Manufacturing Technique Studies On United Arab Emirates Sulphur Hopper Wagon

Based on the project for sulfur hopper car exported to United Arab Emirates (UAE) by CSR Yangtze co., LTD, the manufacturing process of car body has been researched in this thesis. This thesis has described the project background of United Arab Emirates sulfur hopper wagon briefly, the development history of the domestic and international railway wagon manufacturing process, the main purpose and work content of the research.The United Arab Emirates sulfur hopper wagon is fitted with automatic hatch and bottom door. The car body is designed an arc side plate structure with the major components connected by complex curves. The major parts of car body are welding connected. The customer representatives are experts on railway wagon designing and manufacturing from North American, the requirements based on the AAR standard should be met, as well as the manufacturing process. Research shows that the structure of the car body is complicated with difficulty of manufacturing; also there is much difference between AAR and national standards. Through the further researching of manufacturing process and AAR standards, with absorbing opinions from customer's experts, which has far-reaching significance to improve manufacturing process level for railway wagon, and get more close to international standards.This thesis has been analyzed from technology difficulty and components division reasonably on the basis of structure features and technical requirements of the United Arab Emirates (UAE) sulfur hopper wagon. Based on the company's existing hopper car manufacturing process, it has been designed from technological process, production lines and theirs cycle time, manufacturing process of main components, and proposals of key equipments according to the scope and relevant principles of "manpower, equipments, material, process method, environment, inspection", which determines the manufacturing process proposal of the car body in mass production. Numerical simulation technology is brought in for welding simulation to forecast the trend of welding deformation, which also provides analytical data to welding procedure, welding jigs design and welding deformation controlling.In the end, the thesis has verified the feasibility the proposal of car body manufacturing process by means of statistical analysis the actual data extracted in mass production. The above proposal of car body manufacturing process is designed to meet customer demand for product quality and delivery schedule, which is also very helpful to improve the hopper wagon's manufacturing technology level in our country.