铝合金高速动车组端墙弯梁三面转台集成组焊工艺

分析铝合金高速动车组弯梁组成结构,研制了一套端墙弯梁三面转台集成组焊工装,形成了一套高效的端墙弯梁组成快速定位安装组焊工艺。将焊前定位组装、正式焊接、设置定位器、压紧器、反变形量等工艺手段整合为一体,端墙弯梁组焊接完成后无需进行调修工序,其垂直度、轮廓度及平面度直接满足设计要求;在生产上缩小了操作空间,节省了劳动力,大幅降低了劳动强度,有效的解决了端墙弯梁及拱形梁这种小规格薄板工件、大批量生产、标准化作业的生产模式,极大提高了生产效率及产品质量。

Integrative welding process for three-side turntable of bending beam of end wall of aluminium alloy high-speed EMU

In this paper,through analysis the composition structure of curved beam in aluminum alloy high-speed EMU,a set of three-sided turntable integrated welding tool equipment for end-wall curved beam was developed,to form a high-efficiency welding process for end-wall curved beam with rapid positioning and assembly features. Many process steps,the pre-weld positioning assemble,formal welding,setting of positioner,compactor and reverse deformation,are integrated together by our process. The end-wall bending beam does not need to be adjusted after welding,and its verticality,profile degree and flatness meet the design requirements. It reduces the operation space and the labor intensity in production,and effectively solved the production mode of small-size thin-plate work pieces,mass production and standardized operation for end-wall curved beams and arched beams,which greatly improves production efficiency and product quality.