base; wherein the upper loop is designed as a consumable mold, preferably the eleventh inner diameter D11 of the upper loop coincides with the fourth inner diameter D4 of the target steel wheel forming blank, and the thirteenth outer diameter D13 coincides with the third outer diameter D3 of the target steel wheel forming blank, wherein preferably the axial height of the upper loop is determined according to the first hub rim distance H1 of the target steel wheel forming blank; wherein the upper looper is designed as a single stage universal structural mold, preferably, the tenth inner diameter D10 of the upper looper is divided into n steps, where n is a natural number greater than 1, according to the conventional statistics of the third outer diameter D3 and the conventional statistics of the fourth inner diameter D4 of the steel wheel shaped blank, and the twelfth outer diameter D12 of the upper looper at the junction where the upper looper is connected is also divided into n steps, wherein, preferably, the eighth axial height H8 of the upper looper is determined based on the conventional statistics of the first hub rim distance H1 of the steel wheel shaped blank, and factors for avoiding mutual interference between components; wherein, preferably, the difference between the thirteenth outer diameter D13 of the upper loop and the twelfth outer diameter D12 of the upper loop seat is more than or equal to 0 and less than or equal to (D13-D12) and more than or equal to 20mm, and the difference between the eleventh inner diameter D11 of the upper loop and the tenth inner diameter D10 of the upper loop seat is more than or equal to 0 and less than or equal to (D10-D11) and more than or equal to 20 mm; wherein, preferably, the upper loop and the upper loop base are in threaded connection.

Further, the upper mold unit may further include: the upper mandrel head is sleeved in the upper movable sleeve, and a first end of the upper mandrel head facing the steel wheel forming blank is used for contacting a first side core material concave surface of the core material and a radial inner side surface of a first side of the hub; an upper mandrel holder, which is T-shaped, including an upper mandrel holder vertical portion and a second flange as an upper mandrel holder horizontal portion, wherein the second flange is mounted to a first side portion of the upper die holder, and the T-shaped vertical portion is connected to the upper mandrel head, such that the upper mandrel holder extends into the upper looper holder to make the upper mandrel head coaxial with the upper mandrel holder, wherein the first flange of the upper looper holder is connected to the second flange; wherein the upper mandrel head is configured as a consumable mold, preferably the sixteenth diameter D16 of the upper mandrel head is consistent with the fourth inner diameter D4 of the target steel wheel shaped blank, wherein preferably the axial height of the upper mandrel head is determined according to the first hub rim distance H1 of the target steel wheel shaped blank; wherein the upper mandrel holder is designed as a single-stage universal structural mold, preferably, the fifteenth outer diameter D15 of the T-shaped vertical portion of the upper mandrel holder is divided into n steps according to the conventional statistical size of the fourth inner diameter D4 of the steel wheel-formed blank, wherein preferably, the ninth axial height H9 of the upper mandrel holder is determined based on the conventional statistical size of the first hub rim distance H1 of the steel wheel-formed blank and factors for avoiding mutual interference between components; wherein, preferably, the difference between the sixteenth diameter D16 of the upper mandrel head and the fifteenth outer diameter D15 of the upper mandrel seat meets the requirement of between 0 and 20mm (D16-D15); preferably, the upper mandrel head and the upper mandrel base are positioned and connected by the first half-closing tile.

Further, the lower mold unit may include: the lower die base is positioned at the axial and radial outermost sides of the lower die unit; the lower pressing disc is detachably mounted on a second side part, facing the steel wheel forming blank, of the lower die base and is positioned on the outermost side in the radial direction of the lower die base; the first-stage lower adapter ring is respectively connected to the second side part of the lower die holder and the lower pressing disc in the axial direction and the radial direction and is positioned on the radial inner side of the lower pressing disc; the lower cushion disc is axially mounted on the second side part of the lower die base and arranged on the radial inner side of the first-stage lower adapter ring; the first-stage lower adapter ring is designed to be a first-stage universal structural mold in a two-stage universal structural mold, preferably, the radial outer side size of the first-stage lower adapter ring matched with the lower mold seat and the lower pressing disc is a fixed size, the radial inner side size is a stepped size changed according to the specification of a steel wheel product, the conventional size statistic value of an eighth outer diameter D8 of a steel wheel forming blank is p steps, wherein p is a natural number larger than 1, and p is the same as or different from m; and correspondingly designing the outer diameter and the inner diameter of the lower pressing disc as p grades according to the grading of the first-stage lower adapter ring.

Further, the lower mold unit may further include: a second-stage lower adaptor ring connected to the lower saucer in an axial direction and disposed radially inward of the first-stage lower adaptor ring; the lower forming die comprises a lower forming die connecting part and a lower forming die curved surface part which are integrally formed, wherein the lower forming die connecting part is connected to the second-stage lower adapter ring in the radial direction, and the lower forming die curved surface part is used for being in contact with a second side rim end surface of a rim of the steel wheel forming blank, a second side surface of a spoke plate and a radial outer side surface of a second side of the hub; a lower height adjusting shim plate axially mounted between the lower shim plate and the lower forming die; wherein the second stage lower adapter ring is designed as a second stage universal structural mold of the first stage lower adapter ring, preferably, the outer diameter of the second stage lower adapter ring is consistent with the inner diameter of the first stage lower adapter ring and is graded according to the first stage lower adapter ring and is correspondingly graded into p grades, and the inner diameter of the second stage lower adapter ring is determined based on the grading of the eighth outer diameter D8 of the steel wheel forming blank and according to the conventional size statistic of the seventh inner diameter D7 of the steel wheel forming blank and the conventional size statistic of the width of the severe wear region of the forming die and is graded into p grades according to the conventional size statistic of the eighth outer diameter D8 of the steel wheel forming blank; wherein the lower forming die is designed as a consumable die, preferably the diameter of the lower forming die at the contact with the rim second side rim end surface is determined according to the eighth outer diameter D8 and the seventh inner diameter D7 of the steel wheel shaped blank, the outer diameter of the lower forming die is determined based on the step of the eighth outer diameter D8 of the steel wheel shaped blank and according to the conventional size statistic of the seventh inner diameter D7 of the steel wheel shaped blank and the conventional size statistic of the width of the severe wear area of the forming die, and is divided into p steps according to the conventional size statistic of the eighth outer diameter D8 of the steel wheel shaped blank, and the inner diameter of the lower forming die is determined according to the sixth outer diameter D6 of the target steel wheel shaped blank, preferably the tenth axial thickness H10 of the lower forming die from the contact of the lower forming die with the rim second side rim end surface to the connection of the lower forming die with the lower height adjusting shim plate is determined according to the conventional size statistic of the second hub distance H2 of the steel wheel shaped blank, Determining the use strength and maintenance regulation of a die of the forging die assembly; and, the lower height adjusting shim plate is designed as a single-stage general structural mold having a series thickness, the radial outside dimension of which is consistent with the radial outside dimension of the lower forming die, the outer diameter of the lower height adjusting shim plate is determined based on the step of the eighth outer diameter D8 of the steel wheel formed blank and according to the conventional dimension statistical value of the seventh inner diameter D7 of the steel wheel formed blank and the conventional dimension statistical value of the width of the severe wear region of the forming die, and is classified into p steps according to the conventional dimension statistical value of the eighth outer diameter D8 of the steel wheel formed blank, and the inner diameter is determined according to the statistical value of the sixth outer diameter D6 of the steel wheel formed blank of the selected step and is correspondingly classified into p steps based on the step of the outer diameter thereof; preferably, the eleventh axial thickness H11 of the lower height adjustment shim plate is designed to have a range of thicknesses according to single pass throughput and maintenance regulations for the lower forming die, such that the second effective height dimension H12 of the sum of the tenth axial thickness H10 of the lower forming die and the eleventh axial thickness H11 of the lower height adjustment shim plate is constant.

Further, the lower mold unit may further include: the lower movable sleeve is positioned on the radial inner side of the lower forming die and is provided with a first lower movable sleeve end facing the steel wheel forming blank and a second lower movable sleeve end deviating from the steel wheel forming blank, wherein the first lower movable sleeve end is used for contacting with the second side hub end surface of the hub; a lower die holder having a first end connected to the first end of the lower die holder and a second end with a third flange extending toward the second side of the lower die holder and connected to the lower die holder such that the lower die holder is coaxial with the lower die holder; wherein the lower loop is designed as a consumable die, preferably, the inner diameter D19 of the lower loop is determined according to the fifth inner diameter D5 of the target steel wheel forming blank, the outer diameter D18 of the lower loop is determined according to the sixth outer diameter D6 of the target steel wheel forming blank, and preferably, the axial height of the lower loop is determined according to the second hub rim distance H2 of the target steel wheel forming blank; the lower movable sleeve seat is designed into a single-stage universal structural die, and preferably, the inner diameter D20 of the lower movable sleeve seat is divided into q grades according to the conventional size statistic value of a sixth outer diameter D6 and the conventional size statistic value of a fifth inner diameter D5 of a steel wheel forming blank, wherein q is a natural number larger than 1, and q is the same as or different from n; and the outer diameter D21 of the joint of the lower live sleeve seat and the lower live sleeve is correspondingly divided into q grades, wherein, preferably, the thirteenth axial height H13 of the lower live sleeve seat is determined based on the conventional size statistics of the distance H2 between the second hub rim of the steel wheel forming blank and factors for avoiding mutual interference among components; wherein, preferably, the lower loop is in threaded connection with the lower loop seat; preferably, the difference between the outer diameter D18 of the lower looper and the outer diameter D21 of the lower looper is 0. ltoreq. D18-D21. ltoreq.20 mm, and the difference between the inner diameter D20 of the lower looper and the inner diameter D19 of the lower looper is 0. ltoreq. D20-D19. ltoreq.20 mm.

Preferably, the lower mold unit may further include: the lower mandrel head is sleeved in the lower movable sleeve, and a first end of the lower mandrel head facing the steel wheel forming blank is used for contacting a second side core material concave surface of the core material and a radial inner side surface of the hub on the second side; a lower mandrel holder, which is T-shaped, comprising a lower mandrel holder vertical portion and a fourth flange as a lower mandrel holder lateral portion, wherein the fourth flange is mounted to the second side portion of the lower mandrel holder, wherein the lower mandrel holder vertical portion is connected to the lower mandrel head such that the lower mandrel holder extends into the lower looper holder and the lower mandrel head is coaxial with the lower mandrel holder, wherein the third flange of the lower looper holder is connected to the fourth flange; wherein the lower mandrel head is designed as a consumable mold, preferably the twenty-second diameter D22 of the lower mandrel head is consistent with the fifth inner diameter D5 of the target steel wheel forming blank, and the axial height of the lower mandrel head is determined according to the second hub rim distance H2 of the target steel wheel forming blank; wherein the lower mandrel holder is designed as a single stage universal structural mold, preferably the twenty-third diameter D23 of the lower mandrel holder vertical portion of the lower mandrel holder is divided into q steps according to the conventional statistics of the fifth inside diameter D5 of the steel wheel formed blank, wherein preferably the fourteenth axial height H14 of the lower mandrel holder is determined based on the conventional statistics of the second hub rim distance H2 of the steel wheel formed blank and factors to avoid mutual interference between the parts; preferably, the difference between the twenty-second diameter D22 of the lower mandrel head and the twenty-third diameter D23 of the lower mandrel base satisfies 0 ≦ (D22-D23) ≦ 20 mm; preferably, the lower mandrel head and the lower mandrel base are positioned and connected through the second half-closed tile.

According to the utility model discloses a forge mould subassembly for making steel wheel that provides can have following beneficial effect:

firstly, through reasonable design of forging die components such as a rail steel wheel die and the like, the size and volume of a consumable die special for products are greatly reduced, the cost of raw materials and various manufacturing processes of the consumable die is obviously reduced, and the cost of the die is reduced to the maximum extent.

Secondly, in the production process, if the die is worn or failed, only the special part of the product contacting the blank needs to be repaired or replaced, and the whole group does not need to be repaired or scrapped, so that the service life of the related die is greatly prolonged.

Further, the die with less abrasion loss can be designed into a universal die, such as a first adapter ring, a second adapter ring, a height adjusting cushion plate, a movable sleeve seat, a mandrel seat and the like, and the universal die is standardized and serialized and can be used for long-term forging production of the conventional steel wheel product. Furthermore, after the upper forming die and the lower forming die are worn, the upper forming die and the lower forming die can be repaired according to the specified single repair amount and repair times, and the upper forming die and the lower forming die are matched with the adjusting base plate with the corresponding height for use, so that the overall height of the die can be ensured to be constant; in this way, the repairing use of the upper forming die and the lower forming die does not influence the normal use of other dies, and the repeated reusability and the independent repairability of the upper forming die and the lower forming die are realized. Furthermore, the loop and the mandrel after the optimized design are reliable, convenient and easy to use, and are convenient to assemble and transport in the production process of the steel wheel in a positioning and connecting mode which is easy to operate. Further, after the service life of the special consumable mould for the product is up to the limit, the proportion of the weight of the residual part relative to the initial weight of the mould is greatly reduced, and the material utilization rate of the mould is obviously improved. Further, to the lightweight design of steel wheel consumptive nature mould, reduce the manufacturing degree of difficulty of mould, shorten mould manufacturing cycle for the product delivery progress of enterprise.

According to the utility model discloses a forge mould subassembly for making steel wheel for track, applicable in making multiple motorcycle types such as subway, train, applicable forging production in all steel wheels for conventional track very much. The steel wheel forging produced by the die assembly can well meet the requirement of processing of a steel wheel finished product, and keeps high product qualification rate and normal die service life. The mould component obtains good results in production tests, the manufacturing cost of the consumable mould special for the products of steel wheel manufacturing enterprises can be reduced by about 40%, the manufacturing period of the mould is greatly shortened, and the production cost of the products is greatly reduced.

Drawings

In the drawings:

FIG. 1 schematically illustrates a cross-sectional view of a prior art steel wheel forging die assembly for a rail;

figure 2 schematically illustrates a cross-sectional view of a forging die assembly for manufacturing steel wheels for rails according to an embodiment of the present invention;

FIG. 3 schematically illustrates a cross-sectional view of a steel wheel shaped blank used in the forging die assembly of FIG. 2;

FIG. 4 schematically illustrates a cross-sectional view of the first stage upper adaptor ring and upper backing plate in the forging die assembly of FIG. 2;

FIG. 5 schematically illustrates a cross-sectional view of the forming ring and adaptor ring on the second stage in the forging die assembly of FIG. 2;

FIG. 6 schematically illustrates a cross-sectional view of the upper forming die and the upper height adjustment shim plate in the forging die assembly of FIG. 2;

FIG. 7 schematically illustrates a cross-sectional view and a close-up view of the upper looper and the upper looper seat in the forging die assembly of FIG. 2;

FIG. 8 schematically illustrates the upper mandrel head, the upper mandrel base and the first half-closing shoe in the forging die assembly of FIG. 2;

FIG. 9 schematically illustrates a cross-sectional view of the first stage lower adaptor ring and lower backing plate in the forging die assembly of FIG. 2;

FIG. 10 schematically illustrates a cross-sectional view of the second stage lower adapter ring, lower forming die, and lower height adjustment shim plate in the forging die assembly of FIG. 2;

FIG. 11 schematically illustrates a cross-sectional view of the lower looper and lower looper seat in the forging die assembly of FIG. 2;

FIG. 12 schematically illustrates the lower mandrel head, the lower mandrel shoe and the second half shoe in the forging die assembly of FIG. 2.

Detailed Description

The technical solution provided by the embodiments of the present invention is described in detail below with reference to the accompanying drawings.

Referring to fig. 2, there is shown a forging die assembly 100 for manufacturing a steel wheel for a railway, wherein the forging die assembly 100 includes a consumable die that wears relatively more and a universal structural die that wears relatively less due to contact with a steel wheel forming blank 400, wherein the consumable die and the universal structural die are both removable, wherein the universal structural die is designed as a universal series die having different specifications to be suitable for manufacturing steel wheel products of different specifications, wherein the universal structural die includes a single-stage universal structural die and a two-stage universal structural die, and the two-stage universal structural die includes a first-stage universal structural die and a second-stage universal structural die, wherein the second-stage universal structural die is designed in stages according to the first-stage universal structural die.

The above forging die assembly 100 may be structurally divided into an upper die unit 200 and a lower die unit 300 which are independent of each other, wherein a cavity for manufacturing the steel wheel blank 400 may be formed between the upper die unit 200 and the lower die unit 300 when the upper die unit 200 and the lower die unit 300 are fitted together; wherein the upper mold unit 200 includes at least one consumable mold and at least one general structural mold, and the lower mold unit 300 also includes at least one consumable mold and at least one general structural mold.

Typically, steel wheel blank 400 may include a core 410 at a center thereof, a hub 420 surrounding core 410, a rim 440 located at a radially outermost side, and a web 430 connecting hub 420 and rim 440, wherein rim 440 may have a first outer diameter D1 and a second inner diameter D2 at a first side rim end surface facing upper mold unit 200, hub 420 may have a third outer diameter D3 and a fourth inner diameter D4 at a first side hub end surface facing upper mold unit 200, and rim 440 may have an eighth outer diameter D8 and a seventh inner diameter D7 at a second side rim end surface facing lower mold unit 300, and hub 420 may have a sixth outer diameter D6 and a fifth inner diameter D5 at a second side hub end surface facing lower mold unit 300, as shown in fig. 3. The steel wheel-formed blank 400 has a variety of specifications as desired.

Further, referring to fig. 3, the first rim distance H1 is a distance between a first side hub end surface and a first side rim end surface on the side of the upper mold unit 200; the second hub rim distance H2 is a distance between the second side hub end surface and the second side rim end surface on the side of the lower mold unit 300.

For convenience of description, it is assumed herein that the side on which the upper mold unit is located may be a first side and the side on which the lower mold unit is located may be a second side with respect to the steel wheel-formed blank.

On the basis of the design thought, in order to enable the improved forming die assembly to have good adaptability and coverage to conventional steel wheel products of various specifications, the inventor carries out a large amount of statistical analysis on the radial and axial characteristic dimensions and the forming die abrasion range of the existing nearly thousands of steel wheel forming blanks, carries out grading and splitting on a radial universal die according to the radial characteristic dimension distribution density degree and the abrasion range of the steel wheel forming blanks, and determines the axial fixed dimension of the universal die according to the axial characteristic dimension and the die assembly relation so as to ensure the universal applicability of the optimized die assembly. Accordingly, the size of the universal structural mold may include a constant fixed size and a stepped size that is changed according to the specification of the steel wheel product, and the fixed size and the stepped size of the universal structural mold are determined according to the conventional size statistics of the size of the corresponding portion of the existing conventional steel wheel blank, and the consumable mold may also include a stepped size that is changed according to the specification of the steel wheel product.

Referring to the drawings, the composition of an improved forging die assembly for manufacturing steel wheels for rails and the function thereof will now be described.

1. Upper die unit

1.1 first stage Upper adaptor Ring 230 and Upper backing plate 240

In the original upper die unit 2 of fig. 1, the upper adapter ring 23 and the upper pad disc 24 are not contacted with the blank all the time in the steel wheel forming process, and the upper adapter ring and the upper pad disc are universal structural dies without abrasion. To determine a reasonable value for the first outer diameter D1, the inventors statistically collected all of the dimensions of the first outer diameter D1 of the currently commercially available conventional steel wheel-formed billet 400 to obtain a range of conventional statistical dimensions for the first outer diameter D1. During the mold optimization, the inner diameter of the upper adapter ring and the inner and outer diameters of the upper saucer are designed in a stepped manner according to the above conventional statistical size range of the first outer diameter D1 of the rim 440 of the steel wheel blank 400 in fig. 3, and are defined as the first-stage upper adapter ring 230 and the upper saucer 240, respectively, as shown in fig. 4.

Similarly, the inventor also statistically sums other diameter sizes of the currently commercially available conventional steel wheel-formed billet 400, i.e., the sizes of the second inner diameter D2, the third outer diameter D3, the fourth inner diameter D4, the fifth inner diameter D5, the sixth outer diameter D6, the seventh inner diameter D7 and the eighth outer diameter D8, so as to obtain corresponding conventional size statistical value ranges for the diameters, and then performs a step-by-step design according to the conventional size statistical value ranges. For example, the first outer diameter D1 may be divided into five steps. For another example, the fourth inner diameter D4 may be divided into three steps. The utility model discloses not only be limited to above-mentioned shelves that divide into, also can divide into the suitable shelves of other quantity as required.

In one embodiment, referring to fig. 4, first, the first stage upper adaptor ring 230 and the upper backing plate 240 may be designed in stages according to the conventional size distribution density of the first outer diameter D1 of the steel wheel-formed blank 400, which is divided into five sections: the radial outside dimension in the region a where the first-stage upper adapter ring 230 is fitted with the upper die holder and the upper pressing disc can be kept unchanged to be the same as the corresponding dimension of the upper die unit 2 in the prior art, or can be other fixed values as required; the inner diameter of the first-stage upper adaptor ring 230 in the region B where it cooperates with the upper pad 240 and the forming ring 250 may be designed in five steps according to the step of the first outer diameter D1, and accordingly, the upper pad 240 may be divided into five specification series in the diameter direction (including the inner and outer diameters). In other embodiments, the first outer diameter D1 of the steel wheel blank 400 may be divided into other numbers of steps, and accordingly, the inner diameter dimension in the B region where the first stage upper adaptor ring 230 mates with the upper backing plate 240, the forming ring 250, and the diameter dimension (including the inner and outer diameters) of the upper backing plate 240, other numbers of steps may be equally provided. In summary, the first outer diameter D1 of the steel wheel forming blank 400 can be divided into m steps, where m is a natural number greater than 1, and accordingly, the inner diameter of the first-step upper adapter ring 230 in the B region where it cooperates with the upper saucer 240 and the forming ring 250, and the diameter (including the inner and outer diameters) of the upper saucer 240 can also be divided into m steps. When products with different specifications are produced, only the first-stage upper adapter ring and the upper cushion disc with corresponding specifications need to be selected.

The stepped design of the first stage upper adapter ring 230 allows for adjustment according to the requirements of different specification steel wheel products on the first stage upper adapter ring. During the operation of the die, the first stage upper adapter ring 230 and the upper backing plate 240 are not substantially worn, so that they can be used as a structural universal series die for the forging production of steel wheels for a long time.

1.2 Adaptation Ring 251 and Forming Ring 250 on the second stage

In the prior art die assembly 1 of fig. 1, the rim shape size of the steel wheel shaped blank 4 may be determined by the working surface of the shaping ring 28 in contact with the blank; the formed ring 28 may be discarded as a whole after it has worn to a limit. The existence of the upper boss of the forming ring 28 and the high height of the boss make the forging blanking weight of the forming ring 28 heavy, so the die material utilization rate is low. Practice shows that in the blank forming process, the abrasion degree of the inner conical curved surface of the forming ring 28 and the lower bottom surface of the boss is greatly different, the inner conical curved surface is abraded quickly and seriously, the forming ring 28 is abraded to the limit quickly, and meanwhile, the lower bottom surface of the boss is abraded only slightly.

For this reason, the prior art original forming ring 28 is designed in a split configuration, as shown in FIG. 5. The wearing forming ring body portion is separated from the boss portion and is designated as forming ring 250 and second stage upper adaptor ring 251, respectively. A stepped design may be employed on the upper portion of the forming ring 250 to support and position the adaptor ring 251 on the second stage. In one embodiment, as shown in fig. 5, the smallest inner diameter of the forming ring 250 at the conical curved surface portion thereof may be set to the ninth inner diameter D9, the ninth inner diameter D9 of the forming ring 250 may be consistent with the first outer diameter D1 of the rim 440 of the steel wheel blank 400 of the target product, and the radial outer dimension of the forming ring 250 may be matched with the assembling position of the first-stage adapter ring 230 selected for the product, so as to ensure that the wall thickness of the forming ring 250 satisfies the use strength.

In one embodiment, the outer diameter of adapter ring 251 on the second stage may be determined by the inner diameter at step 252 of insert forming ring 250 or the positioning size of step 252, and the outer diameter of adapter ring 251 on the second stage may also be stepped from adapter ring 230 on the first stage and to m steps, and the inner diameter may be determined from conventional statistical sizing of second inner diameter D2 of steel wheel blank 400 of the selected step. To determine a reasonable value for the inside diameter of the adaptor ring 251 on the second level, the inventors statistically aggregated the dimensions of all of the second inside diameters D2 of the currently commercially available conventional steel wheel blanks 400 to obtain a range of conventional statistical dimensions for the second inside diameter D2. Accordingly, the inner diameter of the adaptor ring 251 on the second stage may be determined according to the maximum value of the second inner diameter D2 of the selected grade of the steel wheel forming blank 400, and also classified into m grades based on the grading of the outer diameter thereof. Preferably, the inner diameter of the adaptor ring 251 on the second stage is generally about 15mm greater than the maximum value of the second inner diameter D2 of the selected grade of steel wheel blank 400.

In addition, the shaped ring 250 positioning step 252 and the second stage upper adaptor ring 251 may have the same third axial height H3. By adjusting the pressing stroke parameters of the forging press, the third axial height H3 of the positioning step 252 of the forming ring 250 and the second-stage upper adapter ring 251 is reduced, the forging blanking weight of the forming ring 250 can be obviously reduced, and the utilization rate of die materials is improved. The third axial height H3 may be determined based on conventional dimensional statistics of the first rim distance H1 of the steel wheel shaped blank 400 on the first side, the die strength of the forging die assembly 100, and maintenance specifications. Similarly, to determine a reasonable value for the first rim distance H1, the inventors statistically aggregated all first rim distance H1 dimensions of the currently commercially available conventional steel wheel blank 400 to obtain a conventional statistical range of first rim distance H1 dimensions. Accordingly, the third axial height H3 can be determined based on any value within the above conventional statistical size range that is required to satisfy the first rim distance H1.

After the forming ring is designed in a split mode, the forming ring 250 which is easy to wear can be used as a special consumable die for products, and only the forming ring 250 needs to be scrapped after the wear reaches the limit; the low, wear-free second stage upper adaptor ring 251 can be used for a long time as a second stage universal structural mold for the blank.

1.3 Upper Forming die 260 and Upper height adjusting shim 261

In the master mould assembly 1 of figure 1, the upper forming die 27 is the most important die for determining the shape and size of the first side of the steel wheel blank. In the forging process of the steel wheel-shaped blank, the upper forming die 27 is also the die which has the most serious use defects such as abrasion and cracking due to the severe friction and deformation pressure generated by the metal flow on the working surface, and thus the die consumption and the processing repair frequency are high. The reworking of the upper forming die 27 to ensure the proper shape and size of the steel wheel blank also requires the equivalent machining of the dies without use defects, such as the upper looper 25, the upper core rod 26, and the boss of the forming ring 28, resulting in unnecessary material and machining cost waste.

In order to reduce the amount of forging material used in the working portion of the upper forming die 27 without affecting the normal use of the other dies by reworking the working surface of the upper forming die 27, the upper forming die is divided into an upper portion and a lower portion, which are designated as an upper forming die 260 and an upper height adjustment pad 261, respectively, as shown in fig. 6.

Determining the axial and radial dimensions: referring to fig. 3 and 6, in an embodiment, based on the statistical results of all the first rim distances H1 of the currently commercially available conventional steel wheel formed blank, the most reasonable thickness dimension H4 of the upper forming die 260 can be obtained based on the consideration of the die use strength and the rework specifications such as the single rework amount and the rework times, so as to determine the fifth axial thickness H5 of the upper forming die 260, so as to meet the use requirements of the conventional steel wheel formed blank for a track. Referring to fig. 2 and 3, the first hub rim distance H1 may be a distance between a first side hub end surface of the hub 420 of the steel wheel blank 400 and a first side rim end surface of the rim 440, and the fifth axial thickness H5 may be a distance between the upper forming die 260 from a junction of the upper forming die 260 and the upper height adjustment shim plate 261 to a contact of the upper forming die 260 and the first side rim end surface of the rim 440.

In one embodiment, the upper height adjustment shim plate 261 may be designed to have a sixth axial thickness H6 of a series of thicknesses according to the single working amount and the number of reworks of the upper forming die 260; the upper forming die 260 with different repairing times is matched with the corresponding upper height adjusting shim plate 261 to ensure that the first effective height dimension H7 of the sum of the fifth axial thickness H5 of the upper forming die 260 and the sixth axial thickness H6 of the upper height adjusting shim plate 261 is kept constant, so that the influence of repairing of the upper forming die 260 on other non-worn dies is effectively avoided.

In one embodiment, referring to FIGS. 2 and 6, the radially inner dimension of the upper forming die 260 may be consistent with the third outer diameter D3 of the target steel wheel shaped blank 400, the radially outer dimension may be adapted to the inner diameter of the second stage upper adapter ring 251, may be determined according to the conventional statistical maximum dimension of the second inner diameter D2 of the selected grade of steel wheel shaped blank 400, and is divided into m grades accordingly; upper height adjustment shim plate 261 is a single stage universal structural mold and the radially outer dimension of upper height adjustment shim plate 261 can be determined from the radially inner dimension of upper shim plate 240, e.g., from the inner diameter of upper shim plate 240 at its junction with upper height adjustment shim plate 261 as shown in fig. 2, and thus can also be stepped from first stage upper adaptor ring 230 and correspondingly stepped to m steps, e.g., five steps, and the radially inner dimension of upper height adjustment shim plate 261 can be determined from the conventional statistical maximum dimension of third outer diameter D3 of selected grade steel wheel shaped blank 400 and correspondingly stepped to m steps based on the stepping of its outer diameter.

Note that the positioning step 252 of the forming ring 250 and the third axial height H3 of the second stage upper adaptor ring 251 can be determined in a similar manner as the thickness H4 of the upper forming die 260.

The upper forming die 260 determines the relevant shape of the blank or the steel wheel formed blank 400, so that the upper forming die can be designed as a special consumable die for products, and can be repaired successively according to the specified single processing amount after being worn, and scrapped after being worn to the limit; the upper height adjusting shim plate 261 can be used as a series of universal structural molds and can be used for a long time in the production of steel wheels of the same grade. The upper forming die 260 and the upper height adjusting cushion plate 261 are matched for use, so that the blanking weight of the upper forming die 260 can be effectively reduced, the total effective height size of the upper forming die 260 and the upper height adjusting cushion plate can be kept constant, and the condition that no other non-worn die is machined due to the repair of the upper forming die 260 is fundamentally avoided, so that the manufacturing cost of the upper forming die 260 is remarkably reduced, and the service lives of other related dies are prolonged.

1.4 Upper looper 270 and upper looper mount 271

In the master die assembly 1 of fig. 1, the primary function of the upper loop 25 is to shape the first side hub end face of the blank or steel wheel shaped blank 4. In the working process of the die, only the lower end face of the upper loop 25 causes certain abrasion, and the upper part of the upper loop 25 with the large-diameter flange does not have use defects because the upper part does not contact the steel wheel forming blank 4. In order to avoid the rejection of the whole die due to the local slight abrasion, the upper loop 25 can be optimally designed according to the design principle of separating the abraded part from the non-abraded part.

After the upper loop 25 is disassembled, it can be divided into two parts, which are named as an upper loop 270 and an upper loop base 271, respectively, as shown in fig. 7. Wherein the upper looper 270 with the working surface can be designed as a product-specific consumable die and the upper looper base 271 with the first flange and without contacting the blank can be used as a single stage universal structural die. On the basis of meeting the use performance and assembly relationship, in order to save raw materials, the general part is required to be as long as possible, the special part is required to be as short as possible, and the volume proportion of the consumption part is reduced as much as possible.

And (3) determining the radial dimension: in one embodiment, referring to fig. 7, by statistically analyzing the dimensional data of the third outer diameter D3 and the fourth inner diameter D4 of the hub of the conventional steel wheel forming blank, the third outer diameter D3 and the fourth inner diameter D4 can be divided into three grades of dimensional sections while considering both the inner diameter and the outer diameter and according to the degree of density of size distribution; then, the tenth inner diameter D10 and the twelfth outer diameter D12 of the upper looper 271 are also respectively designed into a series of universal structural molds of three dimensions. Referring to fig. 7, a twelfth outer diameter D12 of upper loop base 271 may be the outer diameter of the connection of upper loop base 271 and upper loop 270. In other embodiments, the third outer diameter D3 and the fourth inner diameter D4 may be divided into other number of steps of size sections; thereafter, the tenth inner diameter D10 and the twelfth outer diameter D12 of the upper looper 271 are also respectively designed as a series of universal structural molds of the other number of dimensional specifications. In short, according to the statistics of the size data of the third outer diameter D3 and the fourth inner diameter D4 of the steel wheel formed blank 400, the tenth inner diameter D10 and the twelfth outer diameter D12 of the connection part of the upper looper base 271 and the upper looper 270 may be divided into n steps, where n is a natural number greater than 1. For different products, the upper looper 271 with the corresponding specification is selected according to the section where the fourth inner diameter D4 and the third outer diameter D3 of the hub of the steel wheel forming blank 400 are located.

In one embodiment, the eleventh inner diameter D11 and the thirteenth outer diameter D13 of the upper loop 270 itself may correspond to the fourth inner diameter D4 and the third outer diameter D3, respectively, of the hub of the target steel wheel product blank 400.

Preferably, in selecting the specifications of the upper looper base 271, it is also required that the difference between the outer diameter of the upper looper 270 and the upper looper base 271 is 0. ltoreq. D13-D12. ltoreq.20 mm, and the difference between the inner diameter thereof is 0. ltoreq. D10-D11. ltoreq.20 mm, in order to prevent the occurrence of seizure or interference in the mold during operation.

Height size determination: in one embodiment, the size range of the first rim distance H1 of the existing conventional steel wheel forming blank is statistically analyzed, and meanwhile, factors such as the fact that interference and clamping stagnation cannot occur with other dies in the assembling, material beating and working processes are considered, for example, the outer cylindrical surface of the upper loop 270 is always kept matched with the inner hole of the upper forming die 260 in the moving process of the upper loop 270, so that the reasonable splitting position of the upper loop 270 and the upper loop seat 271 in the axial direction is determined, and the eighth axial height H8 (see fig. 7) of the upper loop seat 271 is further determined and used as the fixed length of the loop seats of all specifications. In an embodiment, the height of the disassembled upper loop 270 itself may be determined by the first hub-rim distance H1 of the target steel wheel shaped blank 400.

Positioning and connection of upper loop 270 and upper loop base 271: because the upper loop 270 and the upper loop base 271 are both cylinder-like or ring-like parts, and the wall thickness is thin, and the limit of the assembling relation with other dies, the connection mode of the two parts is a great difficulty, so the following requirements are met: the connecting parts of the two parts have enough strength, and cannot deform, crack and the like in the using process; the concentricity is kept during the assembly and use of the die, and the phenomena of interference and clamping stagnation are avoided; the two parts of the mould should be easy to assemble and disassemble with each other.

The utility model discloses in, on the basis of guaranteeing use intensity, to last loop 270 and last loop seat 271 be connected and the mode of suit about can carrying out interlude, annular location or each other to the location to guarantee the concentricity between last loop 270 and last loop seat 271, as shown in fig. 7. In one example, a first V-shaped groove 273 may be formed on the entire outer circumferential surface of the upper looper 270 having an outer circumferential surface that mates with the upper looper base 271 having a mating diameter D14, and the separated two parts may be securely coupled by a first screw, such as a socket head set screw 272, that is threaded into the first V-shaped groove 273, wherein the first screw penetrates the wall of the upper looper base 271. The socket head cap set screw 272 can be tightly fitted to the first V-shaped groove 273 at any angular position of the circumference, so that the assembling work becomes easy.

In the loop assembly of the utility model, after the mould is used normally and fails, only the special consumable mould for the product with smaller material consumption, namely the upper loop 270, is needed to be scrapped; the upper loop base 271 with more materials can be used as a series standard universal mould for the production of the steel wheel for a long time, thereby effectively reducing the material cost for manufacturing the mould.

Preferably, as shown in fig. 2, a clamping sleeve 274 may also be disposed between the upper saucer 240 and the upper looper 271 to fix the upper looper 271.

1.5 Upper core rod head 280, Upper core rod seat 281 and first half-closing tile 282

In the master die assembly 1 of fig. 1, the shape and size of the first side of the core material at the central bore of the steel wheel blank 4 may be determined by the working surface of the upper core rod 26. The upper core rod 26 may be composed of a large circular flange at the upper end, a cylindrical rod body and a rod head with a working surface. During billet forming, the metal flow and extrusion in the center portion causes severe wear or cracking to the working face of the head, resulting in a high consumption of upper core rod 26. The upper core rod 26 can be optimally designed if the entire mold is scrapped due to a local use defect for a long time, resulting in a large waste of material.

Similarly, the upper core rod 26 can be separated into two parts, i.e., an upper core rod head 280 and an upper core rod seat 281 according to the design principle of separating the worn part from the unworn part, and the separated structure is shown in fig. 8. Wherein the upper mandrel head 280, which is very easily worn, may be a product-specific consumable mold, and the upper mandrel holder 281, which does not contact the blank and has the large-diameter second flange, may be a general structural mold. On the basis of satisfying the relation between the use performance and the assembly, the upper mandrel holder 281 as a single-stage general structural mold should be as long as possible, and the upper mandrel head 280 as a special expendable mold should be as short as possible to minimize the volume ratio of the expendable portion.

And (3) determining the radial dimension: in one embodiment, referring to fig. 8, by statistically analyzing the fourth inner diameter D4 of the hub of the prior conventional steel wheel forming blank, the fourth inner diameter D4 is divided into three grades of dimensional sections according to distribution density, and accordingly the upper mandrel holder 281 is designed as a series of universal structural molds having a fifteenth outer diameter D15 of three diameter specifications, as shown in fig. 8. In summary, the fifteenth outside diameter D15 of the upper mandrel seat 281 within the upper nest 271 may also be divided into n steps depending on the fourth inside diameter D4 of the steel wheel blank 400. For different products, the corresponding upper mandrel holder 281 is selected according to the section of the steel wheel forming blank 400 where the fourth inner diameter D4 is located.

In an embodiment, the sixteenth diameter D16 of the upper mandrel head 280 itself may correspond to the fourth inner diameter D4 of the target steel wheel-formed blank 400.

Preferably, in selecting the specification of the upper mandrel holder 281, it may also be required that the difference between the sixteenth diameter D16 of the upper mandrel head 280 and the fifteenth outer diameter D15 of the upper mandrel holder 281 satisfy 0 ≦ (D16-D15) ≦ 20mm in order to prevent jamming or interference of the mold during operation.

Height size determination: in one embodiment, the reasonable splitting position of the upper mandrel head 280 and the upper mandrel seat 281 in the axial direction is determined by statistically analyzing the size range of the distance H1 between the first rim of the existing conventional steel wheel forming blank and considering the relevant factors that the upper mandrel head 280 and the upper mandrel seat 281 cannot interfere with other dies and get stuck during the assembling and working processes, for example, the cylindrical surface of the upper mandrel head 280 is always kept to be matched with the upper movable sleeve 270 during the movement of the upper movable sleeve, and then the ninth axial height H9 of the upper mandrel seat 281 is determined and is used as the fixed length of the existing standard mandrel seat. The ninth axial height H9 of the upper mandrel holder 281 may be the total length of the upper mandrel holder 281 in the axial direction.

In an embodiment, the axial height of the disassembled upper mandrel head 280 itself may be determined by the first hub rim distance H1 of the target steel wheel forming blank 400.

Positioning and connection of the upper mandrel seat 281 and the upper mandrel head 280: after the split design of the mandrel, the positioning and connecting manner of the upper mandrel head 280 and the upper mandrel holder 281 is also a great difficulty. When the blank is removed from the upper mold after forming, upper mandrel head 280 is subjected to a large removal force. Because the upper mandrel head has a small diameter and a small bearing strength limit, if the upper mandrel head 280 and the upper mandrel seat 281 are connected in an unreasonable manner, the connection part of the upper mandrel head and the upper mandrel seat may be deformed and cracked due to the bearing of an excessive tensile force. Meanwhile, the connection mode of the two parts also meets the requirements of keeping concentricity, avoiding interference and clamping stagnation, being easy to assemble and disassemble and the like in the process of assembling and using the die.

In an embodiment of the present invention, the upper core rod head 280 and the upper core rod seat 281 are positioned and connected as shown in fig. 8. Preferably, the adjacent connection portions of the upper core rod seat 281 and the upper core rod head 280 are symmetrically designed into a universal groove form, the upper core rod seat 281 and the upper core rod head 280 are connected at a first groove 283 by two first half-closing tiles 282 which are unique and cut without seams, and the two first half-closing tiles 282 are fastened by four hexagon socket head cap screws 284 and corresponding hexagon nuts 285. The unique half-closed tile connection mode realizes the concentric positioning and connection effect between the upper core rod seat 281 and the upper core rod head 280, and has the advantages of difficult deformation, simple and convenient installation and disassembly. In this design, the inner and outer diameters of the first half-closed tile 282 may be designed to correspond to three standard specifications according to three specification series of the upper mandrel holder 281. In other embodiments, the inner diameter and the outer diameter of the first half-closing shoe 282 may be designed to have n-step standard according to the stepped design of the upper mandrel holder 281.

After the wear failure occurs in production and use, only the special upper mandrel head 280 for the product with smaller material proportion needs to be scrapped, and the upper mandrel seat 281 and the first half-closing tile 282 with larger material proportion can be used as a series standard universal mold for a long time, so that the blanking weight of the mandrel can be effectively reduced, and the mold cost is reduced.

2. Lower die unit

The optimized design of the lower mold unit 300 also follows the following principles: the easily worn part of the die is independent of the less and non-worn parts, so that the weight of the consumable die of the product is effectively reduced, and the manufacturing cost of the die is reduced. The design methods of the corresponding dies having similar functions are also substantially the same in the upper die unit and the lower die unit.

2.1 first stage lower adaptor Ring 330 and lower backing plate 340

In the master die assembly 1 of fig. 1, the lower adapter ring 33 and the lower pad 34 of the lower die unit are not in contact with the blank at all times, and are general structural dies that are not subject to wear. During the optimization of the mold, the inner diameter of the lower adapter ring and the inner diameter of the lower pad are designed in a stepped manner according to the conventional size statistic range of the eighth outer diameter D8 of the steel wheel formed blank 400, and are respectively defined as a first-stage lower adapter ring 330 and a first-stage lower pad 340, as shown in fig. 9.

Referring to fig. 9, in one embodiment, first, the first stage lower adaptor ring 330 and the lower backing plate 340 are designed to be stepped according to the conventional sizing statistics of the eighth outside diameter D8 of the steel wheel-formed blank 400: the radially outer dimension of the first stage lower adaptor ring 330 in region D, which is engaged with the lower die holder and lower clamping disk, may be constant, may be the corresponding dimension in the prior art die assembly 1, or may be some other desired fixed value. Secondly, the inner diameter in the region E, which is engaged with the lower pad 340 and the second-stage lower adapter ring 351, may be correspondingly designed into five steps according to the step of the eighth outer diameter D8 of the steel wheel forming blank 400, and accordingly, the lower pad 340 may be divided into five specification series in the diameter direction (including the inner and outer diameters). In other embodiments, the inner diameter of the region E that cooperates with the lower backing plate 340 and the second stage lower adapter ring 351 may be designed into other number of steps according to the step of the eighth outer diameter D8 of the steel wheel forming blank 400, and the lower backing plate 340 may be divided into an equal number of gauge series in the diameter direction (including the inner and outer diameters). In short, the radial outside dimension of the first-stage lower adapter ring 330, the lower die holder 310 and the lower clamping disk 320 can be constant, while the radial inside dimension can be changed as required, and is divided into p stages according to the eighth outer diameter D8 of the steel wheel forming blank 400, wherein p is a natural number greater than 1, and p and m can be the same or different. According to the step of the first-stage lower adaptor ring 330, both the outer diameter and the inner diameter of the lower pressing disk 320 can be designed to be p steps, accordingly. When products with different specifications are produced, only the first-stage lower adapter ring 330 and the lower backing plate 340 with corresponding specifications need to be selected.

The stepped design of the first-stage lower adapter ring 330 can adjust the requirements of the lower adapter ring according to different specifications of steel wheel products. In the working process of the die, the first-stage lower adapter ring 330 and the lower backing plate 340 are not abraded basically, and can be used as a structural universal series die for long-term use in steel wheel forging production.

2.2 lower forming die 350, second stage lower adapter ring 351 and lower height adjustment shim plate 352

In the master die assembly 1 of fig. 1, the lower forming die 35 is the most important die for determining the shape and size of the second side of the blank, and is also the die with the most serious use defects such as wear and tear of the working surface during the blank forging process, so that the frequency of machining and repairing the lower forming die and the die consumption are high. Meanwhile, in order to meet the requirement of the proper shape and size of the blank, the lower forming die 35 is machined and repaired, and simultaneously, the dies without using defects, such as the lower piston sleeve 36, the lower core rod 37 and the like, can be machined in an equivalent manner, so that unnecessary waste of materials and machining cost is caused.

In order to repair the working surface of the lower forming die 35 without affecting the normal use of other dies and reduce the amount of forging material used in the working portion of the lower forming die, the original lower forming die 35 is axially split into a lower forming die 350 and a lower height adjustment shim plate 352, and radially split into the lower forming die 350 and a second-stage lower adapter ring 351, as shown in fig. 10.

Radial splitting: referring to FIGS. 2 and 10, during blank forming, the wear of the platform surface of the lower forming die curve adjacent the seventh inside diameter D7 of the rim of the steel wheel formed blank 400 is extreme, while only slight wear of the platform occurs slightly beyond. On the basis of grading products according to the eighth outer diameter D8 of the steel wheel forming blank 400, the sizes of the outer diameter of the lower forming die 350 of the selected grade and the inner diameter of the second-stage lower adapter ring 351 can be reasonably determined by carrying out a large amount of statistical analysis on the seventh inner diameter D7 of the inner side of the steel wheel forming blank 400 of the selected grade and the width W of the severe wear area of the platform of the lower forming die 350, wherein the outer diameter of the lower forming die 350 and the inner diameter of the second-stage lower adapter ring 351 can be marked by a seventeenth diameter D17, so that the severe wear part and the slight wear part of the lower forming die 350 can be effectively separated, as shown in FIG. 10. Therefore, the outer diameter of the lower forming die 350 is classified into p-classes based on the classification of the eighth outer diameter D8 of the steel wheel-shaped blank 400 and according to the conventional size statistic of the seventh inner diameter D7 of the steel wheel-shaped blank 400 and the conventional size statistic of the width of the severely worn region of the forming die 350, and according to the conventional size statistic of the eighth outer diameter D8 of the steel wheel-shaped blank 400. The inner diameter of the lower forming die 350 may be determined according to the sixth outer diameter D6 of the target steel wheel-formed blank 400.

Referring to fig. 2 and 10, the outer diameter of the second stage lower adaptor ring 351 may correspond to the inner diameter of the first stage lower adaptor ring 330 and may be stepped according to the first stage lower adaptor ring 330 and stepped to p steps accordingly. Also, the inner diameter of the second-stage lower adapter ring 351 may be determined based on the step of the eighth outer diameter D8 of the steel wheel-shaped blank 400 and according to the conventional size statistic of the seventh inner diameter D7 of the steel wheel-shaped blank 400 and the conventional size statistic of the width of the severe wear region of the forming die 350, and may be classified into p steps according to the conventional size statistic of the eighth outer diameter D8 of the steel wheel-shaped blank 400.

Additionally, the lower height adjustment shim plate 352 may be designed as a single stage universal structural mold having a range of thicknesses with a radially outer dimension that is consistent with the radially outer dimension of the lower forming die 350, and thus, the outer diameter of the lower height adjustment shim plate 352 may be determined based on the sizing of the eighth outer diameter D8 of the steel wheel-shaped blank 400 and based on the conventional statistics of the dimensions of the seventh inner diameter D7 of the steel wheel-shaped blank 400 and the conventional statistics of the width of the severe wear area of the forming die 350, and may be classified as p-sizing based on the conventional statistics of the eighth outer diameter D8 of the steel wheel-shaped blank 400. The radial inner diameter of the lower height adjustment shim plate 352 may be sized according to the statistics of the sixth outer diameter D6 of the selected grade of steel wheel blank 400 and divided into p grades according to its outer diameter.

Axial splitting: referring to fig. 10, in an embodiment, based on the analysis of the conventional statistical size value of the distance H2 between the second hub rim and the second rim of the conventional steel wheel formed blank, the most reasonable size range of the thickness of the lower forming die 350 is obtained on the basis of considering the using strength of the die and the repair regulations such as the single repair amount and the repair times, so as to determine the tenth axial thickness H10 of the lower forming die 350, so as to meet the using requirements of the conventional steel wheel formed blank for the track. Referring to FIGS. 2 and 10, a tenth axial thickness H10 of the lower forming die 350 may be the distance from where the lower forming die 350 contacts the second side rim end surface of the rim 440 to where the lower forming die 350 connects to the lower height adjustment shim plate 352. Further, the lower height adjustment shim plate 352 may be correspondingly designed to have a corresponding eleventh axial thickness H11 of a series of thicknesses according to the single pass amount and the rework times of the lower forming die 350; the lower forming die with different repairing times is matched with the corresponding lower height adjusting cushion plate, so that the total thickness of the lower forming die and the lower forming die, namely the second effective height dimension H12, can be kept constant, and the influence of the repairing of the lower forming die 350 on other non-worn dies is effectively avoided. That is, the second effective height dimension H12 ═ H10+ H11.

In the die assembly of the present invention, the lower forming die 350 determines the shape of the blank or the formed blank, and is a consumable die dedicated for products, and is repaired one by one according to the specified single machining amount after being worn, and is discarded after being worn to the limit; the second-stage lower adapter ring 351 and the lower height adjusting base plate 352 can be used as a second-stage universal structural die of a same-gear forming blank and can be used for producing same-gear steel wheels for a long time.

The separation design of the lower forming die 350 and the second-stage lower adapter ring 351 enables the radial size of the lower forming die to be obviously reduced; the lower forming die 350 and the corresponding lower height adjusting backing plate 352 are matched for use, so that the blanking weight of the lower forming die can be effectively reduced, and the second effective height dimension H12 of the lower forming die and the lower forming die can be kept constant, so that the condition that other non-worn dies are not machined due to the repair of the lower forming die 350 is avoided, the manufacturing cost of the lower forming die is obviously reduced, and the service lives of other related dies are prolonged.

2.3 lower swivel 360 and lower swivel mount 361

In the master mould assembly 1 of figure 1, the lower piston 36 is primarily responsible for shaping the second side hub surface of the steel wheel blank 4. The die only causes certain abrasion to the upper end surface of the die in the working process, and the lower part with the large-diameter flange does not have use defects because the lower part does not contact the blank. In order to avoid the rejection of the whole die due to the slight local abrasion, the lower movable sleeve is optimally designed according to the principle that the abraded part is separated from the non-abraded part.

As shown in fig. 11, the lower looper is divided into two parts, namely, a lower looper 360 and a lower looper mount 361, wherein the lower looper 360 with a working surface can be a consumable mold for a product, and the lower looper mount 361 with a third flange and without contacting a blank can be a one-stage universal structural mold. On the basis of meeting the use performance and assembly relationship, in order to save raw materials, the general part is as long as possible, and the special part is as short as possible, so as to reduce the volume proportion of the consumed part as much as possible.

And (3) determining the radial dimension: in one embodiment, by statistically analyzing the size data of the sixth outer diameter D6 and the fifth inner diameter D5 on the second side of the hub of the existing conventional steel wheel forming blank, the sixth outer diameter D6 and the fifth inner diameter D5 can be divided into q-step size sections, such as three steps, while considering both the outer diameter and the inner diameter and according to the size distribution density, wherein q is a natural number greater than 1, and q is the same as or different from n.

Referring to fig. 2 and 11, the inner diameter D19 of the lower piston 360 may be determined according to the fifth inner diameter D5 of the target steel wheel product shaped blank 400; the outer diameter D18 of the lower loop 360 may be determined according to the sixth outer diameter D6 of the target steel wheel product shaped blank 400.

Thereafter, the lower socket 361 can be designed to have a series of universal structural molds with three dimensional specifications or three grades for both the inside diameter D20 and the outside diameter D21, as shown in fig. 11, according to the step of the sixth outside diameter D6 and the fifth inside diameter D5 of the steel wheel forming blank. In other embodiments, the sixth and fifth outside diameters D6 and D5, and the inside and outside diameters D20 and D21 of the lower socket 361 can also be designed to have other q-step size specifications, where q is a natural number greater than 1, such as two steps, four steps, etc. q and n may be the same or different. For different products, the lower socket 361 of the section is selected according to the sixth outer diameter D6 and the fifth inner diameter D5 of the second side of the hub of the steel wheel forming blank.

Preferably, when the specification of the lower movable sleeve seat 361 is selected, the difference between the outer diameter of the lower movable sleeve 360 and the outer diameter of the lower movable sleeve seat 361 is required to be more than or equal to 0 and less than or equal to (D18-D21) and less than or equal to 20mm, and the difference between the inner diameter of the lower movable sleeve seat 361 is required to be more than or equal to 0 and less than or equal to (D20-D19) and less than or equal to 20mm, so as to prevent the clamping stagnation or interference of the die.

Height size determination: by statistically analyzing the size range of the second rim distance H2 of the existing conventional steel wheel forming blank and considering the relevant factors such as the fact that interference and clamping stagnation cannot occur with other dies in the assembling and working processes, for example, the outer cylindrical surface of the lower movable sleeve 360 is always kept to be matched with the inner hole of the lower forming die 350 in the moving process of the lower movable sleeve 360, the reasonable splitting position of the lower movable sleeve 360 and the lower movable sleeve seat 361 in the axial direction can be determined, and the thirteenth axial height H13 of the lower movable sleeve seat 361 can be further determined and used as the fixed length of the lower movable sleeve seats 361 of all specifications. The height of the disassembled lower swivel 360 itself can then be determined by the second hub rim distance H2 of the target steel wheel shaped blank 400.

The positioning and connection of the lower looper 360 and the lower looper mount 361: in the present invention, the positioning and connection of the lower looper 360 and the lower looper mount 361 can be similar to the positioning and connection of the upper looper 270 and the upper looper mount 271 shown in fig. 7, and the upper and lower insertion, annular positioning or mutual sleeving can be performed. For example, lower looper 360 is threadably connected to lower looper base 361. More preferably, the second end of lower piston 360 and the first end of lower piston seat 361 are inserted together in a nested manner to connect lower piston 360 and lower piston seat 361 and ensure their concentricity. More preferably, a second V-groove is formed along a circumferential direction on an entire outer circumferential surface of the lower looper 360 coupled to the lower looper base 361, and a second screw such as a set screw 362, which penetrates through a wall of the lower looper base 361, is threadedly engaged with the second V-groove to tightly couple the lower looper 360 and the lower looper base 361.

In the lower loop assembly of the utility model, after the die is used normally and fails, only the special consumable die for the product with smaller material consumption, namely the lower loop 360, is needed to be scrapped; the lower movable sleeve seat 361 with more materials can be used as a series standard universal structural mould for long-term production, thereby effectively reducing the material cost for manufacturing the mould.

2.4 lower core rod head 370, lower core rod seat 371 and second half-closing tile 372

In the master die assembly 1 of fig. 1, the second side shape dimension of the core material at the center hole of the steel wheel blank 4 is determined by the working surface of the lower core rod 37. The lower core rod 37 consists of a circular flange at the lower end, a cylindrical rod body and a rod head with a working surface. During the blank forming process, the metal flow and extrusion in the central portion cause severe wear or cracks to the working surface of the lower core rod 37, resulting in a large consumption of the lower core rod 37. If the whole die is scrapped due to local use defects for a long time, a large amount of material is wasted, and therefore, the lower core rod needs to be optimally designed.

Similarly, the lower core rod 37 can be separated into two parts, i.e., a lower core rod head 370 and a lower core rod seat 371, according to the design principle of separating the worn part from the unworn part, as shown in fig. 12. The lower mandrel head 370, which is very easily worn, may be a product-specific consumable mold, and the lower mandrel holder 371, which does not contact the blank and has a fourth flange with a large diameter, may be a single-stage universal structural mold. On the basis of satisfying the relation between the use performance and the assembly, the lower mandrel holder 371, which is a general structural mold, should be as long as possible, and the lower mandrel head 370, which is a special expendable mold, should be as short as possible, so as to reduce the volume ratio of the expendable portion as much as possible.

Referring to fig. 3 and 12, a lower mandrel head 370 may be nested inside the lower looper 360 and a first end of the lower mandrel head facing the steel wheel forming blank 400 may be adapted to contact a second side core concave surface of the core 410 and a radially inner side surface of the hub 420 on the second side; the lower mandrel base 371 may be T-shaped, which may include a lower mandrel base vertical portion and a fourth flange as a lower mandrel base lateral portion, wherein the fourth flange may be mounted to the second side of the lower die base 310, wherein the lower mandrel base vertical portion may be connected to the lower mandrel head 370 such that the lower mandrel base 371 may extend into the lower looper base 361 and the lower mandrel head 370 may be coaxial with the lower mandrel base 371, wherein the third flange of the lower looper base 361 may be connected to the fourth flange.

Preferably, as shown in fig. 2, a lower looper washer 363 may be axially disposed between the third flange of the lower looper base 361 and the fourth flange of the lower mandrel base 371. Between the lower die holder 310 and the lower piston holder 361, a bushing 364 may be radially disposed.

And (3) determining the radial dimension: referring to fig. 3 and 12, in one embodiment, the fifth inside diameter D5 may be divided into, for example, three dimensional segments in order of distribution density by statistically analyzing the conventional dimensions of the fifth inside diameter D5 of the hub of an existing conventional steel wheel-formed blank. Accordingly, in an embodiment, the twenty-second diameter D22 of the lower mandrel head 370 itself may correspond to the fifth inside diameter D5 diameter of the steel wheel formed blank 400 of the target product. In accordance with the classification of the conventional statistics of the dimensions of the fifth inside diameter D5 of the steel wheel-formed blank 400, the lower mandrel holder 371 may also be designed accordingly as a series of universal structural dies having a twenty-third diameter D23 of three gauges or three grades. Referring to fig. 2 and 12, the twenty-third diameter D23 of the lower mandrel base 371 may be the diameter of the lower mandrel base vertical portion. In other embodiments, the twenty-third diameter D23 of the lower mandrel base 371 can also be designed to have other q-step dimensions, such as two steps, four steps, etc. For different products, the corresponding lower mandrel seat 371 is selected according to the section of the fifth inner diameter D5 of the steel wheel forming blank 400.

Preferably, when the specification of the lower mandrel holder 371 is selected, the difference between the diameters of the lower mandrel head 370 and the lower mandrel holder 371 may be required to be 0. ltoreq. D22-D23. ltoreq.20 mm in order to prevent the mold from being stuck or interfered during the operation.

Height size determination: referring to fig. 2 and 12, in one embodiment, the fourteenth axial height H14 of the lower mandrel holder 371 is determined by statistically analyzing the dimensional range of the second hub rim distance H2 of the conventional steel wheel forming blank, while taking into account the factors associated with the lower mandrel head 370 and the lower mandrel holder 371 not interfering with other dies during assembly and operation, such as the fact that the cylindrical surface of the lower mandrel head 370 is always kept in fit with the die of the lower piston 360 during the lower piston movement, and this is used as the fixed length of the lower mandrel holder 371 of all sizes. Referring to fig. 12, the fourteenth axial height H14 of the lower mandrel holder 371 refers to the total length of the lower mandrel holder 371 in the axial direction.

In an embodiment, the height of the disassembled lower mandrel head 370 itself may be determined by the second hub rim distance H2 of the steel wheel blank 400 of the target product.

The positioning and connection of the lower mandrel seat 371 and the lower mandrel head 370: when the blank is demolded from the lower mold unit after being formed, the lower mandrel head 370 is subjected to a large demold force, and therefore, the positioning and connecting manner of the two parts of the lower mandrel seat 371 and the lower mandrel head 370 is also a great difficulty. The utility model discloses in, lower mandrel seat 371 and lower mandrel head 370's location, be connected also can adopt and go up mandrel head 280 and last mandrel seat 281 both to be connected the same mode, utilize two seamless cutting's second half to close tile 372 to be connected and fix a position in mandrel seat 371 and lower mandrel head 370's second recess 373 department under promptly to realize reliable connection and the reasonable location between them, as shown in fig. 12. According to the stepped design of the lower mandrel holder 371, the inner diameter and the outer diameter of the second half-closing shoe 372 can be correspondingly designed to have a standard specification of q steps.

After the wear failure occurs in production and use, only the lower mandrel head 370 with smaller material proportion and special product needs to be scrapped, and the lower mandrel seat 371 with larger material proportion and the second half-closing tile 372 can be used as a series standard universal structural mold for a long time, so that the blanking weight of the mandrel can be effectively reduced, and the mold cost is reduced.

In the steel wheel forging production process, according to the utility model discloses a die assembly's of forging mould consumption mainly reflects on the special mould with product blank direct contact, and other general moulds then can supply to use for a long time with specification steel wheel production. After the forging die assembly is optimized, the raw material and manufacturing cost of the special consumable die for the steel wheel product are obviously reduced.

A forging die assembly for manufacturing a steel wheel for a rail according to an example of the present invention will be specifically described below with a certain phi 920 steel wheel product formed blank as an example of the steel wheel formed blank 400.

In the phi 920 steel wheel forging upper die unit, a forming ring 250, an upper forming die 260, an upper loop 270 and an upper mandrel head 280 may be included as product-dedicated consumable dies in a forming process.

Forming a ring: after the original forming ring 28 with the lug bosses is optimized, the original forming ring can be decomposed into a forming ring 250 and a second-stage upper adapter ring 251, the height direction dimension of the original forming ring is integrally reduced, the weight of the finished forming ring can be reduced from 851kg to 434kg, and the total manufacturing cost including raw materials, forging, heat treatment, machining and detection can be reduced by 38.6%.

An upper forming die: the original upper forming die 27 can be disassembled into the upper forming die 260 and the upper height adjusting cushion plate 261, and the first effective height dimension H7 of the sum of the upper forming die 260 and the upper height adjusting cushion plate 261 can be kept constant when the upper forming die is used in combination, so that the normal use of other dies is not influenced by the repair of the upper forming die. The weight of the upper forming die part can be reduced from 778kg to 503kg, and the total manufacturing cost can be reduced by 35.2%.

And (3) looping: the original upper loop 25 is decomposed and designed into an upper loop 270 and an upper loop seat 271, and the upper loop 270 and the upper loop seat 271 can realize reliable connection through the up-and-down penetration, the annular positioning and the matching of the V-shaped groove and the set screw. The weight of the parts of the upper loop can be reduced from 116kg to 42kg, and the total manufacturing cost can be reduced by 63.4 percent.

And (3) feeding a mandrel head: the original upper core rod 26 is designed into an upper core rod head 280 and an upper core rod seat 281 in an exploded manner, and the upper core rod head 280 and the upper core rod seat 281 are reasonably positioned and connected through a unique first half-closed tile 282, so that the upper core rod 26 is easy to assemble, disassemble and use. The part weight of the upper core rod head can be reduced from 161kg to 39kg, and the total manufacturing cost can be reduced by 75.5%.

In the phi 920 steel wheel forging lower die unit, a lower forming die 350, a lower movable sleeve 360 and a lower mandrel head 370 can be included as product-specific consumable dies in the forming process.

A lower forming die: the original lower forming die 35 can be disassembled into the lower forming die 350 and the lower height adjusting shim plate 352, and the lower forming die 350 and the lower height adjusting shim plate 352 are matched for use, so that the second effective height H12 of the sum of the lower forming die 350 and the lower height adjusting shim plate can be kept constant, and the normal use of other dies cannot be influenced by the repair of the lower forming die 350. The part weight of the lower forming die 350 can be reduced from 1260kg to 664kg, and the total manufacturing cost can be reduced by 44.8%.

A lower loop: the original lower loop 36 can be disassembled into a lower loop 360 and a lower loop seat 361, and the lower loop 360 and the lower loop seat 361 are inserted up and down, positioned in an annular mode, and matched with a set screw through a V-shaped groove, so that reliable connection is achieved. The weight of the parts of the lower loop can be reduced from 158kg to 98kg, and the total manufacturing cost can be reduced by 48.9 percent.

Lower core rod head: the original lower core rod 37 is designed into a lower core rod head 370 and a lower core rod seat 371 in a decomposition way, and the lower core rod head 370 and the lower core rod seat 371 can be reasonably positioned and connected through a unique second half-combined tile 372, so that the lower core rod is easy to assemble, disassemble and use. The part weight of the lower core rod head can be reduced from 174kg to 48kg, and the total manufacturing cost can be reduced by 71.8%.

The results show that the total weight of the product-specific consumable die of the phi 920 steel wheel can be reduced from 3498kg to 1828kg, and the total manufacturing cost can be reduced by 43.5%.

It is noted that, unless expressly stated or limited otherwise, the term "coupled" is intended to mean a coupling that includes a direct coupling and an indirect coupling via an intermediary. The specific meaning of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

Claims

1. A forging die set for manufacturing steel wheels for rails, comprising a consumable die that wears relatively more and a general structural die that wears relatively less due to contact with a steel wheel forming blank (400), wherein the consumable die and the general structural die are both removable, wherein the general structural die is designed as a general series of dies having different specifications to be suitable for manufacturing steel wheel products of different specifications, wherein the general structural die comprises a single-stage general structural die and a two-stage general structural die, the two-stage general structural die comprises a first-stage general structural die and a second-stage general structural die, wherein the second-stage general structural die is designed in stages according to the first-stage general structural die.

2. The forging die set for manufacturing a steel wheel for a railway according to claim 1, structurally divided into an upper die unit (200) and a lower die unit (300) independent from each other, wherein a cavity for manufacturing a steel wheel-formed blank (400) is formed between the upper die unit (200) and the lower die unit (300) when the upper die unit (200) and the lower die unit (300) are fitted together;

wherein the upper mold unit (200) includes at least one expendable mold and at least one universal structural mold, and the lower mold unit (300) also includes at least one expendable mold and at least one universal structural mold.

3. The forging die assembly for manufacturing a steel wheel for a railway according to claim 2, wherein the steel wheel-shaped blank (400) includes a core material (410) at a center thereof, a hub (420) surrounding the core material (410), a rim (440) located at a radially outermost side, and a web (430) connecting the hub (420) and the rim (440), wherein the rim (440) has a first outer diameter D1 and a second inner diameter D2 at a first side rim end surface facing the upper die unit (200), the hub (420) has a third outer diameter D3 and a fourth inner diameter D4 at the first side hub end surface facing the upper die unit (200), and the rim (440) has an eighth outer diameter D8 and a seventh inner diameter D7 at a second side rim end surface facing the lower die unit (300), the hub (420) has a sixth outer diameter D6 and a fifth inner diameter D5 at the second side hub end surface facing the lower die unit (300), wherein the steel wheel formed blank (400) has a plurality of specifications as required.

4. The forging die assembly for manufacturing a steel wheel for railway according to claim 3, wherein the upper die unit (200) includes:

an upper die holder (210) located at the axially and radially outermost side of the upper die unit (200);

an upper pressing disc (220) which is detachably mounted on a first side of the upper die holder (210) facing the steel wheel forming blank (400) and is positioned on the radial outermost side of the upper die holder (210);

a first-stage upper adaptor ring (230) connected to a first side portion of the upper die holder (210) and the upper pressing disk (220) in the axial and radial directions, respectively, and located radially inside the upper pressing disk (220); and

an upper backing plate (240) mounted axially to a first side of the upper die holder (210) and disposed radially inward of the first stage upper adaptor ring (230);

the first-stage upper adapter ring (230) is designed into a first-stage universal structural mould in a double-stage universal structural mould, the radial outer side size of the first-stage upper adapter ring (230), an upper mould seat (210) and an upper pressing disc (220) in matching is a fixed size, the radial inner side size is a stepped size which is changed according to the specification of a steel wheel product, the conventional size statistical value of a first outer diameter D1 of a steel wheel forming blank (400) is divided into m steps, wherein m is a natural number larger than 1;

according to the grading of the first-stage upper adapter ring (230), the radial outer side and the radial inner side of the upper pad disc (240) are designed to be m grades correspondingly.

5. The forging die assembly for manufacturing a steel wheel for railway according to claim 4, wherein the upper die unit (200) further includes:

a forming ring (250) located radially inside the first-stage upper adaptor ring (230) and including a step-shaped connecting portion and a conical curved portion integrally formed, wherein the step-shaped connecting portion is connected to the upper saucer (240) and the first-stage upper adaptor ring (230) in the axial direction and the radial direction, respectively, and is provided with a step (252) adjacent to a first-side rim end surface of the rim (440), wherein the conical curved portion is used for contacting with a radially outer portion of the steel wheel forming blank (400);

a second-stage upper adapter ring (251) fitted at a step (252) of the stepped connecting portion of the forming ring (250) and adapted to be brought into contact with a first-side rim end face of the rim (440);

wherein the forming ring (250) is designed as a consumable mold, the minimum inner diameter of the forming ring (250) at the conical curved surface part thereof is set as a ninth inner diameter D9, the ninth inner diameter D9 is consistent with the first outer diameter D1 of the target steel wheel forming blank (400), the radial outer side size of the forming ring (250) is adapted to the selected first-stage upper adapter ring (230), and the inner diameter size of the step-shaped connecting part of the forming ring (250) is stepped according to the first-stage upper adapter ring (230) and is stepped to m steps;

wherein the second stage upper adapter ring (251) is designed as a second stage universal structural mold of the first stage upper adapter ring (230), the outer diameter of the second stage upper adapter ring (251) is consistent with the inner diameter at the step (252) for embedding the second stage upper adapter ring (251), the outer diameter of the second stage upper adapter ring (251) is also graded according to the first stage upper adapter ring (230) and correspondingly graded into m grades, the inner diameter of each grade of the second stage upper adapter ring (251) is determined according to the conventional dimensional statistics of the second inner diameter D2 of the steel wheel forming blank (400) of the selected grade, the step (252) and the second stage upper adapter ring (251) have the same third axial height H3, the third axial heights H3 of the step (252) and the second stage upper adapter ring (251) are determined according to the conventional dimensional statistics of the first hub rim distance H1 of the steel wheel forming blank (400) on the first side, the forging value of the strength of the mold assembly (100) using the mold, And maintenance specification determination.

6. The forging die assembly for manufacturing a steel wheel for railway according to claim 5, wherein the upper die unit (200) further includes:

an upper forming die (260) which comprises an upper forming die connecting part and an upper forming die curved surface part which are integrally formed, wherein the upper forming die connecting part is connected to the radial inner side of the upper backing plate (240) in the radial direction and is positioned on the radial inner side of the second-stage upper adapter ring (251), and the upper forming die curved surface part is used for being in contact with a first side radial inner side surface of a rim (440) of the steel wheel forming blank (400), a first side surface of a spoke plate (430) and a first side radial outer side surface of a hub (420);

an upper height adjustment shim plate (261) axially installed between the upper shim plate (240) and the upper forming die (260);

wherein the upper forming die (260) is designed as a consumable die, the fifth axial thickness H5 of the upper forming die (260) from the joint of the upper forming die (260) and the upper height adjusting shim plate (261) to the contact part of the upper forming die (260) and the first side rim end surface of the rim (440) is determined according to the conventional dimension statistical value of the first hub rim distance H1 of the steel wheel forming blank (400), the die use strength of the forging die assembly (100) and the maintenance regulation, and the upper height adjustment shim plate (261) is designed as a single-stage universal structural mold having a series of thicknesses, a sixth axial thickness H6 of the upper height adjustment shim plate (261) is determined according to a single pass machining amount and maintenance regulation of the upper forming mold (260), making constant a first effective height dimension H7 of the sum of the fifth axial thickness H5 of the upper forming die (260) and the sixth axial thickness H6 of the upper height adjustment shim plate (261);

the radial inner side size of the upper forming die (260) is determined according to the third outer diameter D3 of the target steel wheel forming blank (400), the radial outer side size is determined according to the conventional size statistical maximum value of the second inner diameter D2 of the steel wheel forming blank (400) of the selected grade, and the steel wheel forming blank is divided into m grades according to the grading of the first-grade upper adapter ring (230); and the radial outside dimension of the upper height adjusting shim plate (261) is determined according to the radial inside dimension of the upper shim plate (240), and is also graded according to the first-stage upper adapter ring (230) and is graded into m grades correspondingly, and the radial inside dimension of the upper height adjusting shim plate (261) is determined according to the conventional statistical maximum dimension of the third outer diameter D3 of the steel wheel forming blank (400) of the selected grade and is graded into m grades correspondingly based on the grading of the outer diameter thereof.

7. The forging die assembly for manufacturing a steel wheel for railway according to claim 6, wherein the upper die unit (200) further includes:

an upper loop (270) located radially inward of the upper forming die (260), the upper loop (270) having an upper loop first end facing the steel wheel forming blank (400) and an upper loop second end facing away from the steel wheel forming blank (400), wherein the upper loop first end is for contacting a first side hub end face of the hub (420);

an upper looper base (271) with a first flange, which is located radially inside the upper saucer (240), and a first end of which is connected to an upper looper second end of the upper looper (270), and a second end with a first flange extends toward a first side of the upper die base (210) such that the upper looper (270) is coaxial with the upper looper base (271);

wherein the upper loop (270) is designed as a consumable die, the eleventh inner diameter D11 of the upper loop (270) coincides with the fourth inner diameter D4 of the target steel wheel forming blank (400), and the thirteenth outer diameter D13 coincides with the third outer diameter D3 of the target steel wheel forming blank (400), wherein the axial height of the upper loop (270) is determined according to the first hub rim distance H1 of the target steel wheel forming blank (400);

wherein the upper movable sleeve seat (271) is designed into a single-stage universal structural die, the tenth inner diameter D10 of the upper movable sleeve seat (271) is divided into n grades according to the conventional size statistic of the third outer diameter D3 and the conventional size statistic of the fourth inner diameter D4 of the steel wheel forming blank (400), wherein n is a natural number larger than 1, and the twelfth outer diameter D12 of the upper movable sleeve seat (271) at the joint connecting the upper movable sleeve (270) is also divided into n grades, wherein the eighth axial height H8 of the upper movable sleeve seat (271) is determined based on the conventional size statistic of the first hub rim distance H1 of the steel wheel forming blank (400) and the factor of avoiding mutual interference between components.

8. The forging die assembly for manufacturing a steel wheel for a railway as recited in claim 7, wherein a difference between a thirteenth outer diameter D13 of the upper looper (270) and a twelfth outer diameter D12 of the upper looper base (271) is satisfied as being 0. ltoreq. D13 to D12. ltoreq.20 mm, and a difference between an eleventh inner diameter D11 of the upper looper (270) and a tenth inner diameter D10 of the upper looper base (271) is satisfied as being 0. ltoreq. D10 to D11. ltoreq.20 mm.

9. The forging die assembly for manufacturing a steel wheel for a railway according to claim 8, wherein the upper looper (270) and the upper looper base (271) are screw-coupled, and the second end of the upper looper (270) and the first end of the upper looper base (271) are inserted together in such a manner as to be fitted over each other to couple the upper looper (270) and the upper looper base (271) and to secure their concentricity.

10. The forging die assembly for manufacturing a steel wheel for a railway according to claim 9, wherein a first V-shaped groove (273) is formed along a circumferential direction on an entire outer circumferential surface of the upper looper (270) coupled to and engaged with the upper looper base (271), and the upper looper (270) and the upper looper base (271) are fastened to each other by screwing a first screw such as an inner hexagonal tapered set screw (272) into the first V-shaped groove (273) through a wall of the upper looper base (271).

11. The forging die assembly for manufacturing a steel wheel for railway according to claim 10, wherein the upper die unit (200) further includes:

an upper mandrel head (280) nested inside the upper looper (270) and facing a first end of the upper mandrel head of the steel wheel forming blank (400) for contacting a first side core material concave surface of the core material (410) and a radially inner side surface of a first side of the hub (420);

an upper mandrel holder (281) having a T-shape, including an upper mandrel holder vertical portion and a second flange as an upper mandrel holder lateral portion, wherein the second flange is mounted to a first side portion of the upper die holder (210), and the T-shaped vertical portion is connected to the upper mandrel head (280) such that the upper mandrel holder (281) extends into the upper mantle holder (271) to make the upper mandrel head (280) coaxial with the upper mandrel holder (281), wherein the first flange of the upper mantle holder (271) is connected to the second flange;

wherein the upper mandrel head (280) is designed as a consumable die, a sixteenth diameter D16 of the upper mandrel head (280) is consistent with a fourth inner diameter D4 of the target steel wheel forming blank (400), and wherein the axial height of the upper mandrel head (280) is determined according to the first hub rim distance H1 of the target steel wheel forming blank (400);

wherein the upper mandrel holder (281) is designed as a single-stage universal structural mold, and a fifteenth outer diameter D15 of a T-shaped vertical part of the upper mandrel holder (281) is divided into n stages according to a conventional dimensional statistic of a fourth inner diameter D4 of the steel wheel forming blank (400), wherein a ninth axial height H9 of the upper mandrel holder (281) is determined based on a conventional dimensional statistic of a first hub rim distance H1 of the steel wheel forming blank (400) and a factor of avoiding mutual interference between components.

12. The forging die assembly for manufacturing a steel wheel for railway as claimed in claim 11, wherein a difference between a sixteenth diameter D16 of the upper mandrel head (280) and a fifteenth outer diameter D15 of the upper mandrel base (281) satisfies 0 ≦ (D16-D15) ≦ 20 mm.

13. The forging die set for manufacturing a steel wheel for a railway as recited in claim 12, wherein the upper core rod head (280) and the upper core rod holder (281) are positioned and connected by a first half-closed shoe (282), adjacent connection portions of the upper core rod head (280) and the upper core rod holder (281) are symmetrically designed in a groove form, and the connection is performed at the first groove (283) of the upper core rod head (280) and the upper core rod holder (281) by using two first half-closed shoes (282) which are seamlessly cut to ensure the concentric positioning and connection of both the upper core rod head (280) and the upper core rod holder (281).

14. The forging die set for manufacturing steel wheels for railway according to claim 13, wherein the first half-shell (282) is also a single-stage universal structural die, and the inner diameter and the outer diameter of the first half-shell (282) are also correspondingly stepped and divided into n steps according to the stepping of the upper mandrel holder (281).

15. The forging die assembly for manufacturing a steel wheel for railway according to claim 14, wherein the lower die unit (300) includes:

a lower die holder (310) located at the axially and radially outermost side of the lower die unit (300);

the lower pressing disc (320) is detachably mounted on a second side part, facing the steel wheel forming blank (400), of the lower die holder (310) and is positioned on the outermost side in the radial direction of the lower die holder (310);

a first-stage lower adapter ring (330) connected to the second side of the lower die holder (310) and the lower pressing disc (320) in the axial direction and the radial direction, respectively, and located radially inside the lower pressing disc (320); and

a lower backing plate (340) mounted axially to a second side of the lower die holder (310) and disposed radially inward of the first stage lower adaptor ring (330);

the first-stage lower adapter ring (330) is designed into a first-stage universal structural mould in a double-stage universal structural mould, the radial outer side size of the first-stage lower adapter ring (330), the lower die holder (310) and the lower pressing disc (320) is a fixed size, the radial inner side size is a stepped size which is changed according to the specification of a steel wheel product, the radial inner side size is divided into p steps according to the conventional size statistic value of an eighth outer diameter D8 of the steel wheel forming blank (400), wherein p is a natural number larger than 1, and p and m are the same or different;

wherein, according to the grading of the first-stage lower adapter ring (330), the outer diameter and the inner diameter of the lower pressing disc (320) are designed to be p grades correspondingly.

16. The forging die assembly for manufacturing a steel wheel for railway according to claim 15, wherein the lower die unit (300) further includes:

a second-stage lower adaptor ring (351) connected to the lower saucer (340) in the axial direction and disposed radially inside the first-stage lower adaptor ring (330);

a lower forming die (350) including a lower forming die connecting portion and a lower forming die curved surface portion which are integrally formed, wherein the lower forming die connecting portion is connected to the second-stage lower adapter ring (351) in the radial direction, and wherein the lower forming die curved surface portion is used for contacting with a second-side rim end surface of a rim (440) of the steel wheel formed blank (400), a second side surface of the web plate (430), and a radial outer side surface of a second side of the hub (420);

a lower height adjustment shim plate (352) axially mounted between the lower shim plate (340) and the lower forming die (350);

wherein the second stage lower adapter ring (351) is designed as a second stage universal structural mold of the first stage lower adapter ring (330), the outer diameter of the second stage lower adapter ring (351) is consistent with the inner diameter of the first stage lower adapter ring (330), and is graded according to the first stage lower adapter ring (330) and is graded as p grades correspondingly, and the inner diameter of the second stage lower adapter ring (351) is determined based on the grading of the eighth outer diameter D8 of the steel wheel forming blank (400), and according to the conventional size statistic of the seventh inner diameter D7 of the steel wheel forming blank (400) and the conventional size statistic of the width of the severe wear region of the forming die (350), and is graded as p grades according to the conventional size statistic of the eighth outer diameter D8 of the steel wheel forming blank (400);

wherein the lower forming die (350) is designed as a consumable die, the diameter of the lower forming die (350) at the contact with the rim end face of the second side of the rim (440) is determined in accordance with the eighth outer diameter D8 and the seventh inner diameter D7 of the steel wheel shaped blank (400), the outer diameter of the lower forming die (350) is determined based on the classification of the eighth outer diameter D8 of the steel wheel shaped blank (400) and on the conventional statistical size of the seventh inner diameter D7 of the steel wheel shaped blank (400) and the conventional statistical size of the width of the severe wear region of the forming die (350) and is classified into p-steps in accordance with the conventional statistical size of the eighth outer diameter D8 of the steel wheel shaped blank (400), and the inner diameter of the lower forming die (350) is determined in accordance with the sixth outer diameter D6 of the target steel wheel shaped blank (400),

the tenth axial thickness H10 of the lower forming die (350) from the contact part of the lower forming die (350) and the second side rim end surface of the rim (440) to the connection part of the lower forming die (350) and the lower height adjusting shim plate (352) is determined according to the conventional dimension statistic value of the second hub rim distance H2 of the steel wheel forming blank (400), the die use strength of the forging die assembly (100) and the maintenance regulation;

and, the lower height adjustment shim plate (352) is designed as a single-stage universal structural mold having a series thickness, the radially outer dimension of which coincides with the radially outer dimension of the lower forming die (350), the outer diameter of the lower height adjustment shim plate (352) is determined based on the step of the eighth outer diameter D8 of the steel wheel-formed blank (400) and on the conventional statistical size of the seventh inner diameter D7 of the steel wheel-formed blank (400) and the conventional statistical size of the width of the severely worn region of the forming die (350), and is classified into p steps based on the conventional statistical size of the eighth outer diameter D8 of the steel wheel-formed blank (400), and the inner diameter is determined based on the statistical size of the sixth outer diameter D6 of the steel wheel-formed blank (400) of the selected step and is classified into p steps based on the step correspondence of the outer diameter thereof; the eleventh axial thickness H11 of the lower height adjustment shim plate (352) is designed to have a range of thicknesses in accordance with the single pass throughput and maintenance regulations of the lower forming die (350) such that the second effective height dimension H12 of the sum of the tenth axial thickness H10 of the lower forming die (350) and the eleventh axial thickness H11 of the lower height adjustment shim plate (352) is constant.

17. The forging die assembly for manufacturing a steel wheel for railway according to claim 16, wherein the lower die unit (300) further includes:

a lower loose sleeve (360) located radially inward of the lower forming die (350), the lower loose sleeve (360) having a lower loose sleeve first end facing the steel wheel forming blank (400) and a lower loose sleeve second end facing away from the steel wheel forming blank (400), wherein the lower loose sleeve first end is for contacting a second side hub end face of the hub (420);

a lower looper mount (361) with a third flange, a first end of which is connected to a lower looper second end of the lower looper (360), and a second end with a third flange which extends toward a second side of the lower die holder (310) and is connected to the lower die holder (310) such that the lower looper (360) is coaxial with the lower looper mount (361);

wherein the lower loop (360) is designed as a consumable die, the inner diameter D19 of the lower loop (360) is determined according to the fifth inner diameter D5 of the target steel wheel forming blank (400), the outer diameter D18 of the lower loop (360) is determined according to the sixth outer diameter D6 of the target steel wheel forming blank (400), and the axial height of the lower loop (360) is determined according to the second hub rim distance H2 of the target steel wheel forming blank (400);

the lower movable sleeve seat (361) is designed into a single-stage universal structural die, and the inner diameter D20 of the lower movable sleeve seat (361) is divided into q grades according to the conventional size statistic value of a sixth outer diameter D6 and the conventional size statistic value of a fifth inner diameter D5 of a steel wheel forming blank (400), wherein q is a natural number larger than 1, and q is the same as or different from n; and the outer diameter D21 of the joint of the lower movable sleeve seat (361) and the lower movable sleeve (360) is correspondingly divided into q grades, wherein the thirteenth axial height H13 of the lower movable sleeve seat (361) is determined based on the conventional size statistics of the distance H2 between the second hub rim of the steel wheel forming blank (400) and factors for avoiding mutual interference among components.

18. The forging die assembly for manufacturing a steel wheel for a railway according to claim 17, wherein the lower looper (360) is screw-coupled with the lower looper base (361), and a second end of the lower looper (360) and a first end of the lower looper base (361) are inserted into each other in such a manner as to be fitted over each other to connect the lower looper (360) and the lower looper base (361) and to secure their concentricity.

19. The forging die assembly for manufacturing a steel wheel for a railway as recited in claim 18, wherein a second V-shaped groove is formed along a circumferential direction on an entire outer circumferential surface of the lower looper (360) coupled to and engaged with the lower looper base (361), and the lower looper (360) is fastened to the lower looper base (361) by a second screw such as a set screw (362) which penetrates through a wall of the lower looper base (361) to be screw-engaged with the second V-shaped groove.

20. The forging die assembly for manufacturing a steel wheel for a railway as recited in claim 19, wherein a difference between an outer diameter D18 of the lower looper (360) and an outer diameter D21 of the lower looper base (361) satisfies 0 ≦ D18-D21 ≦ 20mm, and a difference between an inner diameter D20 of the lower looper base (361) and an inner diameter D19 of the lower looper (360) satisfies 0 ≦ D20-D19 ≦ 20 mm.

21. The forging die assembly for manufacturing a steel wheel for railway as claimed in claim 20,

the lower mold unit (300) further comprises:

a lower mandrel head (370) nested inside the lower loop (360) and facing a first end of the lower mandrel head of the steel wheel forming blank (400) for contacting a second side core material concave surface of the core material (410) and a radially inner side surface of the hub (420) on the second side;

a lower mandrel holder (371) in a T-shape comprising a lower mandrel holder vertical portion and a fourth flange as a lower mandrel holder lateral portion, wherein the fourth flange is mounted to the second side of the lower die holder (310), wherein the lower mandrel holder vertical portion is connected to the lower mandrel head (370) such that the lower mandrel holder (371) extends into the lower looper holder (361) and the lower mandrel head (370) is coaxial with the lower mandrel holder (371), wherein the third flange of the lower looper holder (361) is connected to the fourth flange;

wherein the lower mandrel head (370) is designed as a consumable die, the twenty-second diameter D22 of the lower mandrel head (370) is consistent with the fifth inner diameter D5 of the target steel wheel forming blank (400), and the axial height of the lower mandrel head (370) is determined according to the second hub rim distance H2 of the target steel wheel forming blank (400);

wherein the lower mandrel holder (371) is designed as a single-stage universal structural mold, the twenty-third diameter D23 of the lower mandrel holder vertical portion of the lower mandrel holder (371) is divided into q steps according to the conventional statistical size of the fifth inner diameter D5 of the steel wheel forming blank (400), wherein the fourteenth axial height H14 of the lower mandrel holder (371) is determined based on the conventional statistical size of the second hub rim distance H2 of the steel wheel forming blank (400) and factors for avoiding mutual interference between components.

22. The forging die assembly for manufacturing a steel wheel for railway as claimed in claim 21, wherein a difference between the twenty-second diameter D22 of the lower mandrel head (370) and the twenty-third diameter D23 of the lower mandrel base (371) satisfies 0 ≦ (D22-D23) ≦ 20 mm.

23. The forging die assembly for manufacturing a steel wheel for a railway as claimed in claim 22, wherein the lower core rod head (370) and the lower core rod holder (371) are positioned and connected by a second half-closed shoe (372), adjacent connection portions of the lower core rod head (370) and the lower core rod holder (371) are symmetrically designed in a groove form, and the connection is performed at the second groove (373) of the lower core rod head (370) and the lower core rod holder (371) by using two second half-closed shoes (372) which are seamlessly cut, so as to ensure the concentric positioning and connection of both the lower core rod head (370) and the lower core rod holder (371).

24. The forging die set for manufacturing steel wheels for railways as recited in claim 23, wherein the second half-shell (372) is also a single-stage universal structural die, and the inner diameter and the outer diameter of the second half-shell (372) are also correspondingly stepped and divided into q steps according to the stepped design of the lower mandrel base (371).