Study on welding deformation of the side beam based on numerical simulation method

The welding deformation is a key factor affecting the production quality of the side beam of the subway bogie frame. A major issue is how to control the welding deformation during the manufacturing processes. Based on the ＂Local- Global＂ method, the thermal cycle and the stress of a local model extracted from the global side beam model were simulated. The simulated strain result was mapped into the global model as an initial load to simulate the welding assembly deformation. Then the deformation distribution of the side beam was obtained by elastic finite element method, and compared with the measurement results. Furthermore, the welding deformation under different welding sequences and constraints was simulated. The influence of the welding sequences and constraints on the side beam deformation was analyzed. The results indicate that the deformation is the smallest when the sequence is symmetrical and decreases with the increase in constraints.

Improved Quality Prediction Model for Multistage Machining Process Based on Geometric Constraint Equation

Product variation reduction is critical to improve process efficiency and product quality, especially for multistage machining process（MMP）. However, due to the variation accumulation and propagation, it becomes quite difficult to predict and reduce product variation for MMP. While the method of statistical process control can be used to control product quality, it is used mainly to monitor the process change rather than to analyze the cause of product variation. In this paper, based on a differential description of the contact kinematics of locators and part surfaces, and the geometric constraints equation defined by the locating scheme, an improved analytical variation propagation model for MMP is presented. In which the influence of both locator position and machining error on part quality is considered while, in traditional model, it usually focuses on datum error and fixture error. Coordinate transformation theory is used to reflect the generation and transmission laws of error in the establishment of the model. The concept of deviation matrix is heavily applied to establish an explicit mapping between the geometric deviation of part and the process error sources. In each machining stage, the part deviation is formulized as three separated components corresponding to three different kinds of error sources, which can be further applied to fault identification and design optimization for complicated machining process. An example part for MMP is given out to validate the effectiveness of the methodology. The experiment results show that the model prediction and the actual measurement match well. This paper provides a method to predict part deviation under the influence of fixture error, datum error and machining error, and it enriches the way of quality prediction for MMP.

A New Approach to State Estimation for Uncertain Linear Systems in a Moving Horizon Estimation Setting

This paper addresses the state estimation problem for linear systems with additive uncertainties in both the state and output equations using a moving horizon approach. Based on the full information estimation setting and the game-theoretic approach to the H∞filtering, a new optimization-based estimation scheme for uncertain linear systems is proposed, namely the H∞-full information estimator, H∞-FIE in short. In this formulation, the set of processed data grows with time as more measurements are received preventing recursive formulations as in Kalman filtering. To overcome the latter problem, a moving horizon approximation to the H∞-FIE is also presented, the H∞-MHE in short. This moving horizon approximation is achieved since the arrival cost is suitably defined for the proposed scheme. Sufficient conditions for the stability of the H∞-MHE are derived. Simulation results show the benefits of the proposed scheme when compared with two H∞filters and the well-known Kalman filter.