Study on Welding Deformation Control and Simulation for End Wall of CR400BF EMU

GENG Ming; WANG Yanan; XIAO Yu; GENG Fei; ZHANG Li

doi:10.7512/j.issn.1001-2303.2024.03.15

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Study on Welding Deformation Control and Simulation for End Wall of CR400BF EMU
Vol. 54, Issue 3, Pages: 99-104(2024)
Published： 25 March 2024 ，
DOI： 10.7512/j.issn.1001-2303.2024.03.15

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耿明，王亚男，肖宇，等.CR400BF动车组车体端墙焊接模拟仿真与变形控制研究［J］.电焊机，2024，54（3）：99-104.

GENG Ming, WANG Yanan, XIAO Yu, et al.Study on Welding Deformation Control and Simulation for End Wall of CR400BF EMU[J].Electric Welding Machine, 2024, 54(3): 99-104.
耿明，王亚男，肖宇，等.CR400BF动车组车体端墙焊接模拟仿真与变形控制研究［J］.电焊机，2024，54（3）：99-104. DOI： 10.7512/j.issn.1001-2303.2024.03.15.

GENG Ming, WANG Yanan, XIAO Yu, et al.Study on Welding Deformation Control and Simulation for End Wall of CR400BF EMU[J].Electric Welding Machine, 2024, 54(3): 99-104. DOI： 10.7512/j.issn.1001-2303.2024.03.15.

摘要

CR400BF动车组车体端墙为封闭腔体铝合金型材拼焊结构，焊接量大，焊接变形大，尺寸不易控制，影响车辆装配精度和外观质量。针对CR400BF动车组车体端墙焊接变形的控制方法进行研究，通过焊接模拟仿真和实际生产相结合的方式，从结构优化、焊前预制反变形和焊接工艺优化三个方面提出了一套较为优化的端墙焊接变形控制方法。在结构优化方面，采用带立柱的封闭式型材结构代替传统开式型材结构，增加了端墙的刚度。焊前反变形方面，通过调整侧弯梁单件的外形弧度和外部弯梁的组对宽度，实现了对焊接变形的有效控制。焊接工艺优化方面，采用“先长后短、先大后小”正反面交替焊接顺序，并调整段焊间距和数量，进一步减小了焊接变形，保证了端墙各项关键尺寸，进而提高了产品质量和生产效率。

Abstract

The CR400BF EMU’s body end wall is assembled from closed cavity aluminum alloy extrusions with a significant amount of welding

which results in substantial welding distortion

making size control difficult and affecting vehicle assembly precision and appearance quality. This study investigates methods to control welding distortion in the CR400BF EMU body end walls. By combining welding simulation and actual production

an optimized set of welding distortion control methods for the end walls is proposed from three aspects: structural optimization

pre-welding counter-distortion

and welding process optimization.In terms of structural optimization

an enclosed type extrusion structure with posts is used instead of the traditional open type extrusion structure

which increases the stiffness of the end wall. For pre-welding counter-distortion

effective control of welding distortion is achieved by adjusting the contour curvature of the side bending beams and the assembly width of the external bending beams. Regarding welding process optimization

an alternating “longer then shorter

larger then smaller” front and back welding sequence is employed

and the spacing and number of segmented welds are adjusted to further reduce welding distortion. This ensures the critical dimensions of the end wall

thereby improving product quality and production efficiency.

关键词

CR400BF车体端墙焊接变形模拟仿真结构优化焊前反变形焊接工艺优化

Keywords

CR400BFend wallwelding distortionsimulationstructural optimizationpre-welding counter-distortionwelding process optimization

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