高速动车组端墙焊接变形控制

Control of welding deformation for end wall of high-speed EMU

高速动车组端墙是铝合金车体的重要组成部位,结构复杂、附件多、焊接量大,焊接变形比较大。焊接变形是由于焊接过程中的加热、冷却不均匀引起,而铝合金的变形相对较大,影响焊接结构的制造和使用性能。本文以一种标准动车组端墙为研究对象,通过在端墙的生产制造过程当中,采取适当的工装优化、装配工艺和合理的焊接顺序,有效控制了端墙的焊接变形,保证了端墙的平面度和轮廓度,降低了端墙调修工作强度,提高了生产效率,满足批量生产的需求。不仅如此,本文的控制方法对其他动车组端墙的制造有很好的借鉴意义,推广价值良好。

The end wall is an important part of the aluminum alloy car body in High-speed EMU. It has a complex construction ,amount of accessories and large quantity of welding,all of which may induce the large welding deformation. Welding deformation is caused by uneven heating and cooling during welding. However,the deformation of aluminum alloy is large,which ＂,affects the manufacture and performance of welded structure. In this paper,the end wall of a standard EMU is taken as the research object,by adopting the appropriate tooling optimization,assembly process and reasonable welding sequence in the production and manufacture of the end wall, its welding deformation was well controlled,and so its flatness and profile. This reduced the intensity of working adjustment on end wall,improved production efficiency,and met the requirement of mass production. Moreover,the control method in this paper has a good reference significance for other EMU end wall manufacture,and has good value in popularizing.