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Updated: Aug 7, 2025

Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes
Published on: December 13, 2016
Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle
Marek Hawryluk1, Piotr Cygan2, Jakub Krawczyk1
1Department of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, Poland.
Abstract:
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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