CN115383413B - Manufacturing process method of large-deflection aluminum alloy car body - Google Patents
Manufacturing process method of large-deflection aluminum alloy car body Download PDFInfo
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- CN115383413B CN115383413B CN202211198434.8A CN202211198434A CN115383413B CN 115383413 B CN115383413 B CN 115383413B CN 202211198434 A CN202211198434 A CN 202211198434A CN 115383413 B CN115383413 B CN 115383413B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 17
- 238000000034 method Methods 0.000 title claims abstract description 17
- 238000003466 welding Methods 0.000 claims abstract description 29
- 241001669679 Eleotris Species 0.000 claims abstract description 12
- 238000001514 detection method Methods 0.000 claims abstract description 8
- 229920002334 Spandex Polymers 0.000 claims description 6
- 239000004759 spandex Substances 0.000 claims description 6
- 238000004364 calculation method Methods 0.000 claims description 4
- 238000004088 simulation Methods 0.000 claims description 3
- 230000001502 supplementing effect Effects 0.000 claims description 3
- 239000010953 base metal Substances 0.000 abstract description 5
- 238000009417 prefabrication Methods 0.000 description 5
- 239000013589 supplement Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000011900 installation process Methods 0.000 description 2
- 230000000903 blocking effect Effects 0.000 description 1
- 230000037396 body weight Effects 0.000 description 1
- 210000004556 brain Anatomy 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T30/00—Transportation of goods or passengers via railways, e.g. energy recovery or reducing air resistance
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Automobile Manufacture Line, Endless Track Vehicle, Trailer (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses a manufacturing process method of a large-deflection aluminum alloy vehicle body, which comprises the steps of S1, prefabricating 40mm deflection at the central position of a vehicle roof part during assembly welding of the vehicle roof part; s2, manufacturing a special-shaped side wall structure; s3, introducing deflection interval definition, prefabricating deflection values at the positions of the side walls of the vehicle body, wherein the bottoms of the side walls of the vehicle body are provided with a plurality of supporting points; s4, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, detecting a prefabricated deflection value of the vehicle body, and verifying whether the deflection of the vehicle body reaches an expected value at the moment; s5, welding a block side wall structure; s6, after the welding seam of the vehicle body is naturally cooled to room temperature, lifting the welding seam to a detection tire position for deflection detection, and measuring side beams at two sides of the two sleeper beams and the side beam at the center of the vehicle body; s7, calculating a deflection value. The manufacturing process of the invention greatly reduces the prefabricated deflection value, reduces the applied force on the vehicle body and the tooling, increases the safety, does not need to use flame adjustment and repair, reduces the internal stress of the base metal of the vehicle body, and can reach the final vehicle body deflection value of more than 13 mm.
Description
Technical Field
The invention relates to the technical field of processing technology of a block side wall structure of a railway carriage, in particular to a manufacturing technology method of a large-deflection aluminum alloy car body.
Background
In the prior art, the deflection value of the aluminum alloy urban iron A-type vehicle (a segmented side wall structure) is required to be 7-13 mm, and the deflection value of the B-type vehicle (the segmented side wall structure) is required to be 6-12 mm. In recent years, the requirements of each project on the vehicle body bearing capacity (the upper deflection is more than 0mm when AW3 is loaded) and the vehicle body weight are increased, so that the deflection value calculated by the vehicle body in the design stage is greatly increased, especially in the unified subway project, the required deflection value in the vehicle body stage is 11-15 mm, and before the required deflection value, each main machine factory never stabilizes the produced vehicle body deflection value above 11mm in any urban railway project.
A schematic diagram of deflection prefabrication and supporting points in the prior art is shown in fig. 1, but the arrangement of the deflection prefabrication and the supporting points in the prior art cannot meet the design requirement of the deflection value of a vehicle body above 11mm in the present stage.
Therefore, based on the above technical problems, a person skilled in the art needs to develop a manufacturing process method for a large-deflection aluminum alloy vehicle body.
Disclosure of Invention
The invention aims to provide a manufacturing process method of a large-deflection aluminum alloy vehicle body, which is characterized in that a deflection interval is introduced to define and prefabricate a deflection value at the side wall position of the vehicle body, the prefabrication deflection value is greatly reduced, the applied force to the vehicle body and a tool is reduced, the safety is increased, flame adjustment is not needed, the internal stress of a base metal of the vehicle body is reduced, and the final deflection value of the vehicle body can reach more than 11 mm.
In order to achieve the above object, the present invention provides the following technical solutions:
the invention relates to a manufacturing process method of a large-deflection aluminum alloy vehicle body, which mainly comprises the following steps:
s1, prefabricating deflection in a vehicle roof position assembly welding mode, and prefabricating 40mm deflection in the center position of the vehicle roof position in the vehicle roof position assembly welding mode;
s2, performing simulation calculation on gate compensation to manufacture a special-shaped side wall structure;
s3, introducing deflection interval definition, prefabricating deflection values at the positions of the side walls of the vehicle body, wherein the bottoms of the side walls of the vehicle body are provided with a plurality of supporting points;
s4, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, detecting a prefabricated deflection value of the vehicle body, and verifying whether the deflection of the vehicle body reaches an expected value at the moment;
s5, welding the block side wall structure by using a fixed welding sequence;
s6, after the welding seam of the car body is naturally cooled to room temperature, loosening the tool to hoist the welding seam to a detection tire position for deflection detection, and measuring side beams at two sides of the two sleeper beams and the side beam at the center of the car body;
s7, calculating a deflection value.
Further, in the step S2, when the special-shaped side wall structure is manufactured, both sides of the bottom position of the vehicle door at the middle position of the special-shaped side wall structure are provided with deflection supplement values, and the deflection supplement values are 2mm;
the vehicle door close to the middle position of the special-shaped side wall structure is provided with deflection compensation values, wherein the deflection compensation value of the upper part close to one side of the middle position is 3mm, and the deflection compensation value of the lower part far away from one side of the middle position is 4mm;
the upper part of the side, close to the middle position, of the vehicle door far away from the middle position of the special-shaped side wall structure is provided with a deflection compensation value, and the deflection compensation value is 5mm.
Further, in the step S3, the deflection value of the middle position of the side wall of the vehicle body is 21mm;
the deflection value at the side edge of the vehicle door positioned at the middle position of the side wall of the vehicle body is 20mm;
the deflection values at the side edges of the vehicle door near the middle position are 12mm and 10mm respectively.
Further, in the step S4, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, a level gauge or a lycra detector is used to detect the prefabricated deflection value of the vehicle body, and whether the deflection of the vehicle body reaches the expected value at the moment is verified;
if the deformation of the tooling occurs, the prefabricated deflection value becomes smaller, the clamping is firstly released, then the deflection compensation is carried out on the deformed part, and then the part is clamped.
Further, in the step S5, the sequence of welding the segmented side wall structure is that the welding is performed from the center of the welded structure to the outside, and then from the outside to the inside.
Further, in the step S6, the height values of four points of the side beams at two sides of the two sleeper beams are measured by a level gauge or a lycra detector, and are b1, b2, b3 and b4 respectively;
the height values of two points of the boundary beam at the center of the vehicle body are respectively a1 and a2 by a level gauge.
Further, in the step S7, the vehicle body deflection value is calculated according to the following formula:
b＝(b1+b2+b3+b4)/4 ①
a＝(a1+a2)/2 ②
final deflection value = a-b (3)
Wherein:
b1, b2, b3 and b4 are respectively the height values of four points of side beams at two sides of the two sleeper beams;
a1 and a2 are respectively the height values of two points of the boundary beam at the center of the vehicle body;
b is the average height value of the side beams at the two sides of the two sleeper beams;
a is an average height value at the center of the vehicle body.
In the technical scheme, the manufacturing process method of the large-deflection aluminum alloy vehicle body provided by the invention has the following beneficial effects:
the manufacturing process of the invention greatly reduces the prefabricated deflection value, reduces the applied force on the vehicle body and the tooling, increases the safety, does not need to use flame adjustment and repair, reduces the internal stress of the base metal of the vehicle body, and can reach the final vehicle body deflection value of more than 13 mm.
The manufacturing process of the invention has good universality, and all aluminum alloy metro vehicles can be used for manufacturing deflection by using the invention; the work load of an operator is reduced, the prefabricated deflection value is reduced, the pull-down amount of the vehicle body by the operator is reduced by using the tool, the vehicle body is not required to be secondarily repaired after being assembled and welded, the work load of the operator is greatly reduced, and each trolley can reduce the working time of 2 hours.
The vehicle body quality of the manufacturing process is improved, the vehicle body deflection value is improved, the size of a vehicle body door opening can be controlled, and the development of a subsequent door installation process is ensured.
Drawings
For a clearer description of embodiments of the present application or of the solutions in the prior art, the drawings that are needed in the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments described in the present invention, and that other drawings may be obtained according to these drawings for a person skilled in the art.
FIG. 1 is a schematic view of a prior art deflection prefabrication and support point;
FIG. 2 is a schematic diagram of a prefabricated deflection zone and a supporting point of a manufacturing process method of a large-deflection aluminum alloy vehicle body according to an embodiment of the invention;
fig. 3 is a schematic diagram of deflection supplementing dimensions of a special-shaped side wall structure of a manufacturing process method of a large-deflection aluminum alloy vehicle body according to an embodiment of the invention.
Detailed Description
In order to make the technical scheme of the present invention better understood by those skilled in the art, the present invention will be further described in detail with reference to the accompanying drawings.
See fig. 2-3;
the manufacturing process method of the large-deflection aluminum alloy vehicle body mainly comprises the following steps of:
s1, prefabricating deflection in a vehicle roof position assembly welding mode, and prefabricating 40mm deflection in the center position of the vehicle roof position in the vehicle roof position assembly welding mode; the roof can reach the state that the two ends of the roof sag by 5-10 mm without flame adjustment in the cross checking process.
S2, performing simulation calculation on gate compensation to manufacture a special-shaped side wall structure;
s3, introducing deflection interval definition, prefabricating deflection values at the positions of the side walls of the vehicle body, wherein the bottoms of the side walls of the vehicle body are provided with a plurality of supporting points;
s4, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, detecting a prefabricated deflection value of the vehicle body, and verifying whether the deflection of the vehicle body reaches an expected value at the moment;
s5, welding the block side wall structure by using a fixed welding sequence;
s6, after the welding seam of the car body is naturally cooled to room temperature, loosening the tool to hoist the welding seam to a detection tire position for deflection detection, and measuring side beams at two sides of the two sleeper beams and the side beam at the center of the car body;
s7, calculating a deflection value.
Referring to fig. 3, preferably, in step S2 of the foregoing embodiment, when the profiled side wall structure is manufactured, both sides of the bottom position of the vehicle door at the middle position of the profiled side wall structure have deflection supplement values, and the deflection supplement value is 2mm;
the vehicle door close to the middle position of the special-shaped side wall structure is provided with deflection compensation values, wherein the deflection compensation value of the upper part close to one side of the middle position is 3mm, and the deflection compensation value of the lower part far away from one side of the middle position is 4mm;
the upper part of the side, which is far away from the middle position of the special-shaped side wall structure, of the vehicle door, which is close to the middle position, is provided with a deflection compensation value, and the deflection compensation value is 5mm.
And when the blocking side wall is processed and the upright post is assembled and welded, the special-shaped side wall structure is manufactured so as to improve the control of the width, the height, the diagonal line and other dimensions of the vehicle door under the condition that the final vehicle body is more than 11mm in deflection, and ensure the installation of a subsequent door mechanism.
Preferably, in step S3 of the present embodiment, the deflection value of the middle position of the vehicle body side wall is 21mm;
the deflection value of the side edge of the vehicle door positioned in the middle of the side wall of the vehicle body is 20mm;
the deflection values at the sides of the door near the middle position are 12mm and 10mm, respectively.
Introducing deflection interval definition, prefabricating deflection values at the side wall positions of the vehicle body, increasing the number of support points at the lower part of the vehicle body, reducing the deflection value of a gate area, and greatly reducing the total prefabrication deflection value of the vehicle body compared with the prior art.
Preferably, in step S4 of the present embodiment, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, a level gauge or a lycra detector is used to detect the prefabricated deflection value of the vehicle body, and it is verified whether the deflection of the vehicle body reaches the expected value at this time;
if the deformation of the tooling occurs, the prefabricated deflection value becomes smaller, the clamping is firstly released, then the deflection compensation is carried out on the deformed part, and then the part is clamped.
Because the tool strength of each manufacturer is different, the deformation is different, and the step can not be omitted in order to ensure the accuracy of the prefabricated deflection value.
Preferably, in step S5 of the present embodiment, the sequence of welding the segmented sidewall structures is that the welding structure is performed from the center to the outside, and then from the outside to the inside.
Preferably, in step S6 of the present embodiment, the height values of four points of the side beams on both sides of the two bolster are measured by a level gauge or a lycra detector, and are b1, b2, b3, b4 respectively;
the height values of two points of the boundary beam at the center of the vehicle body are respectively a1 and a2 by a level gauge.
In step S7, the vehicle body deflection value is calculated according to the following formula:
b＝(b1+b2+b3+b4)/4 ①
a＝(a1+a2)/2 ②
final deflection value = a-b (3)
Wherein:
b1, b2, b3 and b4 are respectively the height values of four points of side beams at two sides of the two sleeper beams;
a1 and a2 are respectively the height values of two points of the boundary beam at the center of the vehicle body;
b is the average height value of the side beams at the two sides of the two sleeper beams;
a is an average height value at the center of the vehicle body.
In the prior art, the prefabricated brain degree (more than 28 mm) during the assembly welding of the vehicle body cannot meet the requirement that the final deflection reaches more than 11mm, and experience proves that the ultimate deflection value is 9 to 11mm, even the final deflection value of the vehicle body is ensured by flame adjustment, so that the deformation of the vehicle body and the internal stress of a base metal are overlarge, and meanwhile, the stress of a tool is overlarge, the service life of the tool is greatly shortened, and the operation safety is reduced.
In the technical scheme, the manufacturing process method of the large-deflection aluminum alloy vehicle body provided by the invention has the following beneficial effects:
the manufacturing process of the invention greatly reduces the prefabricated deflection value, reduces the applied force on the vehicle body and the tooling, increases the safety, does not need to use flame adjustment and repair, reduces the internal stress of the base metal of the vehicle body, and can reach the final vehicle body deflection value of more than 13 mm.
The manufacturing process of the invention has good universality, and all aluminum alloy metro vehicles can be used for manufacturing deflection by using the invention; the work load of an operator is reduced, the prefabricated deflection value is reduced, the pull-down amount of the vehicle body by the operator is reduced by using the tool, the vehicle body is not required to be secondarily repaired after being assembled and welded, the work load of the operator is greatly reduced, and each trolley can reduce the working time of 2 hours.
The vehicle body quality of the manufacturing process is improved, the vehicle body deflection value is improved, the size of a vehicle body door opening can be controlled, and the development of a subsequent door installation process is ensured.
While certain exemplary embodiments of the present invention have been described above by way of illustration only, it will be apparent to those of ordinary skill in the art that modifications may be made to the described embodiments in various different ways without departing from the spirit and scope of the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive of the scope of the invention, which is defined by the appended claims.
Claims (4)
1. The manufacturing process method of the large-deflection aluminum alloy car body is characterized by comprising the following steps of:
s1, prefabricating deflection in a vehicle roof position assembly welding mode, and prefabricating 40mm deflection in the center position of the vehicle roof position in the vehicle roof position assembly welding mode;
s2, performing simulation calculation on gate compensation to manufacture a special-shaped side wall structure;
when the special-shaped side wall structure is manufactured, deflection supplementing values are arranged on two sides of the bottom position of the vehicle door at the middle position of the special-shaped side wall structure, and the deflection supplementing values are 2mm;
the vehicle door close to the middle position of the special-shaped side wall structure is provided with deflection compensation values, wherein the deflection compensation value of the upper part close to one side of the middle position is 3mm, and the deflection compensation value of the lower part far away from one side of the middle position is 4mm;
the upper part of the side, close to the middle position, of the vehicle door far away from the middle position of the special-shaped side wall structure is provided with a deflection compensation value, and the deflection compensation value is 5mm;
s3, introducing deflection interval definition, prefabricating deflection values at the positions of the side walls of the vehicle body, wherein the bottoms of the side walls of the vehicle body are provided with a plurality of supporting points;
s4, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, detecting a prefabricated deflection value of the vehicle body, and verifying whether the deflection of the vehicle body reaches an expected value at the moment;
s5, welding the block side wall structure by using a fixed welding sequence;
s6, after the welding seam of the car body is naturally cooled to room temperature, loosening the tool to hoist the welding seam to a detection tire position for deflection detection, and measuring side beams at two sides of the two sleeper beams and the side beam at the center of the car body;
measuring the height values of four points of side beams at two sides of the two sleeper beams by using a level gauge or a lycra detector, wherein the height values are b1, b2, b3 and b4 respectively;
measuring the height values of two points of the boundary beam at the center of the vehicle body through a level gauge, wherein the height values are a1 and a2 respectively;
s7, calculating a deflection value;
the calculation of the deflection value of the vehicle body is according to the following formula:
b＝(b1+b2+b3+b4)/4 ①
a＝(a1+a2)/2 ②
final deflection value = a-b (3)
Wherein:
b1, b2, b3 and b4 are respectively the height values of four points of side beams at two sides of the two sleeper beams;
a1 and a2 are respectively the height values of two points of the boundary beam at the center of the vehicle body;
b is the average height value of the side beams at the two sides of the two sleeper beams;
a is an average height value at the center of the vehicle body.
2. The method for manufacturing a large-deflection aluminum alloy vehicle body according to claim 1, wherein in the step S3, a deflection value of a middle position of a side wall of the vehicle body is 21mm;
the deflection value at the side edge of the vehicle door positioned at the middle position of the side wall of the vehicle body is 20mm;
the deflection values at the side edges of the vehicle door near the middle position are 12mm and 10mm respectively.
3. The method according to claim 1, wherein in the step S4, after the prefabricated deflection of the vehicle body is first performed by using the tool pull-down device, the prefabricated deflection value of the vehicle body is detected by using a level gauge or a lycra detector, and whether the deflection of the vehicle body reaches the expected value is verified;
if the deformation of the tooling occurs, the prefabricated deflection value becomes smaller, the clamping is firstly released, then the deflection compensation is carried out on the deformed part, and then the part is clamped.
4. The method according to claim 1, wherein in the step S5, the sequence of welding the segmented side wall structures is first down, then up, first out and then in, and the welding is performed from the center of the welded structure to the outside.
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| CN202211198434.8A CN115383413B (en) | 2022-09-29 | 2022-09-29 | Manufacturing process method of large-deflection aluminum alloy car body |
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| CN202211198434.8A CN115383413B (en) | 2022-09-29 | 2022-09-29 | Manufacturing process method of large-deflection aluminum alloy car body |
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| CN115383413B true CN115383413B (en) | 2024-03-29 |
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2022
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|---|---|---|---|---|
| KR20020046091A (en) * | 2000-12-12 | 2002-06-20 | 안우희 | Underframe for railway rolling stock and manufacture method |
| JP2008001363A (en) * | 2007-08-20 | 2008-01-10 | Hitachi Ltd | Vehicle body structure |
| CN101456420A (en) * | 2008-12-29 | 2009-06-17 | 南车长江车辆有限公司 | Box shaped central sill assembling method for railway vehicle splicing |
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