Volume 22 Issue 1
Feb.  2022
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Article Navigation >  Journal of Traffic and Transportation Engineering  > 2022  >  22(1): 133-140
LU Yao-hui, LI Zhen-sheng, YIN Xiao-chun, SONG Cheng-yu, LIU Xi, LU Chuan. Calculation methods of stress factor in welding seam quality grade evaluation of EMUs aluminum alloy car body[J]. Journal of Traffic and Transportation Engineering, 2022, 22(1): 133-140. doi: 10.19818/j.cnki.1671-1637.2022.01.011
Citation: LU Yao-hui, LI Zhen-sheng, YIN Xiao-chun, SONG Cheng-yu, LIU Xi, LU Chuan. Calculation methods of stress factor in welding seam quality grade evaluation of EMUs aluminum alloy car body[J]. Journal of Traffic and Transportation Engineering, 2022, 22(1): 133-140. doi: 10.19818/j.cnki.1671-1637.2022.01.011
shu

Calculation methods of stress factor in welding seam quality grade evaluation of EMUs aluminum alloy car body

doi: 10.19818/j.cnki.1671-1637.2022.01.011

  • School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, Sichuan, China

Funds:

National Natural Science Foundation of China 51275428

National Natural Science Foundation of China 51775450

National Natural Science Foundation of China 51875482

Sichuan Science and Technology Program 2022YFG0251

More Information
  • Author Bio:

    LU Yao-hui(1973-), male, professor, PhD, yhlu2000@swjtu.edu.cn

  • Received Date: 2021-07-23
  • Publish Date: 2022-02-25
    Abstract
  • The finite element analysis model of the aluminum alloy welded car body for a type of electric multiple units (EMUs) was established. The welding seam was simplified modeling, and the difference between the welding seam and the actual existence was corrected in the calculation of the equivalent structural stress. The loads on the car body were analyzed based on BS EN 12663-1:2010. Nine fatigue load cases of car body were determined by the Box-Behnken orthogonal matrix design. A multi-axial load was applied to the finite element model of car body, and the stress distribution of the four long welding seams on the car body side wall were analyzed. Six concerned points for stress factor calculations were identified. The stress factors of welding seams on the car body side wall were calculated by using the nominal stress method and the equivalent structural stress method. Two stress analysis methods were compared and analyzed. Analysis results show that the allowable stress ranges of the two stress analysis methods are different at 1.0×107 cycles, with a nominal stress of 16.40 MPa and an equivalent structural stress of 26.61 MPa. The nominal stress ranges of the six concerned points are all smaller than the equivalent structural stress ranges, and the obtained stress factors of the nominal stress and equivalent structural stress are 0.33, 0.25, 0.50, 0.49, 0.76, 0.62 and 0.23, 0.24, 0.39, 0.45, 0.61, 0.48, respectively. For the concerned points of the same welding seam, the stress factors obtained by the nominal stress method are greater than the values obtained by the equivalent structural stress method. The nominal stress method has a large dispersion, which leads to a large stress factor. The structural stress method has a clearer physical meaning, and the calculated stress factor is more reasonable. 2 tabs, 8 figs, 30 refs.

     

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