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<p>The precise prediction of welding deformation in vehicle body structures is essential for the timely implementation of corrective measures and the enhancement of production efficiency. Traditional prediction methods often struggle to balance accuracy with computational efficiency when applied to large, complex structures. This study investigates the lap-joint structure of a train roof by developing and comparing three numerical models: the instantaneous moving heat source model, the thermal cycling curve model, and the inherent strain model. Their accuracy and efficiency are validated through welding experiments. An improved inherent strain method is subsequently proposed, enhancing computational efficiency by approximately 75% for large roof assembly structures while maintaining prediction accuracy. Using this method, the effects of welding sequence and external constraints are systematically analyzed. The results identify “symmetrical welding from the center toward both ends” as the optimal sequence and demonstrate that applying external constraints at critical locations can reduce the maximum welding deformation from approximately 4 mm to less than 1 mm, an 87% reduction.</p>

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Prediction Method of Welding Deformation and its Application in Rail Train Roof

  • 期刊论文

  • 发表日期：

    2026年3月2日

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  • Xin Li,
  • Junxing Hu,
  • Wanguo Li,
  • Kaixuan Sang,
  • Junyuan Wang

摘要

The precise prediction of welding deformation in vehicle body structures is essential for the timely implementation of corrective measures and the enhancement of production efficiency. Traditional prediction methods often struggle to balance accuracy with computational efficiency when applied to large, complex structures. This study investigates the lap-joint structure of a train roof by developing and comparing three numerical models: the instantaneous moving heat source model, the thermal cycling curve model, and the inherent strain model. Their accuracy and efficiency are validated through welding experiments. An improved inherent strain method is subsequently proposed, enhancing computational efficiency by approximately 75% for large roof assembly structures while maintaining prediction accuracy. Using this method, the effects of welding sequence and external constraints are systematically analyzed. The results identify “symmetrical welding from the center toward both ends” as the optimal sequence and demonstrate that applying external constraints at critical locations can reduce the maximum welding deformation from approximately 4 mm to less than 1 mm, an 87% reduction.