Study Of Locomotive Bogie Frame Welding Deformation Prediction System

The bogie frame is the most important bearing structure of the locomotive, and its prediction of welding deformation has important significance in ensuring manufacturing accuracy and quality. The bogie frame is welded by its front beam, behind beam and side beam. The beams'welding deformation is of great influence in the manufacture position and shape accuracy and has the direct influence in the bogie frame structure position and shape accuracy and quality. In the manufacturing to ensure the accuracy of the manufacture position, the beams'welding deformation has to be controlled. Or the welding deformation will be off the limits of the position and shape accuracy and the heat or mechanical method has to be taken to rectification. And the rectification will extend the manufacture period and increase the cost. What's more the rectification will aggravate the distribution of the stress.There are some optional welding methods to control the welding deformation, for example to take the welding deformation compensation, to weld with the more appropriate temperature field, to take more reasonable fixture. And some of those technologies are the most effective. All of those welding technologies have the basis and prerequisite of welding deformation prediction. The calculated welding deformation data and law are the theory basis for choice the most reasonable and effective welding technology and the optimization of undersize. So the accuracy of position and shape of welding parts is ensured.It is very difficult to predict the welding deformation for the welding structure especial the large and complex ones. One of the most effective methods is to predict the welding deformation with the elastic shell element FEM which is of the basic of inherent strain theory. The software Welding Structure Deformation Prediction (WSDP) is made by Shanghai Jiao Tong University and Osaka University. It's one of the most effective and reliable welding deformation prediction software.In this paper, the basic theory of welding simulation is described. It includes the inherent strain method and elastic shell FEM first. Then how to use the WSDP to predict the welding deformation is described. And on the basis, the inherent strain database is made and corrected. The database is made through simulating and computing the JD-4 bogie frame welding deformation and comparing the calculated and practical data. The JD-4 is manufactured now and its law of bogie frame welding deformation is well known. The new six-axised locomotive bogie frame welding deformation is computed with the WSDP and inherent strain database. At last we make an experience of the new bogie frame to get its practical welding deformation data and compare the data with calculated one. The calculated welding deformation data makes the theory basis for choice the appropriate and reasonable fixture and welding deformation compensation.Through the work above, the law of the new six-axised locomotive bogie frame welding deformation is got clearly.