Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM

Railway spike screws are manufactured by hot forging on a massive scale, due to each kilometer of railway track needing 8600 spike screws. These components have a low market value, so the head must be formed in a single die stroke. The service life of the dies is directly related to the amount of en...

Descripción completa

Guardado en:

Detalles Bibliográficos
Autores principales:	Jackeline Alcázar, Germán Abate, Nazareno Antunez, Alejandro Simoncelli, Antonio J. Sánchez Egea, Daniel Martinez Krahmer, Norberto López de Lacalle
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	screw spike hot forging die wear defects computational simulation Mining engineering. Metallurgy TN1-997
Acceso en línea:	https://doaj.org/article/42d5dc6144bf4817a616dc4d3632863d
Etiquetas:	Agregar Etiqueta Sin Etiquetas, Sea el primero en etiquetar este registro!

id	oai:doaj.org-article:42d5dc6144bf4817a616dc4d3632863d
record_format	dspace
spelling	oai:doaj.org-article:42d5dc6144bf4817a616dc4d3632863d2021-11-25T18:22:17ZReduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM10.3390/met111118342075-4701https://doaj.org/article/42d5dc6144bf4817a616dc4d3632863d2021-11-01T00:00:00Zhttps://www.mdpi.com/2075-4701/11/11/1834https://doaj.org/toc/2075-4701Railway spike screws are manufactured by hot forging on a massive scale, due to each kilometer of railway track needing 8600 spike screws. These components have a low market value, so the head must be formed in a single die stroke. The service life of the dies is directly related to the amount of energy required to form a single screw. The existing standard for spike screws specifies only the required tolerances for the head dimensions, particularly the angle of the hub faces and the radius of agreement of the hub with the cap. Both geometrical variables of the head and process conditions (as-received material diameter and flash thickness) are critical parameters in spike production. This work focuses on minimizing the energy required for forming the head of a railway spike screw by computational simulation. The variables with the highest degree of incidence on the energy, forging load, and filling of the die are ordered statistically. The results show that flash thickness is the variable with the most significant influence on forming energy and forming load, as well as on die filling. Specifically, the minimum forming energy was obtained for combining of a hub wall angle of 1.3° an as-received material diameter of 23.54 mm and a flash thickness of 2.25 mm. Flash thickness generates a lack of filling at the top vertices of the hub, although this defect does not affect the functionality of the part or its serviceability. Finally, the wear is mainly concentrated on the die splice radii, where the highest contact pressure is concentrated according to the computational simulation results.Jackeline AlcázarGermán AbateNazareno AntunezAlejandro SimoncelliAntonio J. Sánchez EgeaDaniel Martinez KrahmerNorberto López de LacalleMDPI AGarticlescrew spikehot forgingdie weardefectscomputational simulationMining engineering. MetallurgyTN1-997ENMetals, Vol 11, Iss 1834, p 1834 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	screw spike hot forging die wear defects computational simulation Mining engineering. Metallurgy TN1-997
spellingShingle	screw spike hot forging die wear defects computational simulation Mining engineering. Metallurgy TN1-997 Jackeline Alcázar Germán Abate Nazareno Antunez Alejandro Simoncelli Antonio J. Sánchez Egea Daniel Martinez Krahmer Norberto López de Lacalle Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM
description	Railway spike screws are manufactured by hot forging on a massive scale, due to each kilometer of railway track needing 8600 spike screws. These components have a low market value, so the head must be formed in a single die stroke. The service life of the dies is directly related to the amount of energy required to form a single screw. The existing standard for spike screws specifies only the required tolerances for the head dimensions, particularly the angle of the hub faces and the radius of agreement of the hub with the cap. Both geometrical variables of the head and process conditions (as-received material diameter and flash thickness) are critical parameters in spike production. This work focuses on minimizing the energy required for forming the head of a railway spike screw by computational simulation. The variables with the highest degree of incidence on the energy, forging load, and filling of the die are ordered statistically. The results show that flash thickness is the variable with the most significant influence on forming energy and forming load, as well as on die filling. Specifically, the minimum forming energy was obtained for combining of a hub wall angle of 1.3° an as-received material diameter of 23.54 mm and a flash thickness of 2.25 mm. Flash thickness generates a lack of filling at the top vertices of the hub, although this defect does not affect the functionality of the part or its serviceability. Finally, the wear is mainly concentrated on the die splice radii, where the highest contact pressure is concentrated according to the computational simulation results.
format	article
author	Jackeline Alcázar Germán Abate Nazareno Antunez Alejandro Simoncelli Antonio J. Sánchez Egea Daniel Martinez Krahmer Norberto López de Lacalle
author_facet	Jackeline Alcázar Germán Abate Nazareno Antunez Alejandro Simoncelli Antonio J. Sánchez Egea Daniel Martinez Krahmer Norberto López de Lacalle
author_sort	Jackeline Alcázar
title	Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM
title_short	Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM
title_full	Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM
title_fullStr	Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM
title_full_unstemmed	Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM
title_sort	reduction of die wear and structural defects of railway screw spike heads estimated by fem
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/42d5dc6144bf4817a616dc4d3632863d
work_keys_str_mv	AT jackelinealcazar reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem AT germanabate reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem AT nazarenoantunez reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem AT alejandrosimoncelli reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem AT antoniojsanchezegea reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem AT danielmartinezkrahmer reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem AT norbertolopezdelacalle reductionofdiewearandstructuraldefectsofrailwayscrewspikeheadsestimatedbyfem
_version_	1718411251930890240

Reduction of Die Wear and Structural Defects of Railway Screw Spike Heads Estimated by FEM

Ejemplares similares