Numerical Simulation On Welding Processes In Bogie Frame Of Electric Locomotive

The bogie is the main component of electric locomotive. Its production and design directly impact on the structure and electric locomotive safe operation. The welding quality of the side beam of frame affects the electric locomotive bogie assembly accuracy. For the welding quality, it is necessary for a frame side beam welding deformation was well controled.The article firstly introduced the structure of SS4G electric locomotive bogie frame and the side beam of the frame. Using SolidWorks finite element analysis software Simulation to establish a side beam cover plate, two vertical plates, three lower cover plate finite element mode. Eventually consisted of the locomotive side finite element simulation model.In order to ensure the accuracy of computed reduce amount of calculation, in the simulation model parameter settings, such as the amount of heat input, convection, mesh size, the initial conditions are studied, while the use of Line-Gauss heat source simulating welding heat source. Using SolidWorks Simulation software nonlinear static analysis calculation and thermal analysis function, on side beam welding process of the instantaneous temperature field, static stress field and distortion after welding is investigated by numerical simulation calculation.In order to study the influence of welding sequence welding deformation,to built in4different welding sequence model and calculate4kinds of welding sequence welding stress and deformation. Model No.1welding deformation and displacement is3.227mm, maximum welding stress of1.961×108N/m2. Model No.2welding deformation and displacement is3.529mm, maximum welding stress of1.987×108N/m2. Model No.3welding deformation and displacement is5.859mm, maximum welding stress is in1.601×108N/m2. Model No.4welding deformation and displacement is2.961mm, maximum welding stress is in2.864×108N/m2. On four kinds of welding sequence model calculation results can be seen, Model No.4from two sides to symmetric welding method, welding deformation is minimal, and the maximum stress is relatively small, should be adopted.On the basis of reference line method, the side beam and vertical plate, select two groups of test point, and the bogie side frame beam cover plate axial center lines compared to the measured lateral beam welding vertical bending deformation, horizontal bending deformation and longitudinal shrinkage, the measurement results show that the numerical simulation results, the fourth chapter is accurate the. Developed for different welding sequence scheme, through numerical simulation and analysis of different schemes in the direction of deformation of the outer one or two layers of weld, welding sequence optimization for aâ†'bâ†'câ†'dâ†'eâ†'hâ†'gâ†'f. In addition to the results of the numerical simulation and the actual measured results also suggest, different schemes on the side beam body welding shrinkage effect; different schemes on the side beam body welding vertical and horizontal deformation influence.By changing the side beam welding sequence to control the welding deformation during the welding process, the method is simple, easy operation, low cost features, while the smaller the deformation increases the frame assembly precision make the frame structure dimensions and mounting components with comply with the design requirements, implementation of the electric locomotive light quantification, but also greatly improve the electric locomotive of economic, security.