Simulation Study On Welding Deformation And Residual Stress Of Fast Freight Vehicles Side Beam

As an important part of bogie frame,the quality of side beam has an important influence on the performance of bogies.The side beam is a large welded structure,welding process will inevitably produce welding residual stress and deformation.The peak and distribution of residual stress will influence the dimension accuracy,structure strength and reliability of welded frame,that is especially important for railway vehicle bogies under large static and dynamic loads.Therefore,it is necessary to take effective measures to realize the control of welding deformation and residual stress in the structure design and process design of side beam.In this paper,we take the 160km/h-speed railway freight car bogie side beam as the research object,establish the finite element model with the Hypermesh and simulate the welding process with Sysweld to study the influence of different welding sequence and heat treatment on the welding deformation and residual stress.And take the T joint and butt test plates with different clamp conditions as the cut-in point.The welding process and heat treatment process of the test plate are simulated by the thermal cycling curve method to demonstrate the feasibility of this method used for side bogie beam.Then the welding process of the side beam is simulated by this method.Take the welding sequence of the external long weld as a variable,four schemes were developed to analyze the welding deformation and residual stress of the side beams under different welding sequences.Through the comparison and analysis of welding deformation and residual stress of four schemes,it is found that the deformation of scheme 1 is the least,which is the best scheme.The simulation of heat treatment process of scheme 1 is carried out and compared with the experimental test results.The simulation results are basically consistent with the test results.The peak residual stress is obviously reduced after heat treatment,and the higher the value is,the more obvious the stress relief effect is.The conclusions obtained in this paper are expected to provide theoretical reference and technical support for side beam research.