RailVehicleManufacturing-中国铁道出版社

″

TheBeltandRoad″RailTransitSeriesPlanningTextbook

RailVehicleManufacturing

ZouHua

,

CHINARAILWAYPUBLISHINGHOUSECO.LTD.

·

2022Beijing

″BriefIntroductionoftheBook

ThebookisoneofTheBeltandRoad″railtransitseriesplanningtextbooks.Itmainlyintroduces

themanufacturingprocessofrailwayEMUbogieandcarbody.Itisdividedinto5chapters.Chapter1

;;

introducesthemachiningofEMUbogieChapter2introducestheassemblyofEMUbogieChapter3

;

introducesthepunchingofcarbodypartsofEMUChapter4introducestheweldingprocessforcar

;

bodyassemblyofEMUChapter5introducesthemanufacturingofEMU.

Thebookcanbeusedasateachingmaterialforrailvehiclerelatedmajorsofuniversityorcollege.

Itisalsoavailableforengineeringtechniciansmajoringinvehicleengineeringandurbanrailtransit

vehicle.

图书在版编目CIP数据

()

轨道车辆制造邹骅

=RailVehicleManufacturing/

主编北京中国铁道出版社有限公司

.—:,2022.2

一带一路轨道交通系列规划教材

“”

ISBN978-7-113-28706-1

轨邹轨道车车辆制造教材

Ⅰ.①…Ⅱ.①…Ⅲ.①

Ⅳ.①U216.61

中国版本图书馆数据核字第号

CIP(2021)270829

Booktitle:RailVehicleManufacturing

Writer:

ZouHua

Executiveeditor:Telephone:()E-mail:

YinNa01051873206624154369@qq.com

Coverdesign:

CuiLifang

Proofreadingby:

JiaoGuiying

Printedby:

GaoChunxiao

Publishedanddistributedby:,(,,,

ChinaRailwayPublishingHouseCo.Ltd.100054No.8WestStreetYou′anmen

,)

XichengDistrictBeijing

Website:

http://www.tdpress.com

Printedby:(),

CNPIECDigitalPrintingBeijingCo.Ltd

Editionorder:,,,

FirsteditioninFebruary2022andfirstprintedinFebruary2022

Booksize:printedsheetwordnumber

787mm×1092mm1/16:21.25:651thousand

Booknumber:

ISBN978-7-113-28706-1

Price:

￥118.00

Allrightsreserved

Pleasecontactreaderserviceofficeofourpublishinghouseifthereisanyqualityproblems

concerningbookspublishedbyourpublishinghouse.

Telephone:(010)51873174

,

WiththerapidimprovementofChina′seconomicleveltherailtransitindustryisalsodeveloping

vigorously.High-speedpassengertransportandheavyfreighttransporthavebecomethenew

developmentdirectionof″railwaytransport.High-speedrailwayisahugeandcomplexsystem

,

projectwhichiscalledtechnologyofbigcountry″.Itintegratesnewandhightechnologiesin

,,

multipledisciplinesandfieldsanddemonstratescomprehensivenationalstrengtheconomicand

socialdevelopmentlevelandindependentinnovationability.

TheBeltandRoadInitiativehasaddednewimpetusandprovidedanewplatformforbalanced

andsustainableglobaldevelopment.TheBeltandRoadInitiativecoversbothdevelopingand

,

developedcountriescontributingtothebalancedandsustainabledevelopmentoftheworld.The

,

BeltandRoadInitiativefocusesoninfrastructureconstructionpromotesorderlyandfreeflowof

,

economicfactorsandpromotesmacro-policycoordinationbetweenChinaandrelevantcountries.

,

Asthemainarteryofeconomicoperationrailwaywillbecomeanimportanttooltofacilitatetrade

andpersonnelexchangeandrealizeeconomicintegrationincountriesandregionsrelatedtothe

BeltandRoadInitiative.

()

BeijingJiaotongUniversityBJTUmaintainsitsdistinctivecharacteristicsofrailtransit;Adhering

,

tothefundamentaltaskofcultivatingpeoplethroughmoraleducationBJTUhasmaderemarkable

,

achievementsineducationreformandconstructionandhascultivatedalargenumberoftalentsfor

thedevelopmentofthecountryandtheindustry.Textbookconstructionisanessentiallinkforthe

,

cultivationofstudentsandthedisseminationofknowledgeespeciallyinthecontextofmodern

technologyandknowledgechangingwitheachpassingdayandconstantlyupdating.Itisparticularly

urgenttocompiletextbooksthatcombinethecommonbasictheorywithnewtechnology.The″Vehicle

″,

EngineeringmajorofBJTUisoneofthenationalcharacteristicmajorsoneofthefirstExcellent

EngineerEducationandTrainingProgram″andComprehensiveReformPilotProgramofMajor″of

theMinistryofEducationofthePeople′sRepublicofChina.Ithasalwaysregardedtheteaching

materialconstructionasanimportantworktomaintainthecharacteristicsofrailtransitandleadthe

,

professionaldevelopment.Atthesametimethisseriesoftextbooksarecompiledbytheurgent

needsofrailtransitpractitionersathomeandabroad.

Ⅰ

″

ThisbookisoneoftheTheBeltandRoad″railtransitseriesplanningtextbooks.Thetypesof

,,

railvehiclesincludecityrailwaysgeneral-speedpassengercarsandfreightcarsandEMUs.

,

Althoughthetypesaredifferentthemanufacturingmethodsarebasicallythesame.Thisbookuses

theEMUasanexampletoexplainthemanufacturingmethodofrailvehicles.Itmainlyintroduces

themanufacturingprocessofrailwayEMUbogieandcarbody.Itisdividedinto5chapters.

,

Chapter1introducesthemachiningofEMUbogiefocusingonthemachiningoftypicalbogieparts

,

andthemainmachiningequipment;Chapter2introducestheassemblyofEMUbogiefocusingon

,

wheelsetassemblyaxleboxassemblyandtypicalbogieassembly;Chapter3introducesthe

,

punchingofcarbodypartsofEMUfocusingonvariouspunchingprocessandtheestablishmentof

punchingprocessspecification;Chapter4introducestheweldingprocessforcarbodyassemblyof

,,

EMUfocusingonthestrengthcalculationofweldedstructureandjointweldingdeformationofcar

,

bodystructureweldingofstainlesssteelandaluminumalloycarbody;Chapter5introducesthe

,,

manufacturingofEMUfocusingontheassemblyandweldingprocessofsidewallthegeneral

assemblyofcarbodyandthegeneralassemblyofEMU.

ManufacturingProcessofEMU,

ThebookisadaptedandtranslatedfromtheeditedbyZouHua

ofBeijingJiaotongUniversityandreviewedbySongYongzeng.

,

IntheprocessofcompilingthisbookwehavereceivedgreatsupportandhelpfromCRRC

,,,,

QingdaoSifangCo.Ltd.CRRCTangshanCo.Ltd.andothermainenginecompanies.We

herebyexpressourheartfeltthanks.

,

Duetothelimitedlevelandsourcesofinformationomissionsandinadequaciesareinevitablein

thisbook.Wesincerelyinvitethereaderstoputforwardcriticismandsuggestions.

Editor

May2021

Ⅱ

Chapter1MachiningofEMUBogie……………………

001

…………………

1.1EstablishmentofMachiningProcessSpecification001

…………………

1.2ClampDesignBasis030

……………………

1.3MachiningofTypicalBogieParts055

………

1.4MachiningEquipmentforTypicalBogieParts078

ReviewQuestions…………

081

Chapter2AssemblyofEMUBogie………

082

……

2.1ElementaryKnowledgeofMechanicalAssembly082

…………………

2.2WheelsetAssembly090

…………………

2.3AxleBoxAssembly103

…………

2.4AssemblyofTypicalBogie119

ReviewQuestions…………

128

Chapter3PunchingofCarBodyPartsofEMU………

129

……………

3.1Overview129

……………

3.2Stamping133

………………

3.3Bending159

………………

3.4Drawing168

………………………

3.5ColdExtrusion177

……

3.6EstablishmentofPunchingProcessSpecification182

ReviewQuestions…………

191

Chapter4WeldingProcessforCarBodyAssemblyofEMU…………

192

……………………

4.1WeldingMethodsandEquipment192

…………………

4.2StrengthCalculationofWeldedStructureandJoint215

…………

4.3Weldingdeformationofcarbodystructure227

Ⅰ

…………………

4.4WeldingofStainlessSteelCarBody240

………………

4.5WeldingofAluminumAlloyCarBody244

ReviewQuestions…………

267

Chapter5ManufacturingofEMU………

268

…………

5.1CompositionofCarBodyStructuresandMainParameters268

…………

5.2UnderframeAssemblyandWeldingProcess289

………

5.3AssemblyandWeldingProcessofSideWall294

………………

5.4RoofAssemblyandWeldingProcess301

………

5.5AssemblyandWeldingProcessofEndWall302

……

5.6AssemblyandWeldingProcessofDriver′sCab303

………

5.7GeneralAssemblyofCarBody306

…………

5.8GeneralAssemblyofEMU309

ReviewQuestions…………

330

References……………………

331

Ⅱ

1.1EstablishmentofMachiningProcessSpecification

1.1.1BasicKnowledge

1.Productionprocess

()

Productionprocessreferstothetransformationofrawmaterialsemi-finishedproductinto

finishedproduct.Theproductionprocessofmechanicalproductsusuallyincludesthefollowings

(),,

1Productionandtechnicalpreparationsuchasprocessdesigndesignandmanufacturingof

,,

specialprocessequipmentdevelopmentofproductionplanandpreparationofproductiondata.

(),,

2Blankmanufacturingsuchascastingforgingandpunching.

(),,

3Partmachiningsuchascuttingheattreatmentandsurfacetreatment.

(),,,,

4Productassemblysuchasgeneralassemblycomponentassemblycommissioningtestand

painting.

(),,,

5Productionservicessuchasthesupplytransportationandcustodyofrawmaterialspurchased

partsandtools.

,,

Generallytheproductionprocessofmechanicalproductsarecomplex.Nowadaysmanyproducts

,

arejointlymanufacturedbymultiplespecializedfactoriesinsteadofasinglefactory.Forexample

(,

anaircraftmanufacturingplantneedsproductsfrommanyotherfactoriessuchasengineelectrical

),

equipmentandinstrumentstomanufactureanaircraftthroughmutualcollaboration.Therefore

productionprocessmeanseitherthemanufacturingprocessofthewholemachineorthe

manufacturingprocessofacertaincomponentorpart.

2.Process

Processreferstothemethodandcoursetoturnvariousrawmaterialsandsemi-finishedproducts

intofinishedproducts.

Processtechnologyreferstothetechnicaloperatingexperienceaccumulatedgraduallybyhuman

,,

beingsduringworkwhichisthesumofscienceproductionpracticeandlaborskills.

1

00

,,,,

Processmanagementisfromthesystematicpointofviewtoplanorganizecoordinatecontrol

,

andmonitorvariousprocessactivitiesinproductmanufacturingsoastoachieveestablished

,,

objectivessuchassafetyhighqualityhighyieldandlowconsumption.

Processisabasicfactoroftheprimaryproductiveforceconstitutedbyscienceandtechnology.

,

Wherethereisproductionthereisprocess.Thereasonsareasfollows

()

1Thewholecourseofproductionissubjecttoprocessrequirements.Especiallyinmodern

,

massiveindustrialproductionthefundamentalrolesofprocessareparticularlyimportantandobvious.

()

2Processisthebasisfororganizingandcommandingproduction.Basedonthefundamental

,,,,

andlinkingrolesofprocessproductionfactorssuchashumanbeingsmachinesmaterials

,,

methodsloopsandmeasurementarecombinedorganicallysothatproductionactivitiescanbe

performedeffectively.

()

3Theadvancementofenterprises′processesdeterminesthemodernizationlevelofproduction.

,

Duringtheevaluationofprocessadvancementcomprehensivetechnicalandeconomicevaluations

,,

needtobemaderatherthansolelyconsideringtheprocessadvancementequipmentautomation

,

degreeetc.Theprocessadvancementandapplicabilityreflecttheoptimalconfigurationand

,

reasonableutilizationofenterprises′technicalresourceswheretheevaluationcriterioniswhether

theadvancementandapplicabilityfittheprocesscapabilityfortheenterprises′productionand

,

development.Thereforeprocessprogressisabasicelementandanimportantcontentofenterprises′

productionmodernization.It′shardtoimagineanenterpriseadoptingmodernmanagementbutstill

followingbackwardprocess.

3.Processcourse

,,

Processcoursemeansintheproductionprocesstochangetheshapedimensionrelative

,,,

positionpropertiesetc.ofaproductionobjectsoastoturnitintoafinishedproductorsemi-

,,

finishedproduct.Blankmanufacturingmachiningheattreatmentandassemblyaredifferentkinds

,,,,

ofprocesscourse.Iftheshapedimensionsurfacequalityetc.ofablankarechangeddirectly

,

throughmachiningtoturnitintoanacceptablepartitisknownasmachiningprocesscourse.

,

Similarlytheprocesscourseofassemblingmachinedpartsintoamachinetoprovideitwithrequired

assemblyaccuracyandpresettechnicalperformanceisknownasassemblyprocesscourse.

4.Processequipment

,,,,,

Varioustoolsusedinproductmanufacturingsuchascuttingtoolclampdiegaugeinspection

,,

toolauxiliarytoolfitter′stoolandstationtoolareknownasprocessequipment.

5.Processflow

,

Thesequencefromblankpreparationtopackingandwarehousingoffinishedproductscomponents

andpartsafterworkindifferentdepartmentsoftheenterpriseordifferentproceduresisknownas

processrouteorprocessflow.

6.Processdocument

Varioustechnicaldocumentsfordirectingworkers′operationandtobeusedinproductionand

2

00

processmanagementareknownasprocessdocuments.

7.Processdesign

,,

Theprocedureforpreparingvariousprocessdocumentsanddesigningprocessequipmentetc.

isknownasprocessdesign.

8.Processpreparation

Itisnecessarytomakethefollowingpreparationsbeforeputtingaproductintoproduction

;;

makingreviewandmachinabilityanalysisofproductdrawingsproposingprocessschemes

;,;

preparingvariousprocessdocumentsdesigningmanufacturingandadjustingtheprocessequipment

anddesigningreasonableproductionorganizationform.Suchworkiscollectivelyreferredtoas

processpreparation.

9.Processparameter

Thequantitiestobeselectedorcontrolledintheprocesstoachieveexpectedtechnicalindicators

areknownasprocessparameters.

10.Datum

,

Datumsrefertothepointlineandareausedtodeterminethegeometricrelationshipamongthe

,

geometricelementsontheproductionobjectwhichcanbeclassifiedintodesigndatumandprocess

datumbasedonfunctions.

Designdatumreferstothedatumonthedesigndrawing.

,

Processdatumreferstothedatumusedtodeterminethedimensionshapeandpositionofthe

,

machinedsurfaceinthemachiningprocess.Itcanbeclassifiedintoproceduredatumlocating

,

datummeasuringdatumandassemblydatumbasedondifferentpurposes.

,

Thedatumusedtodeterminethedimensionshapeandpositionofthemachinedsurfaceonthe

,

proceduredrawingisknownasproceduredatum.Inadditionthedimensionofthemachined

surfacemarkedoutisknownasproceduredimension.

,

Locatingdatumreferstothedatumforlocatinginmachiningwhichisusedtoobtainacertain

,

positionoftheworkpiecedimensionally.Moreoverthedatuminmeasurementisknownasmeasuring

datum.

Thedatumfordeterminingtherelativepositionofapartoracomponentintheproductinassembly

isknownasassemblydatum.

11.Workpiecelocating

,,

Aprocesssystemconsistsofmachinetoolclampcuttingtoolandworkpiece.Therelative

positionaccuracyofthemachinedsurfaceoftheworkpieceisguaranteedbythecorrectposition

,

relationshipintheprocesssystem.Thereforeitisrequiredtodeterminewhethertheworkpieceis

,,

intherightpositionintheprocesssystemi.e.workpiecelocating.Theessenceofworkpiece

,

locatingistomaketheworkpieceoccupyacorrectpositionintheprocesssystem.Inotherwords

theworkpiececanoccupythesamepositionafterrepeatedplacementintheclamp.Thestaticerror

3

00

oftheprocesssystemwillleadtothechangeinthepositionofthelocatingdatumofthemachined

surfaceoftheworkpieceandaffecttherelativepositionaccuracybetweenitanditsdesigndatum.

,,

Howeveraslongasthisvariableiswithinthepermissibleerrorrangeitcanbedeemedthatthe

,,

workpiecehasoccupiedacorrectpositionintheprocesssystemnamelytheworkpiecehasbeen

positionedcorrectly.

12.Processspecification

Contentsofmachiningprocesscoursespecifiedintabularformtoactasthetechnicalguidance

,

documentforproductionisknownasmachiningprocessspecificationwhichiscalledprocess

specificationforshort.

Processspecificationisnotonlythebasisfordirectingfieldproductionbutalsothemain

documentfororganizingproductionandmakingtechnicalpreparationsforproduction.Asforanew

,,,

factoryitisthebasisforproposingproductionareaplantlayoutstaffingandequipment

,

procurementetc.Beingtechnicallyadvancedandeconomicallyreasonableisaprerequisitewhen

theprocessspecificationisbeingprepared.

13.Computeraidedprocessplanning(CAPP)

()

1Concept

CAPPisamanufacturingmethodforassistingprocesspersonneltodesignpartsandturnthem

,

intofinishedproductsfromblanksaswellasatechnologyconvertingenterprises′productdesign

dataintoproductmanufacturingdatabasedoncomputertechnology.Itreferstotheprocessfrom

,

inputtingtheoriginaldatamachiningconditionsandmachiningrequirementsoftheparttobe

,,

machinedtothecomputerautomaticcodingandprogrammingbythecomputertooutputtingthe

optimizedprocessspecificationcardfinally.

()

2Purpose

CAPPistoestablishthepartmachiningprocesscoursebycomputerandmachinetheblankinto

thepartrequiredbytheengineeringdrawing.TheapplicationofCAPPwillimprovethequalityof

,

processdocumentsshortentheproductionpreparationcycleandprovideafeasibleroutefor

releasingmassiveprocesspersonnelfromtediousandrepetitivework.

()

3Contents

,,

CAPPsystemismainlyusedtosolvetwoproblemsi.e.thedeterminationofpartprocessroute

andthedesignofprocedure.Thecontentsmainlyinclude

,,

①Processdecision-makingalsoknownasprocessroutedevelopmentwhichincludesdetermining

themachiningmethodofeachcuttingsurfaceofthepartandidentifyingthereasonablemachining

,

sequence.Meanwhileitalsoneedstoselectthemachinetoolandrelevantprocessequipmentfor

,,,

eachproceduresuchasclampcuttingtoolandgauge.Inaddi