Numerical Simulation and Analysis of Welding Deformation of Aluminum Alloy Profiles for Rail Vehicle Bodies

GENG Ming; WANG Yanan; LIU Song; WANG Jun; SHAO Youfa; GUO Chuncheng

doi:10.7512/j.issn.1001-2303.2025.07.07

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Numerical Simulation and Analysis of Welding Deformation of Aluminum Alloy Profiles for Rail Vehicle Bodies
Vol. 55, Issue 7, Pages: 73-78(2025)
Received：15 August 2024，

Revised：2025-01-21，

Published：20 July 2025
DOI： 10.7512/j.issn.1001-2303.2025.07.07
稿件说明：

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耿明，王亚男，刘松，等.轨道车辆铝合金车体不同断面型材的焊接变形数值模拟计算分析［J］.电焊机，2025，55（7）：73-78. DOI： 10.7512/j.issn.1001-2303.2025.07.07.

GENG Ming, WANG Yanan, LIU Song, et al.Numerical Simulation and Analysis of Welding Deformation of Aluminum Alloy Profiles for Rail Vehicle Bodies[J].Electric Welding Machine, 2025, 55(7): 73-78. DOI： 10.7512/j.issn.1001-2303.2025.07.07.

摘要

为优化轨道车辆铝合金车体焊接变形控制工艺，本研究提出一种宽幅断面型材设计方案，即侧墙使用两块型材替代四块型材，地板使用三块型材替代五块型材，车顶使用三块型材替代五块型材，并进行数值模拟仿真计算对比分析宽幅型材断面与窄幅（既有）型材断面的焊接变形趋势与变形量。结果表明：宽幅与窄幅型材的焊接变形趋势一致，均表现为焊缝区域向下凹陷、周围母材向上翘曲，且自由边缘变形量更大；但宽幅型材的变形幅度显著降低。具体数据为：侧墙最大变形量由24.2 mm降至14.0 mm（降幅42.2%），地板由140 mm降至57.4 mm（降幅59%），车顶由178.2 mm降至46.4 mm（降幅74%）。从工艺层面来说，宽幅断面型材焊接变形小，尺寸精度更容易保证，制造效率更高，结构更合理。该研究成果为铝合金车体轻量化设计及工艺优化提供了理论依据。

Abstract

To optimize the welding deformation control process for aluminum alloy bodies in rail vehicles

this paper proposes a wide-section profile design. The design involves replacing four profiles with two for the side wall

five with three for the floor

and five with three for the roof. A numerical simulation analysis was conducted to compare the welding deformation trends and magnitudes between the wide-section profiles and the conventional narrow-section (existing) profiles.

Results

indicate that both wide- and narrow-section profiles exhibit consistent deformation trends: weld zones show downward concavity

surrounding base metal warps upward

and free edges experience greater deformation. However

the wide-section profiles demonstrate significantly reduced deformation. Specific data reveal that the maximum deformation of the side wall decreases from 24.2 mm to 14.0 mm (a reduction of 42.2%)

the floor from 140 mm to 57.4 mm (a reduction of 59%)

and the roof from 178.2 mm to 46.4 mm (a reduction of 74%). From a process perspective

wide-section profiles exhibit smaller welding deformation

improved dimensional accuracy

higher manufacturing efficiency

and a more rational structure. This study provides theoretical support for lightweight design and process optimization of aluminum alloy vehicle bodies.

关键词

Keywords

references

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