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Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling

This study examines the possibilities of applying numerical and physical modeling to the elaboration of technology and design of tools used in the hot forging of needle rails for railroad turnouts. First, a numerical model of a three-stage process for forging a needle from lead was built in order to...

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Autores principales: Hawryluk, Marek, Cygan, Piotr, Krawczyk, Jakub, Barełkowski, Artur, Ziemba, Jacek, Lewandowski, Filip, Wieczorek, Igor
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10003943/
https://www.ncbi.nlm.nih.gov/pubmed/36903220
http://dx.doi.org/10.3390/ma16052103
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author Hawryluk, Marek
Cygan, Piotr
Krawczyk, Jakub
Barełkowski, Artur
Ziemba, Jacek
Lewandowski, Filip
Wieczorek, Igor
author_facet Hawryluk, Marek
Cygan, Piotr
Krawczyk, Jakub
Barełkowski, Artur
Ziemba, Jacek
Lewandowski, Filip
Wieczorek, Igor
author_sort Hawryluk, Marek
collection PubMed
description This study examines the possibilities of applying numerical and physical modeling to the elaboration of technology and design of tools used in the hot forging of needle rails for railroad turnouts. First, a numerical model of a three-stage process for forging a needle from lead was built in order to develop a proper geometry of the tools’ working impressions for physical modeling. Based on preliminary results of the force parameters, a decision was made to verify the numerical modeling at 1:4 scale due to forging force values as well as agreement of the numerical and physical modeling results, which was confirmed by the similar courses of forging forces and a comparison of the 3D scan image of the forged lead rail with the CAD model obtained from FEM. The final stage of our research was modeling an industrial forging process in order to determine the preliminary assumptions of this newly developed method of precision forging using a hydraulic press as well as preparing tools to reforge a needle rail from the target material, i.e., 350HT steel with a 60E1A6 profile to the 60E1 profile used in railroad turnouts.
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spelling pubmed-100039432023-03-11 Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling Hawryluk, Marek Cygan, Piotr Krawczyk, Jakub Barełkowski, Artur Ziemba, Jacek Lewandowski, Filip Wieczorek, Igor Materials (Basel) Article This study examines the possibilities of applying numerical and physical modeling to the elaboration of technology and design of tools used in the hot forging of needle rails for railroad turnouts. First, a numerical model of a three-stage process for forging a needle from lead was built in order to develop a proper geometry of the tools’ working impressions for physical modeling. Based on preliminary results of the force parameters, a decision was made to verify the numerical modeling at 1:4 scale due to forging force values as well as agreement of the numerical and physical modeling results, which was confirmed by the similar courses of forging forces and a comparison of the 3D scan image of the forged lead rail with the CAD model obtained from FEM. The final stage of our research was modeling an industrial forging process in order to determine the preliminary assumptions of this newly developed method of precision forging using a hydraulic press as well as preparing tools to reforge a needle rail from the target material, i.e., 350HT steel with a 60E1A6 profile to the 60E1 profile used in railroad turnouts. MDPI 2023-03-05 /pmc/articles/PMC10003943/ /pubmed/36903220 http://dx.doi.org/10.3390/ma16052103 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Hawryluk, Marek
Cygan, Piotr
Krawczyk, Jakub
Barełkowski, Artur
Ziemba, Jacek
Lewandowski, Filip
Wieczorek, Igor
Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling
title Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling
title_full Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling
title_fullStr Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling
title_full_unstemmed Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling
title_short Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling
title_sort development of preliminary precision forging technology and concept for tools used to reforge 60e1a6 profile needle rails with the use of numerical and physical modeling
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10003943/
https://www.ncbi.nlm.nih.gov/pubmed/36903220
http://dx.doi.org/10.3390/ma16052103
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