| The draft, bolster and buffer assembly of aluminium alloy carbody possesses the effect that holds the balance to the whole car, and must have the fail-safe technology measure to pledge reliability and the stability. Therefore ,study on the technology process for the draft, bolster and buffer assembly of aluminium alloy carbody having the important meaning to raise the manufacturing standard . It's possessing the effect of decisiveness to increasing the competition ability at the same time. Through trial-production with the small batch of the aluminium alloy carbody have been finished, Our design concept and technology guaranty measure still remains in further to raise. The complete set drawings has been recommend from advanced country once on the structural design; But their complete set technology method can not be recommend. There are two chiefly reasons in here: Firstly, the key of any enterprise or company is technology, so any company is never willing to make over and transfer its technology secret to others' around the world. Secondly, the process technology is completely different from other technology, it must be finalized according to infrastructure and our company actual manufacture standard, and can only be transferred and used as a reference with selecting. As far as the concrete product, something can be done, for instance: technology equipment design, technology scheme formulation and quality control etc. In general , the technology of our country aluminium alloy carbody is not as advanced as that of advanced country. Contrast with the process flow between China astral and Germany ICE3 for the draft, bolster and buffer assembly of aluminium alloy carbody, the obvious problem with our process flow is: complicated, superabundance and inconvenient, etc. Through analyzing thoroughly and thinking fully over the actuality of our factories technology and advanced country's technology flow, we formulated detailed process flow for draft ,buffer assembly and bolster assembly. Two kinds of method for thick aluminium board blanking are: plasma arc cutting under water ( retain allowance for machine process ) and high pressure water cutting. Owing to plasma arc cutting under water has scattering appearance , and reflects on the workpiece there has a slope in the thickness band. So it need a machining process to finish the workpiece. High pressure water cutting has finished the various complicated configuration by the method that compile programme (welding slope is processed by machining). Two kinds of methods possess the excellent and the shortcoming respectively. Plasma arc cutting under water need low investment, can accomplish with now available equipment, and the speed of blanking is quick at the same time; The shortcoming is the process that need to increasing machining, Making the manufacturing cost increase of cell. And enhancing consumption capacity of raw and processed material. No matter how the configuration workpiece has,the method can finish it by a step, It can reduces the consumption of raw material. The shortcoming is the investment greatly at prelimimary, and processes low speed relatively. Combine to the real need, This equipment should be purchased for long-range market foreground of product. It is key to the final quality of product with the concept and thought for device designing. Two kinds of the jag is difference: the draft, buffer assembly jag and bolster assembly jag. Among them, two sets for the draft, buffer assembly. The one jig is buffer assembly. The other jig is draft assembly. The design thought of this jig is reversed loading for position location, and that the end face adopts the fixed position location in hole. One jig is used to bolster assembly for workpiece being 4reversed itself once a time in the course of welded. All jigs adopt the fail-safe tight method of mechanical type clamp, fixes on the position-changed machine, and it can realize the workpieces reversed with jigs. So most weld can be finished at the level position. Thermal conductivity and the linear expansion coefficient of aluminium alloy is longer than the carbon steel. It extremely easily appear welding deformation and weld defect in welding course. The dimension of welding deformation is very hard to counted out on theory formula, So it can only be sumed up with experience numerical value ,and the reasonable welding sequence can be prescribe to reduce welding deformation. The main welding deformations are horizontal deformation and the fillet deformation. The most common weld defect is air-hole and crack. The reason the air-hole gives rise to is to short the time of welding pool exist in the air process of air floating. Hydrogen in the weld does not spill over completely. The welding material or welding method is unsuitable can lead to the crack. The major measure of preventing on welding deformation and weld defect are anti-deformation of reasonable welding; Reasonable welding sequence and welding specification are set down; Welding in the process strict act on according to prescriptive welding. Rectify method to the workpiece after welding is corrected with the flame. Not adopting machinery to correct. The principle which corrected is to the full, which the part after the overall, secondary after the primary, and accessory after impotant is being done. Laying down the quality assurance system is advanced the reliable guaranty of product quality. The process of material is wanted the technology documents of concrete operation nature. Critical parts one document for the one part exactly is necessary. The workpiece welded area before welding must be processing according to prescriptive, and the requirement of manual welding, automatic welding and welding equipment must be enforced rigorously. Operator must possess the... |
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