Finite Element Analysis Of Stress And Distortion In Magnetic-assisted GMAW Of Bogie Side Beam

The bogie is a key core component of high-speed trains.In the manufacturing process of the bogie,GMAW welding is the main forming process.During the welding process,residual stress and deformation will inevitably occur,which will affect the operational reliability and safety of high-speed trains.magnetic-assisted GMAW not only improves welding efficiency,but also suppresses weld forming defects such as hump and undercut.It has great application potential in the bogie manufacturing process.However,when conventional GMAW and magnetic-assisted GMAW are used for bogie welding,what is the difference in stress and deformation?Do not know yet.It is of great significance to establish the equivalent heat source model of magnetic-assisted GMAW and conventional GMAW,carry out finite element analysis on the stress and deformation of its typical joints,and conduct pre-research on the welding process of its application to the bogie.Using Simufact Welding software,the equivalent heat source model of magnetic-assisted GMAW and conventional GMAW was established,and verified according to the test and calculation results of weld cross-section fusion line and weld pool length,thermal cycle curve and residual stress.Taking the local model T-joint multi-pass welding of the bogie side beam as the research object,the temperature field,stress field and deformation field of the T-joint in the magnetic-assisted GMAW and the conventional GMAW are compared and analyzed.The results show that the peak temperature of the magnetic-assisted GMAW is higher than that of the conventional GMAW on the T-joint,and the cooling rate is faster than that of the conventional GMAW.The residual stress and deformation of magnetic-assisted GMAW are smaller than those of conventional GMAW.The thermal cycle curves of different positions on the T-joint weld are extracted as the input of the thermal cycle method,compared with the calculation results of the thermo-elastoplastic method,and the center of the weld edge is found to be the best point of the thermal cycle curve.Extract the thermal cycle curve of each weld and use it as the input of the bogie side beam numerical model.The distribution of residual stress and deformation of bogie side beams under the two welding conditions of magnetic-assisted GMAW and conventional GMAW are compared and analyzed,and the influence of four different welding sequences on the side beam stress and deformation in magnetic-assisted GMAW is investigated.The results show that the residual stress and deformation of the bogie side beams under the condition of magnetic-assisted GMAW are smaller than those of conventional GMAW.Among the four welding sequences of magnetic-assisted GMAW,the first welding sequence is the optimal welding sequence.