Research on Efficient Simulation and Correction Method for Welding Deformation of High-Speed Train Sidewalls

SHEN Gang; WANG Yanan; GENG Ming; LIU Song; GUO Chuncheng; WU Yilin; CHEN Jingqing

doi:10.7512/j.issn.1001-2303.2026.07.05

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Research on Efficient Simulation and Correction Method for Welding Deformation of High-Speed Train Sidewalls
Vol. 56, Issue 7, Pages: 41-46(2026)
Received：01 April 2025，

Revised：2025-04-27，

Published：20 July 2026
DOI： 10.7512/j.issn.1001-2303.2026.07.05
稿件说明：

移动端阅览

沈　刚，王亚男，耿明，等.动车侧墙焊接变形高效模拟与修正方法研究［J］.电焊机，2026，56（7）：41-46. DOI： 10.7512/j.issn.1001-2303.2026.07.05.

WANG Yanan, GENG Ming, LIU Song, et al.Research on Efficient Simulation and Correction Method for Welding Deformation of High-Speed Train Sidewalls[J].Electric Welding Machine, 2026, 56(7): 41-46. DOI： 10.7512/j.issn.1001-2303.2026.07.05.

摘要

针对轨道交通行业动车组侧墙结构多工序焊接变形数值模拟存在的计算效率低、刚体位移干扰等问题，提出一种融合局部热循环映射与变形修正的有限元分析方法。通过建立局部精细化焊缝模型进行温度场瞬态模拟，提取典型接头的热循环曲线参数，构建等效热源模型并将其映射至整体结构网格，实现了基于顺序耦合的焊接应力变形快速计算。为解决多工序累积效应导致的刚体位移偏差，提出空间变形修正算法，通过建立基准坐标系对模拟结果进行刚体运动分解，采用坐标变换消除平移和旋转分量，提取纯变形分量进行统计对比。以某型动车组侧墙结构为对象，对激光-MAG复合焊接工艺进行全过程模拟，结果表明：局部-整体映射策略使计算效率显著提升，变形误差<20%。该方法有效解决了大型复杂结构多工序焊接模拟的精度与效率矛盾，为轨道交通装备制造工艺优化提供了可靠的分析工具。

Abstract

To address the issues of low computational efficiency and rigid body displacement interference in numerical simulations of multi-process welding deformation for high-speed train sidewall structures in the rail transit industry

this paper proposes a finite element analysis method integrating local thermal cycle mapping and deformation correction. By establishing a local refined weld seam model for transient temperature field simulation

the thermal cycle curve parameters of typical joints are extracted to construct an equivalent heat source model

which is then mapped to the global structural mesh. This achieves rapid calculation of welding stress and deformation based on sequentially coupled analysis. To resolve rigid body displacement deviations caused by cumulative multi-process effects

a spatial deformation correction algorithm is proposed. A reference coordinate system is established to decompose rigid body motion from simulation results

and coordinate transformation is applied to eliminate translational and rotational components

thereby extracting pure deformation components for statistical comparison. Taking a high-speed train sidewall structure as an example

the laser-MAG hybrid welding process is simulated comprehensively.

Results

indicate that the local-global mapping strategy significantly improves computational efficiency

with deformation errors <20%. This method effectively resolves the conflict between accuracy and efficiency in multi-process welding simulations for large-scale complex structures

providing a reliable analytical tool for optimizing rail transit equipment manufacturing processes.

关键词

Keywords

references

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