Numerical computation methods of welding deformation and their application in bogie frame for high-speed trains

Abstract The welding deformation of a single-side double-pass welding T-joint is simulated by using a thermal elastic-plastic method (TEPM) and inherent strain method (ISM) respectively, and comparisons are made. Consequently, the numerical simulation results using the two methods are approximately consistent; thus, the application of the thermal elastic-plastic method and inherent strain method for predicting the welding deformation of T-joints is validated. Then, the inherent strain method based on empirical formulas is applied to simulate the welding deformation of a shell model and solid model of the side beam of a bogie frame. A comparative analysis of the two models shows that the simulated result of the solid model is more accurate than that of the shell model. However, the two results are basically consistent with the measured welding deformation of the side beam of the frame, further demonstrating the effectiveness of the inherent strain method in predicting the welding deformation of large complex structures. The prediction methods provided in this paper give a reference to the welding deformation correction and the corresponding welding process optimization for large-scale welded structures.

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