Reduction of die wear and structural defects of railway screw spike heads estimated by FEM

Autores
Alcázar, J.; Abate, G.; Antunez, N.; Simoncelli, A.; Sánchez Egea, A. J.; Martínez Krahmer, D.; López de Lacalle, L. N.
Año de publicación
2021
Idioma
inglés
Tipo de recurso
artículo
Estado
versión publicada
Descripción
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.
Fil: Alcázar, J. Universidad Nacional de Lomas de Zamora. Facultad de Ingeniería; Argentina
Fil: Abate, G. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: Antunez, N. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: Simoncelli, A. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: Sánchez Egea, A. J. Universitat Politècnica de Catalunya; España
Fil: Martínez Krahmer, D. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: López de Lacalle, L. N. Universidad del País Vasco; España
Fuente
Nanomaterials, 11(11)
Materia
Biosensores
Métodos electroquímicos
Impresiones
Tintas
Nanotubos de carbono
Nanopartículas
Silicio
Nivel de accesibilidad
acceso abierto
Condiciones de uso
http://creativecommons.org/licenses/by/4.0/
Repositorio
Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI)
Institución
Instituto Nacional de Tecnología Industrial
OAI Identificador
nuevadc:Abate2021Reduction_pdf
Acceder
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oai_identifier_str nuevadc:Abate2021Reduction_pdf
network_acronym_str RIINTI
repository_id_str
network_name_str Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI)
spelling Reduction of die wear and structural defects of railway screw spike heads estimated by FEMAlcázar, J.Abate, G.Antunez, N.Simoncelli, A.Sánchez Egea, A. J.Martínez Krahmer, D.López de Lacalle, L. N.BiosensoresMétodos electroquímicosImpresionesTintasNanotubos de carbonoNanopartículasSilicioRailway 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.Fil: Alcázar, J. Universidad Nacional de Lomas de Zamora. Facultad de Ingeniería; ArgentinaFil: Abate, G. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; ArgentinaFil: Antunez, N. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; ArgentinaFil: Simoncelli, A. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; ArgentinaFil: Sánchez Egea, A. J. Universitat Politècnica de Catalunya; EspañaFil: Martínez Krahmer, D. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; ArgentinaFil: López de Lacalle, L. N. Universidad del País Vasco; EspañaMDPI2021info:eu-repo/semantics/articleinfo:eu-repo/semantics/publishedVersionhttp://purl.org/coar/resource_type/c_6501info:ar-repo/semantics/articuloapplication/pdfAbate2021Reduction.pdfhttps://app.inti.gob.ar/greenstone3/sites/localsite/collect/nuevadc/index/assoc/Abate202.dir/doc.pdfNanomaterials, 11(11)reponame:Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI)instname:Instituto Nacional de Tecnología Industrialenginfo:eu-repo/semantics/openAccesshttp://creativecommons.org/licenses/by/4.0/openAccess2025-09-04T11:42:58Znuevadc:Abate2021Reduction_pdfinstacron:INTIInstitucionalhttps://app.inti.gob.ar/greenstone3/biblioOrganismo científico-tecnológicohttps://argentina.gob.ar/intihttps://app.inti.gob.ar/greenstone3/oaiserver?verb=Identifypfalcato@inti.gob.arArgentinaopendoar:2025-09-04 11:42:58.862Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI) - Instituto Nacional de Tecnología Industrialfalse
dc.title.none.fl_str_mv Reduction of die wear and structural defects of railway screw spike heads estimated by FEM
title Reduction of die wear and structural defects of railway screw spike heads estimated by FEM
spellingShingle Reduction of die wear and structural defects of railway screw spike heads estimated by FEM
Alcázar, J.
Biosensores
Métodos electroquímicos
Impresiones
Tintas
Nanotubos de carbono
Nanopartículas
Silicio
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
dc.creator.none.fl_str_mv Alcázar, J.
Abate, G.
Antunez, N.
Simoncelli, A.
Sánchez Egea, A. J.
Martínez Krahmer, D.
López de Lacalle, L. N.
author Alcázar, J.
author_facet Alcázar, J.
Abate, G.
Antunez, N.
Simoncelli, A.
Sánchez Egea, A. J.
Martínez Krahmer, D.
López de Lacalle, L. N.
author_role author
author2 Abate, G.
Antunez, N.
Simoncelli, A.
Sánchez Egea, A. J.
Martínez Krahmer, D.
López de Lacalle, L. N.
author2_role author
author
author
author
author
author
dc.subject.none.fl_str_mv Biosensores
Métodos electroquímicos
Impresiones
Tintas
Nanotubos de carbono
Nanopartículas
Silicio
topic Biosensores
Métodos electroquímicos
Impresiones
Tintas
Nanotubos de carbono
Nanopartículas
Silicio
dc.description.none.fl_txt_mv 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.
Fil: Alcázar, J. Universidad Nacional de Lomas de Zamora. Facultad de Ingeniería; Argentina
Fil: Abate, G. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: Antunez, N. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: Simoncelli, A. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: Sánchez Egea, A. J. Universitat Politècnica de Catalunya; España
Fil: Martínez Krahmer, D. Instituto Nacional de Tecnología Industrial. INTI-Mecánica; Argentina
Fil: López de Lacalle, L. N. Universidad del País Vasco; España
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.
publishDate 2021
dc.date.none.fl_str_mv 2021
dc.type.none.fl_str_mv info:eu-repo/semantics/article
info:eu-repo/semantics/publishedVersion
http://purl.org/coar/resource_type/c_6501
info:ar-repo/semantics/articulo
format article
status_str publishedVersion
dc.identifier.none.fl_str_mv Abate2021Reduction.pdf
https://app.inti.gob.ar/greenstone3/sites/localsite/collect/nuevadc/index/assoc/Abate202.dir/doc.pdf
identifier_str_mv Abate2021Reduction.pdf
url https://app.inti.gob.ar/greenstone3/sites/localsite/collect/nuevadc/index/assoc/Abate202.dir/doc.pdf
dc.language.none.fl_str_mv eng
language eng
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
http://creativecommons.org/licenses/by/4.0/
openAccess
eu_rights_str_mv openAccess
rights_invalid_str_mv http://creativecommons.org/licenses/by/4.0/
openAccess
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv MDPI
publisher.none.fl_str_mv MDPI
dc.source.none.fl_str_mv Nanomaterials, 11(11)
reponame:Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI)
instname:Instituto Nacional de Tecnología Industrial
reponame_str Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI)
collection Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI)
instname_str Instituto Nacional de Tecnología Industrial
repository.name.fl_str_mv Repositorio Institucional del Instituto Nacional de Tecnología Industrial (INTI) - Instituto Nacional de Tecnología Industrial
repository.mail.fl_str_mv pfalcato@inti.gob.ar
_version_ 1842346557707386881
score 12.623145

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