Design Study For Mechanical Power Flexibility In Locomotive Skin Welding

Based on the present status of mechanical power flexibility in domestic locomotive skin welding technology, theoretical analysis for metal inner-stress and stain and type test analysis for sheet free, visual and inner deformation have been carried out. As a result, it is found there existed primary problems such as uneven mesh density of side-wall skeleton, insufficient rigidity of lateral column, inappropriate selection of skin material, unreasonable tension technology and inaccurate parameters, etc.. This article takes the new developed DF8B high power diesel locomotive equipped with 12V280ZJ diesel engine as a typical type, describes old and new welding technology separately, analyzes the reasons and influence factors of wave transformation appeared from thin steel plate skin. On the purpose of reducing weld length and proving side wall assembly procedures, we have made finite element analysis, improved traditional locomotive side wall skin welding process, analyzed new characteristics of stress and shape changes around side wall weld area, designed adjustable welding fixture for new locomotive side wall skeleton, locomotive side wall upper chord and lateral column anti-deformation tooling, and lifting tools for long & large thin steel plate skin. In addition, we have designed and analyzed locomotive skin tension equipment, electric heating methods selection and parameters selection, plasma magnetic cutting equipment, tension heat transferring mechanism and hydraulic program-controlled station. The new pre-stress technology change the assembly sequence into: before skinning the side wall skeleton, weld the carbody under-frame and partition wall together so as to manufacture by using the locomotive skin welding mechanical power flexible tooling in order to achieve the desired efficiency and effectiveness and filled a gap in this project...