DD201981A5 - PROCESS FOR PRODUCING NORMAL AXES, IN PARTICULAR. RAILWAY CARRIAGE AXIS - Google Patents

Abstract

1. Process for producing axles, especially of railway rolling stock, by forging in a mould (9, 10, 13, 14) a heted blank (8) of a diameter less than the largest diameter of the axle to be produced, characterised in that at least some of the blank (8) is heated to a temperature of between 1 100 degrees and 1 300 degrees C, preferably near 1 260 degrees C, in that the axle has two spindles (f1 , f2 ), and in that forging includes a simultaneous operation of upsetting the central parts (c, pc, pd) of the axle and extruding at least one of the two spindles (f1 , f2 ), this simultaneous operation being carried out as a result of a movement towards the centre of the axle of at least one ring (13, 14) forming part of the mould, this movement being produced by means of a single press stroke.

Description

Berlin, 29. 10.81 59 450 26

Process for the production of Normai axes, in particular railway car axles

Field of application of the invention:

The present invention relates to the manufacture of car axles and other metallic axles of similar shape in all cases where these car axles or axles terminate at both ends in cylindrical or conical parts - the steering knuckles - whose mean diameter is smaller than the largest diameter of the considered ones Car axle or axle is.

The invention is particularly applicable to the production of railway car axles.

Characteristic of the known technical solutions

Such axes generally have the following structure, which is also shown in Figs. 1 and 2:

a first knuckle f1, which is formed from a cylinder or cone of medium diameter d (f) and terminates with a rounded connecting piece for the following discharge surface, this knuckle serving as a vehicle carrier via a stub axle bearing or a kingpin bushing

a first discharge surface pd1, also sometimes called a "grease baffle", whose length is small, whose profile is rounded and whose mean diameter d (pd) is generally greater than the diameter d (f) of the steering knuckle;

a first bearing surface pe with a diameter d (pe),

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which is greater than the diameter d (f) of the steering knuckle and the mean diameter d (pd) of the deflection surface, on which bearing surface an Ead of the vehicle is fastened;

a body c, which may be cylindrical, with a diameter a (c) in certain yaw axis types as in Fig. 1, or cylindrical-double conical in certain other types as in Fig. 2 (d (c), in the latter case the diameter d (c) of the body is always smaller than the diameter d (pc) of the bearing surface and generally larger than the diameter d (f) of the steering knuckle;

a second bearing surface pc2, which is identical to the first and serves to receive a further wheel of the vehicle;

a second discharge area pd2 identical to the first one;

- And finally a second stub axle f2, which is identical to the first and serves as a vehicle carrier via a Achsschenkellager.

It should be noted that a normal axis can also include:

either a gear surface pe with a diameter d (pe), which is generally larger than the diameter of the body d (c) and larger than the diameter of the support

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area d (pc) is; on this surface the gear drive for the locomotive drive is attached;

- or (see Fig. 3) two additional surfaces ρ disc 1 and ρ disc 2, which serve to accommodate the brake discs of Heisezügwagen, wagons or locomotives. Their diameter d (disc) is generally larger than the diameter of the body d (c) and larger than the diameter of the bearing surface d (pc). The intermediate bodies C ^ and Cp have a similar diameter as d (c;

This has been brought to the understanding of the following statements. Hereinafter, the known for the production of normal axes Warmmassivumformverfahren be briefly explained j which are all characterized by .Recken the Eohlings. They can be classified into three different categories:

a). Vertical open-die forging with a leveling die, with a lower die or die, made either by means of a vertical hydro press or a forging hammer.

b) Horizontal open-die forging, which is carried out with the help of a horizontal forging machine with several hammers.

c.) rolling on a special rolling mill with rolling elements whose basic principle reminds of the principle of rolling steel pipes oiane welds.

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These known methods have great disadvantages:

On the one hand, the forging methods call for a) and b) a large number of hammer blows: between 100 and 130 for the method for &) and between 400 and 500 for the method for bj, whereby the production speed is not very high.

- Then, in all known methods, the quality of the result obtained depends inter alia on the reliability of the control of the press, the forging machine or the roller, and this reliability is difficult to ensure because of the very large variety and the expense of successive basic operations.

In addition, the excess thicknesses are strong in the process of a) and quite strong in the process of b), so that the conversion coefficients (the ratio between the weight of the blank and the finished carriage axis after machining) are high: 1.300 in the process too a) and 1,250 in the process to b).

- The intrinsic quality of the car axles made by the method of a) is good, but the thicknesses obtained during forging are large. By contrast, the internal quality of the carriage axles produced by the method according to b) is already countervailable by the deformations which occur essentially in the form of overlaps, while the over thicknesses are smaller than in the method according to a).

- In the process of a) the straightness is very inexact and it must be the axis in an additional operation

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Another known type of production of some carriage axles is a non-forging method by means of a round rolled blank, which is oriented by a normalizing process and then machined. The two main disadvantages of this known method are that the cutting cuts some fibers of the rolled metal lower mechanical strength of the carriage axis can cause, and that the metal turnover coefficient, that is, the ratio between the weight of the blank and the weight of the finished axle, is very high.

Object of the invention

The object of the invention is to provide a method of the generic type for the production of normal axes, in particular of railway car axles in such a way that the effort in the production of the same lowered, the metal conversion coefficient is low and beyond the utility properties of the axes are increased.

Explanation: the essence of the invention

The invention has for its object to provide a method for producing normal axes, in particular of railway car axles by means of warm passive forming, with a hot massive deformation is brought by hot compression extrusion presses, which completely dispensed with the stretching and in contrast upsets the middle parts of a heated blank and at the same time its ends are extruded, so that this process is characterized by a one-step operation of

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Compression of the blank in a closed matrix distinguishes *

For this purpose, the subject of the present invention is a production method of normal axes by compression extrusion of a full or tubular, heated blank, characterized in that the diameter of the blank is smaller than the largest diameter of the normal axis to be produced, that at least a portion of the blank to a temperature between 1100 and 1300 C, preferably to 1260 ⁰ C is heated and that the hot massive forming by Stauchfließpressen comprises at least one of the two stub axles, wherein these simultaneously performed operations are realized by a single press stroke.

According to a first variant of the invention, the hot massive forming by upsetting extrusion of a certain normal axis is carried out in a die in which all parts are immovable, by two consecutive strokes of the press, that is, a stroke of the press for each of the two lateral halves of the normal axis, the two strokes of the press being separated by an intermediate heating and an intermediate transport.

According to a second variant of the invention, the hot massive forming by upsetting extrusion of a full normal axis is made with a single stroke of the press, the body of the normal axis remains immobile, while the die comprises two movable stub axle, by extrusion the two stub axles and the two Ableitflächen and simultaneously by compression

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shape the bearing surfaces.

According to a special feature of the invention, the blank is heated in its entirety to a temperature between 1100 and 1300 ⁰ C, preferably to about 1260 ⁰ C.

According to another particularity of the invention, which differs from the preceding, the blank is subjected to a gradual differentiated heating.

So is specifically recommended that the parts of the blank which are to form the stub axles, to heat to a temperature between 1100 and 125O ⁰ C, preferably to about 1180 ⁰ C.

In addition to the previous recommendation, the parts of the blank which are intended for forming the intermediate contact surfaces which are intended to accommodate the brake discs or wheels, to heat to a temperature between 1200 and 13OO ⁰ C, preferably to about 1260 ⁰ G is also recommended.

If it is a carriage axle whose cylindrical body is not to be deformed by forging, the part of the blank intended to form the normal axle body is not heated.

According to a further feature, the method of producing tubular normal axes is characterized in that the blank is previously hollow-bored and filled with silicon oxide or any other refractory powdery material whose dilation coefficient with respect to that of the axle steel is such that its adhesive

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good on the blank, without being too large, and that its removal at ambient temperature has no difficulty.

In order to heat the blank in the method according to the invention and especially when it comes to a stepwise differentiated heating, preferably an induction heating should be used.

According to a further special feature of the invention, the blank consists of a rolled, round rod which is encrusted before heating.

It can also consist of a square bar with rounded corners or of a bar with an arcuate cross-section, that is a square bar with curved side surfaces, which is encrusted before heating.

The hot massive forming method according to the invention of normal axes by upset extrusion can be carried out on a vertical forging press as well as on a horizontal forging press. In the worst case, the forging can also be oblique, but this does not provide any practical advantage.

In the method according to the invention, each part of the matrix is lubricated individually and effectively independently of the forging direction.

It will be readily apparent that the present invention has great advantages over the known forging or rolling methods of carriage axles.

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On the one hand, the speed of production is much higher, since for a given car axle this would require two or even a single press stroke instead of 100 to 130 or even 400 to 500, as in this or that known process.

In addition, the quality of the result obtained is independent of a more or less high reliability of the control system, since the geometric profile of the die parts, which is set with great precision, prescribes the dimensions of the carriage axle thus produced.

On the other hand, the blank may be cylindrical, which simplifies the preparation ·

Also, the oversizes in the forging blank thus obtained in the upsetting extrusion process, which are removed in the subsequent processing in order to obtain the finished carriage axis, are lower than in the known methods.

Thus, in order to obtain an axis of 520 kg, it is sufficient to assume a Kohling of less than 600 kg, compared to 680 kg for a type known by the vertical forging method and 65Ο kg for a blank produced by the forging method between the weight of the blank and the weight of the finished axle below 1.150.

Before machining the oversize, the axis produced by the method according to the invention does not require deburring, since it has no burrs.

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"As far as the inner quality of the car axle thus obtained is concerned, this procedure ensures a complete Ifaser process, and in the final production, whole fibers are cut off without breaking an existing fiber."

In general, the accuracy of the inventive forging is better than in all known methods.

As far as heating is concerned, the variants of the method according to the invention which provide stepwise differentiated heating, for example by induction, allow a significant saving in energy compared to complete heating of the blank.

The invention thus has many advantages. Ausführungsoeispiel

For a better understanding of the invention, three examples of the invention for the production of railcar axles according to the invention are described below.

The first example relates to a car axle A with a cylindrical body. The second example relates to a car axle B with a cylindrical-double conical body. The third example relates to a carriage axis C with a cylindrical body and four bearing surfaces. In the drawings show:

Fig. 1: a longitudinal profile of the carriage axis A; Fig. 2: a longitudinal profile of the carriage axis B;

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Fig. 3ι a longitudinal profile of the carriage axis C with four edition ef laugh;

Fig. 4 shows temperature curves of the stepwise differentiated and 5: heating for each of the two ends of the carriage axis C;

Fig. 6, 7 are schematic illustrations of the Stauchfließpreß- and 8: method of the carriage axis A; they each include:

- in Figure _# 6: a view of the blank of the press and movable Ashsschenkelringe before Stauchfließpreßverfahren;

in Fig. 7i, an overall view at the end of the compression molding process;

- in.Fig »8: an overall view after the compression molding process, ie after the withdrawal of the upper part of the press and after the withdrawal of the movable kingpin rings;

Fig. 9, 10th

and Fig. 11: also a schematic representation of the compression molding process of the carriage axis B;

they each include:

in Figure 9: a view before the compression molding process;

in FIG. 10: a view at the end of the compression molding process;

in Figure 11: a view after the compression molding process;

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12 -

12, 13 a schematic representation of the compression flow rate of the carriage axis C and 14: they each include:

- S'ig. 12: a view in front of the upsetting flow

press;

FIG. 13 is an overall view at the end of FIG

Stauchfließpressens;

- S ¹ Ig. 14: an overall view after the compression

flow squeeze.

These three axle types A, B and C shown in the figures can be produced according to the invention under identical forging conditions, the only differences being geometric, especially for the parts of the carriage axle forming the body and the number of bearing surfaces.

Their respective dimensions are as follows; (In mm):

Carriage axis A steering knuckle Ableitfläche bearing surface body

Diameter d (f) = 130 d (pd) = 152 d (pc) = 200 d (c) =

173 length 191 58 180 1369

Car axle B

Diameter d (f) = 157.25 ä (pc) = 222.25

d (pd) = 191.28 d (c) =

Length 298.85 46 193.7 x = 524

7 = 152

x = 524 1200

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Car axle G (see overview of dimensions)

If the hot massive forming by upsetting extrusion presses is performed in two successive press strokes so that in each case a stroke for gede the two axle halves applies, the first stepwise differentiated heating for the first half of the axis after the temperature curve 2 of FIG. 4 is made. In this pig. is the blank 1 shown schematically the suitable for an axis G type. It is a round bar of 2 430 millimeters in length and 195 millimeters in diameter. Its heating is done by induction in the following way:

The part 4 of the blank 1, which is 335 millimeters long, is heated to a temperature of 1260 ⁰ C. It is intended to form the bearing surface of the disc and the intermediate body.

The part 3 of the Eohlings 1, which is 600 mm long, is heated to a temperature of 1180 ⁰ C. It is designed to form the contact surface of the Eades, the discharge surface and the steering knuckle.

The remaining part 5 <e © Eohlings 1 is not heated and remains at ambient temperature.

After the hot massive deformation of this first half by compression extrusion, as will be explained below, the induction heating of the second half of the fiohlings 1 made after the first, already forged half was surrounded with a protective jacket 6.

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The heat profile 7 used is shown in FIG. It is symmetrical to that of FIG. 4. Then the second stroke of the press is used ·

Overview of dimensions of the roll axis G (in gun).

Carriage axis C Axle diverting bearing support. Intermediate body

leg surface area d, d · disk. C3

Ben wheels or

gear transmission

Diameter d (f) = 130 d (pd) = i60 d (pol) = 1-85 d (p disc 1) d (C1) = i60 (c) = 155

= 188

Length 217 49 165 184 107 836 ^

VD

-J ^ VJI

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Hot massive forming by upset extrusion can also be done with a single press lift if the two halves of the blank are heated simultaneously and if the available press permits

Hot massive forming by upset extrusion of a type A car axle with a cylindrical body is shown schematically in FIGS. 6, 7 and 8.

In Fig. 6, the middle part of the blank 8 is pressed before forging between the two semi-cylindrical halves y and 10 of the die, on the other hand, two recesses 11 and 12 having a diameter which can be achieved for the two bearing surfaces' dimensions is adapted. In addition, two movable dies in the form of kingpin rings 13 and 14 of suitable profile are attached to each end of the carbon ring.

As can be seen in the comparison of FIGS. 6 and 7, the hot massive deformation according to the invention by upset extrusion presses therein, the movable kingpin rings 13; 14 (Fig. 6) and 13 '; 14 * (Fig. 7) either in two successive operations of the press or in a single operation to advance so that the two stub axles are obtained by extrusion, while the two bearing surfaces arise by compression, the extrusion and the upsetting simultaneously going on.

After forging (Figure 8), the two movable kingpin rings 13 "; 14 "subtracted and the half b of the die removed, so that the forged carriage axle 15, which rests on the other half 10 of the die, now trans-

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can be ported.

FIGS. 10 and 11 also schematically illustrate the same hot mass forming operations by upsetting extrusion of a car axle with four type C bearing surfaces. The only difference is the fact that the two halves 16 and 17 of the die have two additional bearing surfaces and have no cylindrical or cylindrical-double conical profile more.

A major advantage of the invention according to the invention by compression extrusion presses is that after forging the remaining machining allowances to be eliminated by further processing are much smaller than in the known forging processes.

FIGS. 12, 13 and 14 also schematically illustrate the same operations for hot mass forming by upsetting extrusion of a car seat with four support surfaces of type C. The only difference is that the two halves 18 and 19 of the die have two additional bearing surfaces and none have cylindrical or cylindrical-double conical profile more.

Thus, Table I below, for a Type A caravan, gives the dimensions of the diameter and length of the finished finished car axle, the forging blank prior to machining according to the known forging methods and forging blank prior to machining according to the invention.

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Table II gives the same dimensions for a Type B car axle »

Table III gives the same dimensions for a type C car axle.

Table I Type A car axle with cylindrical body (dimensions in mm)

Axle Ableit- support body thigh flat surface

diameter

Finished axle 130 152 200 173

Forging blank after known

Method 150 172 220 193

Forged blank according to the inventive method 138 178 208 181

length

Finished axle 1 ^ 1 58 180 1369

Schmiederoüling after known

Method 225 60 250 1300.

Forging blank according to the invention according to method 205 58 188 1314

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Table II Type B car axle with cylindrical-double conical body (dimensions in mm)

Axle Ableit- support body thigh surface area

Pass through ,. ,

Finished axle 157,25 191,28 222,25 201,5 /

Forging blank according to known method 182 213 243 221 /

Forging blank according to the invention 165 199 232 208 /

Length . χ y χ

Finished axle 298.85 46 193.7 524 152

Forging blank according to the known method 325 45 255 415 3OO

Forging blank according to the method according to the invention 314 45 202 496 200

Table III C-type carriage with cylindrical body and four bearing surfaces (dimensions in mm)

Axis- Ableit- support- intermediate support- central body thigh surface area for body surface for

Wheels disc

diameter

Finished axle

Forging blank according to known method

Forging blank according to the inventive method

160

160 205 168

188

205

196

155

175

163

O O CD

Long

Finished axle

Forging blank according to known method

Forging blank according to the inventive method

107

460

99

184

152

836

780

828

VJl VC

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These results are all advantageous for the process of the invention.

In order to make the results more expressive, Table IV below, which describes the sequence of operations, shows the coefficients of Uznsatz between the output bar and the finished car axle in three cases:

- 1st case: type A axle, rolled, not forged

det, edited.

- 2 · Case: Type B car axle, rolled, forged after

a known method, edited.

- 3 · Case: car axles type A or B, rolled, invented

Forged in accordance with, processed.

'fabeile IV

Consecutive operations and relationships between the weight of the starting bar and the weight of the finished carriage axle

1st case Rolled, machined car axle, type A

2 · case

Rolled car axle, type B, forged and machined by a known method

3. Case

Rolled car axle, forged and machined according to the invention, type A or B

ümsatzkoef roll 1,000 roll Umsatzkoef roll fizient bars bars fizient bars Tiefenöfen Tiefenöfen Tiefenöfen roll roll 1,000 roll hot saw hot saw Cool Cool 1,185 Cool Peel blank blank saw normalizing blank judge 1,185 processing Forge Forge roughing 1,518 warming Warming by finishing Forge induction Finished cars 1,798 Cool Forge axis Double Nor Cool malglühen Two normal

turnover coefficient

1,000

1,268

OJ

ro σ ο ο

ro ι

VJi VD

Table IV (continued)

Starting .directions

processing

Roughing finishing

Finished car axle glow 1,015 Hichten 1,009

Machining roughing 1,290 final production Numerical

Control 1.067 Finished car axle 1.365

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In the case of tubular carrousels, the blank comprises a silica core or core of any other refractory material of suitable diameter, the dilation coefficient of which is 1260 C relative to that of the axle steel such that its adhesion to the blank is good, without To be too large, and that its removal at ambient temperature has no difficulties.

It will be understood that other variants and improvements of detail may be developed as well as the use of equivalent means may be considered without departing from the scope of the invention.

Claims (7)

invention claim 1. A process for the production of normal axes, in particular of railway car axles by hot massive forming by compression extrusion of a heated solid or tubular blank, characterized in that the diameter of the blanks is smaller than the largest diameter of the normal axis to be produced, that at least a portion of the blank to a temperature between 1 100 and 1 3OO ⁰ C, preferably heated to about 1 260 ⁰ C, that the hot massive forming by upsetting extrusion of this blank comprises a simultaneous compression process of the middle parts and extrusion of at least one of the two stub axles (fi) and (f2), this at the same time running process is performed by a single press stroke · 2 «method according to item 1, characterized in that the hot massive forming by upsetting extrusion of a certain axis in a die, the parts of which are all fixed, by two successive press strokes, wherein a press stroke for each of. two lateral halves of the normal axis applies and the two press strokes are separated by an intermediate heating and an intermediate transport. Method according to item 1, characterized in that the hot massive forming is performed by upset extrusion of a complete normal axis with a single press stroke, the body (c) of the normal axis remaining stationary while the die has two movable 59 450 26 232000 0 - Achsschenkelringe (13; 14), which form the two stub axles (f1) and (f2) and the two Ableitflächen (pd1) and (pd2) by extrusion and the bearing surfaces (pd) and (pc2) by simultaneous compression · 4. The method according to any one of items 1 to 31 characterized in that the entire! Blank is heated to an equal temperature between 1 100 and 1 300 ⁰ C, preferably to about 1 260 ⁰ C. Method according to one of the items 1 to 3 »characterized in that the blank is subjected to a stepwise differentiated heating. 6. The method according to item 5, characterized in that the formation of the stub axles (fi) and (f2) of the STormalachse certain parts of the hollow ring to a temperature between 1 200 and 1 300 ⁰ C, preferably to about 1 260 C to be heated. 7. The method according to item 6, characterized in that the formation of the axle body (c) of the normal axis certain part of the blank is not heated, that for forming the support surfaces Cp disc 1) and (p disc 2) of the brake discs or the bearing surfaces the Hader for gear transmission certain parts of the blank are heated to a temperature between 1 200 and 1 300 ⁰ C, preferably to about 1 260 ⁰ C and that for forming the bearing surfaces (pd) and (pc2) of the wheels certain parts of the hollow and the Achsscüenkel (fi) and (f2) to a temperature between 1 100 and 1 250 ⁰ C, preferably to about 1 180 ⁰ C are heated. 45Ü 26 232000 8. The method according to one of the items 1 to 7 »characterized in that the Kohling from a round, rolled
Bar is formed, which encrusted before warming
becomes. Method according to any one of items 1 to 7, characterized in that the blank is formed from a square bar with rounded corners, prior to heating
is exterminated « 10. The method according to any one of points 1 to 7ι characterized in that the blank is formed from a rod with spitzbogenförmigem cross section, which is descaled before heating. 11. A method for producing tubular normal axes according to one of the items 1 to 7 characterized
that the blank is previously drilled hollow and filled with silica or any other refractory, powdery material whose dilation coefficient with respect to that of the Achsstahls is such that its adhesion to the blank is good, without being too large
to be, and that its removal at ambient temperature has no difficulties » For this 5 pages drawings