基于局部-整体映射的高速列车车体地板焊接变形预测与工装优化研究

Welding Deformation Prediction and Fixture Optimization for High-Speed Train Car Body Floor Structures Based on Local-Global Mapping

  • 摘要: 本文针对高速列车车体地板大型铝合金型材结构的焊接变形控制问题,提出一种基于局部-整体映射的焊接变形预测与优化方法。研究采用分步式数值仿真策略,首先通过建立典型焊缝接头三维有限元模型,结合移动热源加载方法实现焊接温度场的精确模拟。基于温度相似性原理,将局部模型的热循环特征参数映射至车体地板整体结构,构建考虑材料非线性与接触非线性的多物理场耦合模型,显著提高大型结构模拟效率。在建模过程中集成机械夹具、液压夹具与重力夹具的复合约束条件,并引入结构自重及焊接顺序等工艺参数,建立与实际工况相符的边界条件。数值模拟结果显示,地板结构最大焊接变形量为3.5mm,与现场实测数据的平均相对误差控制在15%以内,验证了模型的可靠性。进一步研究工装约束布局对变形分布的影响规律,优化后的工装配置方案使关键区域变形量降低50%以上。该方法突破了传统整体建模的计算效率瓶颈,为大型复杂焊接结构的变形预测与控制提供了新的技术路径。

     

    Abstract: This paper addresses the welding deformation control of large aluminum alloy profile structures in high-speed train body floors by proposing a welding deformation prediction and optimization method based on local-global mapping. A stepwise numerical simulation strategy is adopted: First, a three-dimensional finite element model of a typical weld joint is established, and precise simulation of the welding temperature field is achieved through a moving heat source loading method. Guided by the temperature similarity principle, the thermal cycle characteristic parameters of the local model are mapped to the global floor structure, establishing a multi-physics coupling model that considers material nonlinearity and contact nonlinearity, thereby significantly improving simulation efficiency for large-scale structures. The modeling process systematically integrates composite constraints from mechanical clamps, hydraulic clamps, and gravity fixtures, while incorporating process parameters such as structural self-weight and welding sequence to establish boundary conditions consistent with actual working conditions. Numerical results indicate a maximum welding deformation of 3.5 mm in the floor structure, with an average relative error below 15% compared to field measurements, validating the model's reliability. Further parametric analysis reveals the influence mechanism of fixture constraint layouts on deformation distribution, with the optimized fixture configuration reducing deformation in critical regions over 50%. This method overcomes computational efficiency limitations inherent in traditional global modeling approaches, providing a novel technical pathway for deformation prediction and control in large-scale complex welded structures.

     

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