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 screws. These components have low market value, so the head must be formed in single die stroke. The service life dies is directly related amount energy required form screw. existing standard for specifies only tolerances dimensions, particularly angle hub faces and radius agreement with cap. Both geometrical variables process conditions (as-received material diameter flash thickness) critical parameters production. This work focuses minimizing forming screw computational simulation. highest degree incidence energy, load, filling ordered statistically. results show that thickness variable most significant influence as well filling. Specifically, minimum was obtained combining wall 1.3° an as-received 23.54 mm 2.25 mm. Flash generates lack at top vertices hub, although this defect does not affect functionality part or its serviceability. Finally, wear mainly concentrated splice radii, where contact pressure according simulation results.