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CN-116460478-B - Manufacturing method of honeycomb aluminum end wall, honeycomb aluminum end wall and railway vehicle

CN116460478BCN 116460478 BCN116460478 BCN 116460478BCN-116460478-B

Abstract

The invention belongs to the field of manufacturing of end walls of a train body of a railway train, and particularly relates to a manufacturing method of a honeycomb aluminum end wall, the honeycomb aluminum end wall and the railway train; the invention reduces the deformation of the end wall after welding by means of assembly sequence optimization, welding parameter adjustment, welding sequence optimization and the like, and ensures the integral manufacturing precision of the end wall with the honeycomb aluminum structure after assembly welding by means of assembly and release setting and reverse deformation control, thereby realizing adjustment-free repair.

Inventors

  • LIU TONG
  • ZHANG FENGDONG
  • ZHANG TIEHAO
  • ZHANG HE
  • Tan Yaqun
  • FANG XIFENG
  • LI GANGQING

Assignees

  • 中车青岛四方机车车辆股份有限公司

Dates

Publication Date
20260512
Application Date
20230529

Claims (13)

  1. 1. The manufacturing method of the honeycomb aluminum end wall comprises a first bent beam, a second bent beam, a third bent beam, a first honeycomb aluminum wallboard, a second honeycomb aluminum wallboard, a third honeycomb aluminum wallboard, a first upright post, a second upright post, a first cross beam, a second cross beam and a third cross beam, and is characterized by comprising the following manufacturing steps: Placing the first bent beam, the second bent beam and the third bent beam with the right side upwards on a welding tool for assembly and welding; placing the first honeycomb aluminum wallboard, the second honeycomb aluminum wallboard, the first upright post and the second upright post on a welding tool in sequence with the front faces upwards, then placing the third honeycomb aluminum wallboard and the first cross beam on the welding tool in sequence with the front faces upwards, and finally placing the second cross beam and the third cross beam on the welding tool in sequence with the front faces upwards; adjusting the outline size of the end wall, taking the central line as a reference in the width direction, taking the bottommost part of the end wall as a reference in the height direction, and sequentially compacting all the bent beams, the wallboards, the upright posts and the cross beams; Spot welding is carried out on the welding line on the front surface of the end wall, installing a process support to control the size, and welding the front surface of the end wall; When the front face is welded, welding the first honeycomb aluminum wallboard, the first upright post and the second upright post, welding the third honeycomb aluminum wallboard, the first upright post, the second upright post and the first cross beam, and welding the first honeycomb aluminum wallboard, the second honeycomb aluminum wallboard, the first bent beam, the second bent beam and the third bent beam; and after the front weld is cooled, turning the end wall to the reverse assembly tooling, and pressing the tooling with the reverse side of the workpiece upwards to carry out reverse welding.
  2. 2. The method of manufacturing a cellular aluminum headwall of claim 1, wherein the front face is assembled with a width-wise and a length-wise assembly.
  3. 3. The method for manufacturing a honeycomb aluminum end wall according to claim 1, wherein the welding directions of the first honeycomb aluminum wall plate and the first upright post and the second upright post are from top to bottom, the welding is divided into three sections, the welding is performed after the welding line of the last section is cooled to room temperature, and the two sides are welded synchronously.
  4. 4. The method of manufacturing a cellular aluminum headwall of claim 1, wherein the welding of the first cellular aluminum wallboard, the second cellular aluminum wallboard, and the first curved beam, the second curved beam, and the third curved beam is performed from a top center to a bottom of both sides, and both sides are simultaneously performed.
  5. 5. The method of manufacturing a cellular aluminum headwall of claim 1, wherein the welding of the first cellular aluminum wall panel, the second beam, and the third beam is performed from the center to both sides.
  6. 6. The method of manufacturing a cellular aluminum headwall of claim 1, wherein the clamps are attached to the first curved beam, the second curved beam, the third curved beam, the first upright, the second upright, and the first cross beam.
  7. 7. The method for manufacturing a honeycomb aluminum headwall of claim 6, the plurality of compactors are arranged at intervals.
  8. 8. The method of manufacturing a cellular aluminum headwall of claim 1, wherein a compactor is provided to add nylon spacer blocks to the first cellular aluminum wallboard and the second cellular aluminum wallboard.
  9. 9. The method of manufacturing a cellular aluminum headwall of claim 8, wherein the four corners of the contact surface of the nylon spacer and the cellular aluminum wallboard are rounded.
  10. 10. The method of manufacturing a cellular aluminum headwall of claim 1, wherein prior to welding the opposite side, the first cellular aluminum wall panel and the second cellular aluminum wall panel are cushioned in the main deformation positions by cushion blocks and the opposite side of the wall panel is raised by pressing the two sides.
  11. 11. The method of making a cellular aluminum headwall of claim 1, wherein the total out of flatness caused by the protrusions of the primary deformation locations of the first cellular aluminum wall panel and the second cellular aluminum wall panel are slightly adjusted by hammering the first post and the second post.
  12. 12. A honeycomb aluminum headwall obtained by the method of manufacturing a honeycomb aluminum headwall according to any one of claims 1 to 11.
  13. 13. A rail vehicle characterized in that the body end wall of the rail vehicle employs the cellular aluminum end wall of claim 12.

Description

Manufacturing method of honeycomb aluminum end wall, honeycomb aluminum end wall and railway vehicle Technical Field The invention belongs to the field of manufacturing of end walls of railway vehicles, and particularly relates to a manufacturing method of a honeycomb aluminum end wall, the honeycomb aluminum end wall and the railway vehicle. Background With the requirement of light weight of railway vehicles, the honeycomb aluminum wallboard is used for replacing the original end wallboard with a plate girder structure and a profile structure, and is one of effective means for reducing the weight of the vehicles. The honeycomb aluminum structure end wall effectively reduces the weight of the end wall while ensuring the structural strength. But the thickness of the honeycomb aluminum wallboard joint is reduced, and the welding quality is required to be higher. And the honeycomb aluminum structure skin is thinned, so that the appearance of the honeycomb aluminum wallboard is damaged easily due to overlarge pressure intensity in the process of fixture compaction in the manufacturing process, and the compaction and reverse deformation prefabrication difficulty in the welding process is increased. And the common post-welding repair means such as flame repair and pressure repair are easy to cause irreversible structural damage or surface damage to the honeycomb aluminum wallboard. Therefore, the manufacturing precision of the honeycomb aluminum end wall needs to be strictly controlled, and the maintenance-free honeycomb aluminum end wall is realized. Disclosure of Invention Aiming at the defects existing in the prior art, the first invention aims to provide a manufacturing method of the honeycomb aluminum end wall, the second invention aims to provide the honeycomb aluminum end wall obtained by the manufacturing method, and the third invention aims to provide a railway vehicle comprising the honeycomb aluminum end wall; in order to achieve the above object, the present invention is realized by the following technical scheme: In a first aspect, an embodiment of the present invention provides a method for manufacturing an aluminum honeycomb end wall, where the aluminum honeycomb end wall includes a first curved beam, a second curved beam, a third curved beam, a first aluminum honeycomb wall panel, a second aluminum honeycomb wall panel, a third aluminum honeycomb wall panel, a first upright, a second upright, a first cross beam, a second cross beam, and a third cross beam, and the manufacturing steps are as follows: Placing the first bent beam, the second bent beam and the third bent beam with the right side upwards on a welding tool for assembly and welding; placing the first honeycomb aluminum wallboard, the second honeycomb aluminum wallboard, the first upright post and the second upright post on a welding tool in sequence with the front faces upwards, then placing the third honeycomb aluminum wallboard and the first cross beam on the welding tool in sequence with the front faces upwards, and finally placing the second cross beam and the third cross beam on the welding tool in sequence with the front faces upwards; adjusting the outline size of the end wall, taking the central line as a reference in the width direction, taking the bottommost part of the end wall as a reference in the height direction, and sequentially compacting all the bent beams, the wallboards, the upright posts and the cross beams; Spot welding is carried out on the welding line on the front surface of the end wall, and installing a process support to control the size of the doorway; Welding the front surface of the end wall; and after the front weld is cooled, turning the end wall to the reverse assembly tooling, pressing the tooling with the reverse side of the workpiece upwards, and performing reverse welding. The invention reduces the deformation of the end wall after welding by means of assembly sequence optimization, welding sequence optimization and the like, and ensures the integral manufacturing precision of the end wall with the honeycomb aluminum structure after assembly welding by means of assembly and release amount setting and reverse deformation control, thereby realizing maintenance-free. As a further technical scheme, the assembly amount in the width direction and the length direction is required to be set during front assembly. According to the technical scheme, when the front face is welded, welding of the first honeycomb aluminum wallboard and the first upright post and the second upright post is firstly carried out, welding of the third honeycomb aluminum wallboard and the first upright post, welding of the second upright post and the first cross beam are then carried out, welding of the first honeycomb aluminum wallboard, the second honeycomb aluminum wallboard and the first bent beam, welding of the second bent beam and welding of the third bent beam are finally carried out, and welding of the first honeycomb aluminum