构架侧梁焊接顺序与方向优化分析

构架是机车车辆的重要承载部件,控制其侧梁的焊接残余变形至关重要。以热弹塑性理论为基础,采用APDL语言对侧梁进行焊接变形数值仿真计算,并对侧梁进行现场跟踪测量。其焊接变形仿真计算结果与测量值基本吻合,误差在7%之内。以此仿真模型为基础,以焊接弯曲变形为目标函数,采用多层优化计算,对焊接顺序和方向进行数值仿真优化,得到最优方案。最优方案与现用方案相比,可使弯曲变形量降低34%左右。通过数值仿真优化所得的焊接方案可为焊接变形的控制、焊接工艺设计的选择和预留变形量的确定等提供可靠依据。

Analysis on the Optimization of Welding Sequence and Welding Direction of the Side Beam of Bogie Frame

The bogie frame is the main carrying part of locomotive.It is of utmost importance to control of the welding residual deformation of its side beam.In this paper,applying the thermal-elastic-plastic theory,numerical simulation of welding esidual deformations of the side beam was done with APDL,and field tracking measurement was also made with the side beam.The computation result was found basically consistent with the measured data,the error being below 7%.Relying on the above numerical simulation model,taking the welding bend deformation as the objective function and utilizing the multi-layer optimizing computer,the welding sequence and welding direction were optimized through numerical simulation and the optimum scheme was obtained.The optimum scheme was compared with the current scheme,the bending deformation being reduced about 34%.The optimum scheme provides reliable theoretical references to control of welding residual deformations,selection of the welding technology and determination of the reserved deformation volume.