Controlling Of Welding Distortion For The Frame Of Motorcycle

The frame is the main components of motorcycle, consisted of many types of pipe and plate, which are welded together and form a complicated three-dimensional structure. Frame combines engine, drive system, hanging unit, veer unit and wheel together as a whole. The frame not only bears the weight of driver, engine and other components, but also is subject to different impact and vibration. Hence it is important to ensure the strength and stiffness of frame by controlling welding stress and welding distortion in the frame manufacturing.The paper first presents the position and role of welding in the motorcycle manufacturing. Meantime, it emphasizes the important role of manufacturing technologies and welding technologies of the frame in the motorcycle manufacturing. Secondly, the principles and the reasons of welding distortion are introduced. It lay a foundation for analysis of the welding deformation of the frame in theory. After that the way of eliminating welding stress and preventing and controlling welding distortion are presented. Meantime, the new way of controlling welding distortion is discussed, such as the finite element method. At last, the welding distortion problems and the main reasons of one manuefucturing motorcycle in the Zhuzhou Jianshe YAMAHA Motor Co.,Ltd. (ZJYM)-ZY125's frame distortion are analyzed. The distortion of the frame is controlled by the discussed method effectively. The main conclusions are as follows:Combinated with the experience of production, welding structure and welding distortion of the frame are researched. Welding distortion is controlled by the initial structural design. Adjusting welding fixture and optimizing the welding technologies also can reduce the welding distortion. On the base of calculating the modulus of deformation, through anti-distortion and rigid fixed structure, the percent of pass of the frame manufacturing is from 20% to 95% without rectifying. It eliminates effectively the welding distortion in the process of production.The results of the paper have been used in production. It has created good social and economic benefits. It also provides a valuable basis and method for further research on the motorcycle frame welding.