澳煤车转向架工艺研制与开发

C32型煤漏斗车是齐车公司为出口澳大利亚开发的新型货车，该车采用30t轴重转向架，采用呋喃树脂自硬沙有箱造型工艺在造型线上生产。由于生产试制周期短、技术水平要求高，为此齐车公司决定在转向架生产过程中大量采用数值模拟技术。本文将以澳车转向架侧架的开发生产过程为例，阐述ProCAST在澳车开发过程中的应用情况。首先分析了澳车转向架侧架的结构特点，并根据车间现有的生产条件及产品的批量确定了生产工艺。然后按照ProCAST在铸件产品工艺上应用技术线路要求，应用ProCAST基本模块、流动模块和应力分析模块对澳车侧架充型和凝固过程流场、温度场和应力场进行详细模拟分析，预测了缩孔、缩松、热裂等缺陷。通过数值模拟验证，提出工艺改进意见，优化铸造工艺，实现工艺的完整性。使如此复杂而关键的铸件一次试验成功，极大地缩短了工艺准备周期，降低了试制成本，对实际生产起到了重要的指导作用。

Research and Development of Australia Coal Car Bogie

C32 coal hopper car is the development of new freight car for exporting Australia,the car uses 30 t axle load and producted by furan resin having box shape in the form of line.Because of short production cycle,high requirement of technical level,Qiqihaer Railway Rolling Stock(Group)Co,.Ltd decide to use large numerical simulation technology in bogie production.This paper will be as an example for Australian car bogie side frame the development and production process,introduce ProCAST application in the process of developing.First analysis structure characteristic of side frame and base the workshop production condition and product quantities to determine the production process.Then with ProCAST application of technology product line requirement on casting production process,application ProCAST basic module,mobile module and stress analysis module on the side frame filling and solidification process mobile,temperature and stress field for detail simulation analysis,forecast shrinkage pore,shrinkage porosity,thermal crack defects.Through numerical simulation validation,raise comment of process improvement,optimize casting process,realize integrity of process.So the complex and crux casting successful test one time,shorten process prepare Cycle greatly,reduce trial production costs,play an important guiding role in actual production.