Optimization of the welding sequence and direction for the side beam of a bogie frame based on the discrete particle swarm algorithm

Abstract

For any large weldment with many welding seams, the welding sequence and direction have a strong influence on the assembly and service performance, especially for the side beam of the bogie frame of a high-speed rail passenger car (CHR3; CRRC, Changchun, China). Because different combinations of the welding sequence and direction greatly increase the computational time and research costs, a three-dimensional finite element approach was developed to investigate the optimal welding sequence and direction. Then, a surrogate model was established by design of experiment and used the concepts of a pointer and stack. Finally, the welding sequence and direction were optimized by the discrete particle swarm optimization algorithm. The max residual deformation and stress of the optimal result were 23.92 mm and 212.56 MPa, respectively, which is approximately 22% and 38% lower than the traditional enterprise plan, respectively. Furthermore, a weighted form of the residual deformation and stress was proposed to the end of optimum comprehensive effect, and the result also had 11% and 28% reduction, respectively. The simulation result of the optimal plans well reproduced the theoretical distribution results of the residual deformation and stress. It is proven that the optimal result can improve the welding quality and process of the side beam weldment in production.

Multi-Objective Optimization of MIG Welding and Preheat Parameters for 6061-T6 Al Alloy T-Joints Using Artificial Neural Networks Based on FEM

“…The application of the moving heat source is realized by the moving welding heat source method [29]. The welding process of metal gradually filled is simulated by the birth-death method [30].…”

Investigation of Welds and Heat Affected Zones in Weld Surfacing Steel Plates Taking into Account the Bead Sequence

“…In their analysis of the influence of welding sequences on thermomechanical states, the researchers' interests focus mainly on predicting the displacements (deformations) and the residual stresses after welding. This scope is dominated by research and optimization of the bead sequence when making welded joints, dividing the weld path into multiple seams and taking into account different directions of their execution [ 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 ]. In the works [ 13 , 14 , 15 , 16 , 17 , 18 ] only the results of numerical analysis were presented for various sequences of beads in simulated states of strain (deformation) and stress in welded joints.…”

“…Deng [ 24 ] used the electric strain gauge method to measure strains in longitudinal and transverse directions. The values of calculated residual stresses using the X-Ray method were verified in [ 22 , 25 , 26 ]. Displacements and distortions were measured in [ 27 , 28 , 29 , 30 ].…”

“…In welding practice, the choice of surfacing bead sequences is often made on the basis of experience and intuition. Although tests of multi-pass welded joints are conducted [ 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 ], detailed information on the effects of using certain sequences of surfacing beads is very scarce [ 31 , 32 , 33 ]. In welding handbooks (e.g.…”