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Analysis of railway wheel rolling process based on three-dimensional simulation

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Abstract

Rolling is one of the key stages of railway wheel hot forming process. In this work, a three-dimensional finite element analysis on wheel vertical rolling process based on some strategies proposed has been carried out by using FE code SuperForm. In modeling, a virtual mandrel is exploited in the hub hole to keep the wheel central instead of the guide rolls and centering rolls. Some features of the wheel forming are deeply investigated such as the rim diameter expanding, the rim lateral spreading, the metal flow in the circumferential direction, and the stresses distribution. The results show that (1) the rim radius expanding mainly occurs in the two affected zones before and after the back roll deformation zone; (2) the rim metal has flow trend in the circumferential direction during rolling, the metal of the intersection area, between the tread and the rim external side surface has the largest relative angular displacement; and (3) the tensile stresses of the web both in radial and circumferential directions during rolling result in the web thickness decreasing by about 3 mm for the investigated wheel. The simulations results reveal the forming mechanisms of wheel rolling, laying the basis for designing and optimizing railway wheel forming process.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Anhui University of Technology, Ma’anshan, Anhui, 243002, China

    Xiaohui Shen, Jun Yan & Jing Zhang

  2. Tyre and Wheel Company, Ma’anshan Iron and Steel Co., Ltd., Ma’anshan, Anhui, 243010, China

    Tao An & Zhangze Xu

Authors
  1. Xiaohui Shen
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  2. Jun Yan
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  3. Tao An
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  4. Zhangze Xu
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  5. Jing Zhang
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Correspondence to Xiaohui Shen.

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Shen, X., Yan, J., An, T. et al. Analysis of railway wheel rolling process based on three-dimensional simulation. Int J Adv Manuf Technol 72, 179–191 (2014). https://doi.org/10.1007/s00170-014-5637-6

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  • DOI: https://doi.org/10.1007/s00170-014-5637-6

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