Study On Thick Aluminum Plate Cutting Of Train Bodyshell

The quality of railway car is required higher and higher with times developing. Low weight and high speed are important symbol of modern transportation. The best method to reach low weight and high speed is to reduce the car body weight. Aluminum car body superiority lies in high safety, low weight, low energy consumption, anti-corrosion, high riding index, recycled material. Aluminum plate incising technology will directly influence the output, quality and production cost of high speed aluminum train set, urban railway car and metro car. Furthermore it will influence the competition train set company and production level of train set in our country. It has practical and economic effect to study aluminum incising technology for producing high speed aluminum train set, urban railway car and metro car and improving company competition.Aluminum urban and metro car technology was transferred to our company from Europe in 2000. The start point of the technology transfer is high, but we did not absorbed advanced technology absolutely, especially in thick aluminum plate incising. So, we have a certain room and significance to study incising technology. We can study the aspects below to improve thick plate incising technology. Firstly, by analyzing car body and parts, it will be confirmed for aluminum plate incising standards and technology requirement. Then we can design the proper plate incising process. Secondly, make a suitable technology requirement of material in order to reduce and avoid incised rejected production. Finally by study on machine, find the factors which influence incising, improve incising quality and efficiency and reduce the production cost.We have no mechanics ability assessment and comparison between the parts incised by waterjet, plasma and laser cutting machine. So, we are not clear about those parts capability. It is necessary to test the parts mechanics and providereference for incising process.Aluminum parts can be found nearly every where in the car body. Different sub-assembly has different requirement about quality and size precision of aluminum parts. By analyzing plate parts, we can define the level of quality and choose the appropriate cutting machine and cutting process. Then the machines can be used to a perfect extent. We will change the statue of machines and material waste, decrease the cost and improve the production efficiency to a certain extent.Because of native technology limitation, the material will become warped after being cutting-that is the plane degree is not up to standard. It influence the following process. Sometimes the parts can not be used any more. Raw material is wasted. During our production, the above state often happens. Because the plate become warped, the cutting line become curved. The parts can not meet the requirement. The worst thing is the machine cutting head can be damaged. By adding the flattening and thermal treatment process, we can remove the inner stress and avoid the plate becoming warped. Moreover we can find good operation method to reduce and avoid cutting head damage.Cutting process is not up to the requirement of the follow-up forming and welding. In daily production, the crack were occurred frequently because of the improper cutting process. By analysing the process of forming, fitting and welding, we can define the right cutting method to prevent the crack occurred while forming. In this way we can reduce the rejected parts. If it does not work, we can use thermal treatment and trimming to solve the problem.Operators can not operate the machines properly to cut different size aluminum part. Operators can not master the operation regulation. So, the parts seldom are in ideal state. Another thing is the machines and energy were consumed. My job is to find the potential capability of each machine and ensure that the machine work in a good state.