Abstract:

Bending process of outside profile pillar assembled in highspeed railway vehicle was simulated and analyzed using finite element software PamStamp 2G for researching bending process of large scale profile with complicated nonsymmetrical hollow section. Methods for controlling bending defects such as cross section distortion, line segment curve and low longitudinal profile precision were proposed. The results show that line segment curve can be improved effectively by adjusting forming direction and using back load is. The larger the back loadis, the smaller the curve value of line segment becomes. A new mandrel was used for controlling cross section distortion and improving longitudinal profile precision, and the smaller gaps between mandrel and inside wall of profile yields smaller section distortion value and higher longitudinal profile precision. The rationality of optimized process was tested and verified by experiments.

Key words: railway vehicle, profile bending, process optimization, numerical simulation