Process optimization–oriented deformation control of large aluminum alloy structures from high-speed EMU

IF 2.4 4区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING
Yana Li, Jiahao Liu, Zeyang Zhang, Changlun Dai, Xingfu Yin, Xinpeng Shi
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Abstract

Predicting and controlling the welding deformation of large aluminum alloy structures are crucial to ensure the accuracy during the manufacturing of high-speed electric multiple units (EMUs). On the basis of heat source calibration, the dual ellipsoid heat source model and simplified equation parameters were used for metal-inert gas (MIG) welding, and the simulation of residual stresses obtained from the three numerical simulation methods was compared with the experimental values, and it was determined that the thermoelastic-plasticity method was used as a method to establish a high-precision inherent strain database. Based on this database, the welding deformation of the entire sidewall (23 m, 44 welds) was predicted and compared with the experimental data, and the error of the two results was less than 1 mm, and the simulation model was able to reflect the actual situation. Meanwhile, on the basis of this model, the effects of welding sequence, spot fixing method, and number of clamps on welding deformation were investigated separately, and the results showed that the reasonable welding sequence reduced the maximum deformation by 30.90%; the appropriate spot fixing method reduced the maximum deformation by 12.56%; and the reduction of the number of clamps by 9% could get the same effect as the original scheme, and the reduction of the number of fixtures by 18% could still ensure that the overall deformation was basically unchanged. Thus, process optimization can effectively control welding deformation, providing insights for improving the welding quality of aluminum alloy-based high-speed EMU structures.

Abstract Image

以工艺优化为导向的高速 EMU 大型铝合金结构变形控制
预测和控制大型铝合金结构的焊接变形对于确保高速电动多联机组(EMU)制造过程中的精度至关重要。在热源标定的基础上,对金属惰性气体(MIG)焊接采用了双椭圆体热源模型和简化方程参数,并将三种数值模拟方法得到的残余应力模拟值与实验值进行了比较,确定采用热弹性塑性方法作为建立高精度固有应变数据库的方法。在此数据库的基础上,对整个侧壁(23 米,44 道焊缝)的焊接变形进行了预测,并与实验数据进行了对比,两者的结果误差小于 1 毫米,模拟模型能够反映实际情况。同时,在该模型的基础上,分别研究了焊接顺序、点焊固定方法和夹具数量对焊接变形的影响,结果表明,合理的焊接顺序可使最大变形量减少 30.90%;适当的点焊固定方法可使最大变形量减少 12.56%;夹具数量减少 9% 可获得与原方案相同的效果,夹具数量减少 18% 仍可保证整体变形量基本不变。因此,工艺优化能有效控制焊接变形,为提高铝合金基高速电磁单元结构的焊接质量提供了启示。
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来源期刊
Welding in the World
Welding in the World METALLURGY & METALLURGICAL ENGINEERING-
CiteScore
4.20
自引率
14.30%
发文量
181
审稿时长
6-12 weeks
期刊介绍: The journal Welding in the World publishes authoritative papers on every aspect of materials joining, including welding, brazing, soldering, cutting, thermal spraying and allied joining and fabrication techniques.
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