Study Of Welding Deformation Predition On Typical Component Of Locomotivge Car Body

Because the electric locomotive car body is mainly manufactured by weldingprocess, weld deformation straightening in manufacture process is extremely timeconsuming and costly process, which will have big effect on productive efficiency.Weld deformation prediction and control of car body is always an important task inmanufacturing process.Precisely identified compensation allowance of variouscomponents and backward deformation on assemble process is a key point toensure the quality of body manufacture, which need precise prediction on welddeformation of typical components.Regarding deformation prediction on the big complex weld structure likeelectric locomotive car body, we mainly identify it with experience onmanufacture. However, this method can’t satisfy modern production requirement.Inherent strain method use linear-elastic finite element to replace elastic-plasticfinite element to calculate the deformation, which can largely reduce thecalculation time and receive certain calculate precision and has great practicalvalue in production practice.In this paper, the general method and theory of weld deformation numericalsimulation is described, and highly state the inherent strain theory. Parameterizedmodel for typical welding of the electrical locomotive car-body has been set up viacollecting and analyzing information from car-body welding and its processrespectively.The simplified calculation formula is also provided for the inherentstrain of the typical welding based on the study of current inherent strain theoryand its applied research results. Meanwhile, via thermal-elastic–plastic analysisfor the joints of the typical welding, combining with testing and measuring of thereal test results, the correction factors for deduced inherent strain formulafor vehicle car-body welding has been proposed.Based on this, the generalmethod and theory of WELD_STA is described. And predict the weld deformationon car-body bolster (typical component of car-body) with using inherent straindatabase and software WELD_STA. Through the deformation measure on bolsterand have a comparison between the calculation result from software WELD_STAand bolster measure result. the result shows that the calculation result fromsoftware agrees well with measure result.Through above studies, the reliability ofinherent strain database special use for typical weld of car-body is demonstratedpreliminarily.