高速列车铝合金车体焊接变形的多维度协同控制  

Multidimensional Coordinated Control of Welding Deformation Control of Aluminum Alloy Carbody for High-Speed EMUs

作　　者：耿明 孙明双 安志飞 范明保 GENG Ming;SUN Mingshuang;AN Zhifei;FAN Mingbao(CRRC Changchun Railway Vehicles Co.,Ltd.,Changchun 130062,China)

机构地区：[1]中车长春轨道客车股份有限公司,吉林长春130062

出　　处：《电焊机》2025年第3期65-71,共7页Electric Welding Machine

摘　　要：高速列车铝合金车体因焊接量大、热膨胀系数高,易产生显著焊接变形,传统调修手段难以矫正,严重影响制造精度与效率。以复兴号智能动车组车体为研究对象,通过分析整车关键尺寸变形机理,提出多维度协同控制策略:针对车体轮廓变形,优化侧墙与车顶反变形量组合(宽度方向+4~+6 mm,高度方向+5~+7 mm);针对挠度变形,采用底架与侧墙等量反变形预制(+8 mm);结合内定位工装优化与对称焊接顺序调整,实现焊接变形主动控制。试验表明,该方法可有效抑制车体弯曲与轮廓变形,焊后关键尺寸稳定性显著提升,调修工作量大幅减少。研究结果为高速列车铝合金车体高精度焊接提供了可复用的工艺方案。Due to the large amount of welding and high coefficient of thermal expansion,the aluminum alloy carbody of high-speed trains is prone to significant welding deformation.Traditional adjustment methods are difficult to correct,severely affecting manufacturing precision and efficiency.Taking the Fuxing Hao intelligent EMU carbody as the research object,through analyzing the deformation mechanism of key dimensions of the whole vehicle,a multidimensional coordinated control strategy is proposed:for the contour deformation of the carbody,optimize the combination of sidewall and roof antideformation amount(width direction+4~+6 mm,height direction+5~+7 mm);for the deflection deformation,adopt the equal anti-deformation presetting of the underframe and sidewall(+8mm);combined with the optimization of internal positioning tooling and adjustment of symmetrical welding sequence,achieve active control of welding deformation.Tests show that this method can effectively suppress the bending and contour deformation of the carbody,significantly improve the stability of key dimensions after welding,and greatly reduce the adjustment workload.The research results provide a reusable process scheme for the high-precision welding of high-speed train aluminum alloy carbody.

关 键 词：高速列车 铝合金车体 焊接变形控制 反变形优化 工装设计 

分 类 号：TG457.14[金属学及工艺—焊接]