CN220724716U - Inlay type combined frog core rail and inlay block structure - Google Patents

Abstract

The utility model provides a mosaic formula combination frog core rail, inlay block structure, the core improvement lies in: the casting mold for manufacturing the core rail and the insert after the forging ratio is determined according to the embedded type of the combined frog; the casting mold is used for casting and forming steel ingots corresponding to the triangular abrasion areas of the core rail and the insert harmful space; and the rest part of the cast steel ingot is a profiling casting area, wherein part of the cast steel ingot is a local forging rolling area; the purpose of dividing the forging and rolling area into a partial forging and rolling area and a profiling casting area is as follows: the method is used for carrying out integral heat treatment after the local forging and rolling in the local forging and rolling area, and carrying out machining forming after the detection is qualified so as to obtain the finished product of the core rail and the insert. The utility model solves the technical problems of limited life of harmful space caused by triangular abrasion of the prior embedded combined frog head rail and the embedded block, low efficiency of the manufacturing process of the head rail and the embedded block, high manufacturing cost and unstable quality; can meet the batch production of factories, has relatively low manufacturing cost and higher popularization value.

Description

Inlay type combined frog core rail and inlay block structure

Technical Field

The utility model belongs to the technical field of railway track crossing frog, and particularly relates to an embedded combined frog core rail and embedded block structure.

Background

The railway turnout at 160km/h and below mostly adopts fixed frog. The embedded high manganese steel or alloy steel combined frog has high strength and long service life, can realize seamless connection of lines, is one of main representatives of fixed frog, and is applied to heavy load and common speed lines in a large quantity.

In the manufacturing process of the embedded high manganese steel or alloy steel combined frog, shrinkage cavity, shrinkage porosity and inclusion defects exist on the cast high manganese steel substrate at times, so that the service life of the product is restricted; the forging high manganese steel can fully overcome the defects of shrinkage porosity, shrinkage cavity and the like through a forging process, and the structure is compact, so that the toughness of the high manganese steel is remarkably improved, and test detection data shows that the mechanical property of the product is far higher than that of a cast high manganese steel frog, so that a main-stream switch manufacturer in China refers to an embedded type combined frog structure, and sequentially develops a core rail and embedded integral type forged high manganese steel combined frog, and the core rail and embedded split type forged high manganese steel combined frog, so that small-batch production and application are carried out, and after a heavy-load circuit is tried out, the service life (through total weight) reaches more than 4 hundred million tons, and the service life of the alloy steel frog is longer than that of the alloy steel frog. Experiments show that the split forging high manganese steel combined frog of the core rail and the insert is superior to the integral forging high manganese steel frog in both material mechanical property and service life; therefore, the split forging high manganese steel combined frog with the core rail and the insert has better development prospect.

The core rail and insert split type forged high manganese steel combined frog is of an embedded structure, and the combined frog consists of the core rail, the insert and a common rail; wherein the head rail and the insert are the core components of the combined frog. The core rail and the insert are produced by adopting high manganese steel integral free forging, and the core rail and the insert have the characteristics of high strength and high toughness, and the section of a forging stock is rectangular, but the machining allowance and the thermal deformation are larger, so that the machining efficiency is low, the manufacturing cost is higher than that of alloy steel frog of the same type, and the mass production cannot be carried out at present.

At present, the frog paved on the railway front line in China is mainly a cast high manganese steel frog and alloy steel combined frog. The main disease forms of the frog in the service process are three types of longitudinal cracks of the working edge of the head rail with the section of 20 mm-50 mm, peeling off of the running surface, and collapse of the rail top surface. The cast defects such as shrinkage cavity, shrinkage porosity, microcrack, coarse grains, component tissue segregation and the like of the integral cast high manganese steel frog cannot be thoroughly eliminated in the casting process, and the frog is easy to collapse, peel off and fall off in the use process, so that the service life of the frog is reduced. The alloy steel combined frog has higher strength because the core rail structure is a bainite structure or a bainite/martensite complex phase structure, and the higher the strength of the material is, the lower the plasticity and toughness of the material are. In the severe working conditions that the load born by the frog is high-speed impact and friction of train wheels, and the like, after the running surface is damaged, such as cracks, falling blocks and the like, the development speed is far higher than that of a high manganese steel material, but the safety use performance of the high manganese steel material is reduced.

When used in the field: the common contact area of the tread of the wheel and the frog consists of an insert abrasion triangle area and a section abrasion area of 20-50 mm of the head rail, and the total contact width of the tread of the frog is 95-110 mm. The bearing width of the insert abrasion triangle area is gradually reduced from the tip end of the core rail to the 50mm section of the head of the core rail; the stress width of the area is larger, the area belongs to the transition area of the core rail and the insert bearing load, the area bears the larger impact load of the wheel, and the contact stress of the wheel and the core rail is far larger than that of the wheel and a common rail, so that the frog is in a state of being still intact at other parts, and the abrasion of the triangle area of the insert abrasion and the abrasion area of the core rail with the section of 20 mm-50 mm is serious or the abrasion is limited, so that the frog is in a down-road state.

The forged high manganese steel overcomes the defects of shrinkage porosity, shrinkage cavity and the like through a forging process, has compact structure, and has good mechanical properties, high strength of alloy steel materials and high toughness of high manganese steel materials. Therefore, the integral forged high manganese steel combined frog is developed by the company at present, is applied to heavy load lines in batches, and has a good use effect. However, the existing manufacturing process of the core rail and insert integral forging high manganese steel has the technical problems of high manufacturing cost, unstable quality and the like.

It is found by research that: as the main components of the embedded forged high manganese steel combined frog are the core rail and the embedded blocks, the area from 200mm before the theoretical tip of the frog to 50mm in the core rail is called as a 'harmful space', the track gauge line of the working edge of the area is intermittent, the bearing range of the frog is reduced, the train runs to the area, the smoothness is reduced, the wheel load force is increased, the wear of the frog is aggravated, the triangular wear is commonly generated in the area along with the continuous increase of the transportation capacity, the wear is obviously larger than other parts of the frog, and most of the frog finally comes down due to the fact that the wear of the 'harmful space' reaches the serious injury standard. In this regard, the following improvements have been proposed.

Disclosure of Invention

The utility model solves the technical problems that: the utility model provides a mosaic type combined frog core rail, inlay block structure adopts the mould that carries out local forging to mosaic type combined frog core rail, inlay block harmful space triangle wearing and tearing district region to other positions still adopt the split type manufacturing process of profile modeling casting technology manufacturing, solve current mosaic type combined frog core rail, inlay block whole manufacturing process and lead to core rail, inlay block triangle wearing and tearing harmful space life limited, and core rail, inlay block current manufacturing process inefficiency, manufacturing cost is high, the unstable technical problem of quality.

The utility model adopts the technical scheme that: an embedded combined frog core rail and embedded block structure, the core improvement is that: the casting mold for manufacturing the core rail and the insert after the forging ratio is determined according to the embedded type of the combined frog; the casting mold is used for casting and forming steel ingots corresponding to the triangular abrasion area of the harmful space of the core rail and the insert; and the rest part of the cast steel ingot is a local forging and rolling area and the rest part is a profiling casting area; the purpose of dividing the forging and rolling area into a partial forging and rolling area and a profiling casting area is as follows: the method is used for carrying out integral heat treatment after the local forging and rolling in the local forging and rolling area, and carrying out machining forming after the detection is qualified so as to obtain the finished product of the core rail and the insert.

In the above technical solution, further: and the boundary between the local forging rolling area and the profiling casting area of the casting mold is in slope or fillet transition.

In the above technical solution, preferably: the cross section of the local forging rolling area is circular or polygonal; the section shape of the profiling casting area is profiling convex-concave shape.

In the above technical solution, further: and the machining allowance 7 before machining and forming after the detection of the profiling casting area and the local forging and rolling area is qualified is less than or equal to 20mm.

In the above technical solution, further: the forging ratio is 3-12.

In the above technical solution, preferably: the core rail and insert casting mold is an ingot mold or a wood mold.

In the above technical solution, preferably: when the core rail and the insert are locally forged and rolled in the local forging and rolling area, the core rail and the insert are locally forged and rolled: heating the core rail and the insert steel ingot to 900-1250 ℃, then cogging and forging, controlling the final forging temperature to 800-1150 ℃ and striking and forging by a hammer head; and heating the billets after cogging to 950-1250 ℃, and then preparing forging billets on a quick forging machine, wherein the final forging temperature is controlled to be higher than 950 ℃.

In the above technical solution, further: the heat treatment is water toughening treatment.

In the above technical solution, preferably: the core rail and the insert are made of forged high manganese steel or alloyed high manganese steel; the forged or alloyed high manganese steel is a high manganese steel specified in the national standard GB/T5680-1998 and a high manganese steel alloyed with one of chromium, molybdenum, nickel, titanium, vanadium, boron, aluminum, nitrogen, saw and rare earth elements and/or a composite thereof on the basis of this.

In the above technical solution, further: the triangular abrasion zone area of the harmful space of the heart rail is an area from the end face of the heart rail to the width Y of the 1-rail of the heart rail, which is less than or equal to 100 mm; the area of the triangular abrasion zone of the harmful space of the insert corresponds to the area from X less than or equal to 500mm in front of the theoretical tip of the frog to Y less than or equal to 100mm in width of 1 track of the head rail.

In the above technical solution, preferably: the core rail and the insert are in an embedded combined frog; the embedded combined frog comprises a core rail, an embedded wing rail, a fork heel rail, a high-strength bolt pair, a fastener system, a backing plate and a bridge backing plate, and is characterized in that: the bottom surface of the front section of the heart rail and the bottom surface of the rear section of the heart rail are in step structure transition; the insert is provided with a front end arc structure and a rear end arc structure which are inlaid in the steel rail.

In the above technical solution, further: the outer side of the core rail and the steel rail are in a wedge-shaped matching structure; the section of the core rail and the steel rail are in a lock catch matching structure; the section of the insert matched with the steel rail is provided with an equal-width convex structure manufactured by processing a forming cutter.

Compared with the prior art, the utility model has the advantages that:

1. the utility model relates to an embedded combined frog core rail and insert structure and a preparation method thereof, wherein the partial forging is carried out on the triangular abrasion area of the harmful space of the embedded combined frog core rail and insert, the rest parts are still manufactured by adopting a split type manufacturing process manufactured by a profiling casting process, the life of the harmful space of the triangular abrasion of the core rail and the insert is effectively prolonged, the manufacturing process efficiency is also improved, the cost is effectively controlled, and the quality is relatively stable.

2. Compared with the manufacturing process of integrally forging the high manganese steel core rail and the insert, the manufacturing process of the utility model forges the forging local (namely harmful space) area of the high manganese steel core rail and the insert, reduces the forging difficulty, improves the forging quality and the yield, and reduces the manufacturing cost; correspondingly, the geometric dimensions of the forged high manganese steel core rail and the insert are smaller before heat treatment, and the heat treatment process can be favorable for accelerating cooling, reducing carbide precipitation and having more excellent mechanical properties; meanwhile, 50% -70% of the areas of the forged high manganese steel core rail and the insert are profiling casting areas, machining allowance is small, machining difficulty is reduced, and production efficiency is improved.

3. According to the utility model, the bottom surface of the front section of the heart rail is in a step structure, so that the bonding quality of the steel rail and the heart rail is improved.

4. The insert is of a circular arc structure from front to back and is inlaid in the steel rail, so that the matching quality is effectively improved, the matching section of the insert and the steel rail is of an equal-width structure, and the insert and the steel rail are cooperatively manufactured by adopting a forming cutter, so that the processing efficiency and the processing precision are improved.

5. The boundary between the forging and casting areas is in slope or fillet transition, the reserved forging and rolling manufacturing reserve and the machining allowance of the profiling casting machine are reserved, and the quality is stable.

6. The utility model is refined by an electric arc furnace and an LF+VD furnace, the chemical components, gas content and inclusion of molten steel meet the corresponding standards, and the high efficiency and quality stability consistency of the product are ensured.

7. The technical scheme of the utility model is mature, can meet the batch production of factories, has relatively low manufacturing cost and has higher popularization value.

Drawings

FIG. 1 is a schematic view of an inlaid combination frog core rail and insert structure of the present utility model;

FIG. 2 is a front view of a casting steel ingot structure before forging and rolling a high manganese steel core rail according to the present utility model;

FIG. 3 is a top view of FIG. 2;

FIG. 4 is an enlarged cross-sectional view of one embodiment A-A of FIG. 3;

FIG. 5 is an enlarged cross-sectional view of another embodiment A-A of FIG. 3;

fig. 6 is a front view of the ingot structure after the forging and rolling of the high manganese steel core rail part according to the present utility model;

FIG. 7 is a top view of FIG. 6;

FIG. 8 is a cross-sectional view A-A of FIG. 6;

FIG. 9 is a B-B cross-sectional view of FIG. 6;

FIG. 10 is a cross-sectional view of C-C of FIG. 6;

FIG. 11 is a D-D sectional view of FIG. 6;

FIG. 12 is a sectional E-E view of FIG. 6;

fig. 13 is a schematic view of a steel ingot structure before forging and rolling of the insert for forging high manganese steel according to the present utility model;

FIG. 14 is a top view of FIG. 13;

FIG. 15 is an enlarged cross-sectional view of one embodiment A-A of FIG. 13;

FIG. 16 is an enlarged cross-sectional view of the alternative embodiment A-A of FIG. 13;

fig. 17 is a front view of a steel ingot structure after forging and rolling of a forged high manganese steel insert;

FIG. 18 is a top view of FIG. 17;

FIG. 19 is a cross-sectional view A-A of FIG. 18;

FIG. 20 is a B-B cross-sectional view of FIG. 18;

FIG. 21 is a cross-sectional view of C-C of FIG. 18;

FIG. 22 is a top view of a shaped core rail;

fig. 23 is a front view of fig. 22;

FIG. 24 is a schematic cross-sectional view of the core rail section associated with FIG. 22 in a snap-fit configuration with the rail;

FIG. 25 is a front view of a forming insert;

FIG. 26 is a schematic view of an equivalent width projection arrangement of the insert associated with FIG. 25;

fig. 27 is a schematic view of a casting mold corresponding to the casting ingot of fig. 14 of fig. 3;

in the figure: 1-core rail, 2-insert, 3-local forging and rolling area, 4-profiling casting area, 5-slope or fillet transition, 6-round or polygonal, 7-machining allowance, 101-core rail front section bottom surface, 102-core rail rear section bottom surface, 201-front end arc structure, 202-rear end arc structure and 203-equal width convex structure.

Detailed Description

The technical solutions of the embodiments of the present utility model will be clearly and completely described below with reference to the accompanying drawings 1 to 27 related to the embodiments of the present utility model, and it is apparent that the described embodiments are only some embodiments of the present utility model, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the utility model without making any inventive effort, are intended to be within the scope of the utility model.

An inlaid combined frog core rail and inlaid block structure, the improvement is that: the casting mould for manufacturing the point rail 1 and the insert 2 after the forging ratio is determined according to the embedded type combined frog model; the casting mold is used for casting and forming steel ingots corresponding to the triangular abrasion area of the harmful space of the core rail 1 and the insert 2; and a part of the cast steel ingot is a local forging and rolling area 3, and the rest part of the cast steel ingot is a profiling casting area 4; the purpose of the division into the partial forging rolling zone 3 and the profiling casting zone 4 is to: the method is used for carrying out integral heat treatment after the local forging and rolling in the local forging and rolling area 3, and carrying out machining forming after the detection is qualified so as to obtain the finished products of the core rail 1 and the insert 2.

In the above embodiment, further: the boundary between the local forging rolling area 3 and the profiling casting area 4 is in a slope or fillet transition 5. The boundary between the forging and casting areas is in slope or fillet transition, the reserved forging and rolling manufacturing reserve and the machining allowance of the profiling casting machine are reserved, and the quality is stable.

On the basis of any of the foregoing embodiments, it is preferable that: the cross section of the local forging rolling area 3 is circular or polygonal 6; the section shape of the profiling casting area 4 is profiling convex-concave shape. When the embodiment of the shape is adopted, the improvement of the processing efficiency is relatively favorable.

On the basis of any of the foregoing embodiments, it is preferable that: and the machining allowance 7 before machining and forming after the profiling casting area 4 and the local forging and rolling area 3 are detected to be qualified is less than or equal to 20mm. When the allowance is maintained, the processing efficiency is relatively high, and the quality is relatively stable.

On the basis of the utility model points, the utility model adopts the utility model point combination of the prior art as follows: the forging ratio is 3-12; the casting mould of the core rail 1 and the insert 2 is an ingot mould or a wood mould; when the core rail 1, the insert 2 and the local forging and rolling area 3 are subjected to local forging and rolling: the steel ingot of the core rail 1 and the insert 2 is heated to 900-1250 ℃ and then is cogged and forged, the final forging temperature is controlled to 800-1150 ℃, and the hammer head is used for striking and forging; heating the billets after cogging to 950-1250 ℃, then preparing forging billets on a quick forging machine, and controlling the final forging temperature to be above 950 ℃; thereafter, again on this basis, it is preferable that: the heat treatment is water toughening treatment.

On the basis of any of the foregoing embodiments, the present utility model is relatively further defined and preferred as follows: the core rail 1 and the insert 2 are made of forged high manganese steel or alloyed high manganese steel; the forged or alloyed high manganese steel is a high manganese steel specified in the national standard GB/T5680-1998 and a high manganese steel alloyed with one of chromium, molybdenum, nickel, titanium, vanadium, boron, aluminum, nitrogen, saw and rare earth elements and/or a composite thereof on the basis of this.

Based on any of the foregoing embodiments, for a specific track type, the preferred technical solutions and embodiments are: the region of the triangular abrasion zone of the harmful space of the heart rail 1 is a region from the end face of the heart rail 1 to the width Y of the heart rail 1, which is less than or equal to 100 mm; the harmful space triangular abrasion zone area of the insert 2 corresponds to an area from the front X of the theoretical tip of the frog to the width Y of the head rail 1 to the width Y of the head rail to the width of 100 mm.

It should be understood that: the utility model discloses an embedded combined frog core rail and an embedded block structure, which are claimed to be: the method for manufacturing the point rail 1 and the insert 2 in any one of the technical schemes and the embodiment of the "mosaic combined frog" point rail and the insert comprises the steps of improving the related structures of the point rail 1 and the insert 2, and the method needs to be explicitly: the mosaic type combined frog comprises: the rail comprises a core rail 1, an insert 2, wing rails, fork heel rails, a high-strength bolt pair, a fastener system, a backing plate and a bridge backing plate. On the basis, for the mosaic type combined frog, the improvement is that: the bottom surface 101 of the front section of the heart rail and the bottom surface 102 of the rear section of the heart rail 1 are in step structure transition (see fig. 23); furthermore, the insert 2 has a front end arc structure 201 and a rear end arc structure 202 (see fig. 25) that are inlaid into the rail.

On the basis, the outer side of the core rail 1 and the steel rail form a wedge-shaped matching structure (as shown in figure 1); the section of the core rail 1 and the steel rail are in a lock catch matching structure (shown in figure 24); the insert 2 and the steel rail are matched in cross section and provided with an equal-width convex structure 203 (shown in fig. 26) manufactured by machining with a forming knife.

The embedded combined frog core rail and insert structure adopts the split manufacturing thought that the harmful space triangular abrasion area of the embedded combined frog core rail and insert is locally forged, and the rest parts are manufactured by adopting the profiling casting process, so that the harmful space life of the core rail and insert triangular abrasion is effectively prolonged, the manufacturing process efficiency is also improved, the cost is effectively controlled, and the quality is relatively stable.

From the above description it can be found that: compared with the manufacturing thought of integrally forging the high manganese steel core rail and the insert, the method provided by the utility model has the advantages that the forging is carried out on the forging local (namely harmful space) area of the high manganese steel core rail and the insert, the forging difficulty is reduced, the forging quality and the yield are improved, and the manufacturing cost is reduced; correspondingly, the geometric dimensions of the forged high manganese steel core rail and the insert are smaller before heat treatment, and the heat treatment process can be favorable for accelerating cooling, reducing carbide precipitation and having more excellent mechanical properties; meanwhile, 50% -70% of the areas of the forged high manganese steel core rail and the insert are profiling casting areas, machining allowance is small, machining difficulty is reduced, and production efficiency is improved.

Moreover, the bottom surface of the front section of the heart rail is of a step structure, so that the bonding quality of the steel rail and the heart rail is improved. Meanwhile, the front and rear parts of the insert are in arc structures and are inlaid in the steel rail, so that the matching quality is effectively improved, the matching section of the insert and the steel rail is of an equal-width structure, and the insert and the steel rail are cooperatively manufactured by adopting a forming cutter, so that the processing efficiency and the processing precision are improved again.

In addition, the boundary between the forging area and the casting area is in slope or fillet transition, the forging rolling manufacturing reserve amount and the profiling casting machine machining allowance are reserved, and the quality is stable.

The utility model is refined by an electric arc furnace and an LF+VD furnace, the chemical components, gas content and inclusion of molten steel meet the corresponding standards, and the high efficiency and quality stability consistency of the product are ensured.

Therefore, the technical scheme of the technical idea is mature, can meet the batch production of factories, has relatively low manufacturing cost and has higher popularization value.

In summary, the method for combining the local forging rolling and the local casting process combines the later heat treatment and machining; on one hand, the forging and rolling cost is reduced, the machining allowance is reduced, and on the other hand, the operation is simple, the quality is stable, the safety and the reliability are high, and the popularization value is high.

In this specification, each embodiment is described in a related manner, and identical and similar parts of each embodiment are all referred to each other, and each embodiment mainly describes differences from other embodiments.

The foregoing description is only of the preferred embodiments of the present utility model and is not intended to limit the scope of the present utility model. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present utility model are included in the protection scope of the present utility model.

Claims (9)

1. An inlaid combined frog core rail and inlaid block structure is characterized in that: the casting mold for manufacturing the point rail (1) and the insert (2) after the forging ratio is determined according to the embedded type combined frog model; the casting mold is used for casting and forming steel ingots corresponding to the triangular abrasion areas of the harmful spaces of the core rail (1) and the insert (2); and part of the cast steel ingot is a local forging and rolling area (3), and the rest part of the cast steel ingot is a profiling casting area (4).

2. The mosaic composite frog core rail and insert structure of claim 1 wherein: and the boundary part of the local forging rolling area (3) and the profiling casting area (4) of the casting mold is in a slope or fillet transition (5).

3. The mosaic composite frog core rail and insert structure of claim 1 or 2, wherein: the cross section of the local forging rolling area (3) is circular or polygonal (6); the section shape of the profiling casting area (4) is profiling convex-concave shape.

4. A mosaic composite frog core rail and insert structure as claimed in claim 3, wherein: and machining allowance (7) before machining and forming after the profiling casting area (4) and the local forging and rolling area (3) are detected to be qualified is less than or equal to 20mm.

5. The mosaic composite frog core rail and insert structure of claim 1 wherein: the forging ratio is 3-12; the casting mould of the core rail (1) and the insert (2) is an ingot mould or a wood mould.

6. The mosaic composite frog core rail and insert structure of claim 5 wherein: the core rail (1) and the insert (2) are made of forged high manganese steel or alloyed high manganese steel.

7. The mosaic composite frog core rail and insert structure of claim 1 wherein: the region of the triangular abrasion zone of the harmful space of the heart rail (1) is a region from the end face of the heart rail (1) to the width Y of the heart rail (1) which is less than or equal to 100 mm; the harmful space triangular abrasion zone area of the insert (2) corresponds to the area from X less than or equal to 500mm in front of the theoretical tip of the frog to Y less than or equal to 100mm in rail width of the core rail (1).

8. The mosaic composite frog core rail and insert structure of claim 1 wherein: the core rail (1) and the insert (2) are core rails and inserts in the embedded combined frog; the embedded combined frog comprises a core rail (1), an embedded block (2), a wing rail, a fork heel rail, a high-strength bolt pair, a fastener system, a backing plate and a bridge backing plate, and is characterized in that: the bottom surface (101) of the front section of the heart rail and the bottom surface (102) of the rear section of the heart rail (1) are in step structure transition; the insert (2) has a front end arc structure (201) and a rear end arc structure (202) which are inlaid into the steel rail.

9. The mosaic composite frog core rail and insert structure of claim 8 wherein: the outer side of the core rail (1) and the steel rail form a wedge-shaped matching structure; the section of the core rail (1) and the steel rail are in a lock catch matching structure; the section of the insert (2) matched with the steel rail is provided with an equal-width convex structure (203) manufactured by a forming cutter.