Research On Welded Bogie Quality Analysis And Method For High-speed Train

With the rapid development of China economy, developing high-speed, heavy-duty railway transportation is one of the most effective solutions for improving railway transport capacity and easing transport pressures nationally. And locomotive bogies, as driving mechanisms, are key components. Therefore, to meet the requirements above, research and developing well qualified solutions for bogie manufacturing and quality guarantee are very important and fundamental work.In this paper, the CW-200 high-speed train bogie frame welding quality as case study,against the frame often leads to the phenomenon of quality fluctuations combining the practical production,manufacturing quality of framework have been fully investigated and analyzed. Key analysis objectives and feasible testing scenarios are identified by using advanced quality engineering theory and statistical method. Through a lot of test for welded structures in workshop, author found the clear quality links and the main reasons for quality issues. On the basis above, the existing bogie structures and their welding processes are studied in details in order to explore the rule in welding distortion. After that, the quality improvement and control measures are presented according to the production situation. Also a welding process quality management system is established. The outcome of this paper could settle the foundation for high performance bogies manufacturing. Relevant results of this study are being applied further study and practice for high-speed train bogie manufacturing quality control.The main contributions of this paper are as follows:1. Through detailed investigation for CW-200 welded frame of the current status of the welding process, author finds out the existing problems of production in structure design, manufacturing process and quality management, respectively. These results offer the references for improving process quality management.2. The tracking measurement is made in whole welding process for side-beams of CW-200 bogie, and using statistics, the inherent laws of welding deformation are identified in terms of vertical and horizontal bend deformation, torsion deformation, and longitudinal shrink. Which are the fundamental for box-shape beam design and selecting suitable parameters in welding process.3. The statistical analysis is made for historical deformation data of CW-200 welded frame, and inherent law of welding deformation is found according to the distribution characteristic of mending and rectification, aiming at reducing the volume of mending and rectification and aid improving manufacturing quality. 4. After determining the main processes and the reasons of the quality issues, through amending, supplementing and perfecting existing quality guarantee system, a complete set of the bogie manufacturing quality control and management system is proposed hopefully.