时速400km动车组车体侧墙焊接模拟仿真及变形控制研究

Study on welding deformation control and simulation of EMU vehicle side wall at 400 km/h

利用有限元软件对时速400km动车组车体侧墙进行焊接过程模拟仿真,结果显示模拟双机械手臂同时焊接,在均匀分布的专用工装装夹条件下,焊后变形程度最小,呈现反面拱起的圆弧形状,以中间型材为中心两侧对称,变形量最大值5.13mm。实际焊接试验结果与模拟仿真结果吻合,变形趋势一致,变形量偏差在0.5mm以内。根据变形结果进行反变形预制,焊后变形量进一步降低,当反变形量达到6mm时,焊后变形量最大值为1.5mm。

The finite element software is used to simulate the welding process of the body side wall of EMU at 400 km/h.The results show that when simulating the simultaneous welding by double manipulator arms,the postwelding deformation is the smallest under the condition of uniform distribution of special fixtures.The deformation presents a circular arc arched in reverse,and the both sides are symmetrical taking middle section as the center,and the maximum deformation is 5.13 mm.The actual welding test results coincide with the simulation results,the deformation trends are the same,and the deformation deviation is less than 0.5 mm.According to the deformation results,the predeformation is prefabricated and the postwelding deformation reduces further.The maximum postwelding deformation is 1.5 mm when the predeformation is 6 mm.