焊接是列车车体装配过程中应用最为广泛的连接方式，焊接变形会对动车组装配尺寸精度产生较大的影响.针对动车组侧墙窗口模块焊接装配尺寸控制问题，利用热弹塑性有限元法提取3种典型焊接接头的固有应变，并基于固有应变法得到窗口模块的焊后变形量；结合三维尺寸装配偏差分析，最终给出计及焊接收缩量变化的侧墙窗口模块的偏差结果.将模拟结果与实测数据进行对比分析，结果表明：考虑焊接变形因素的装配偏差模拟结果与实际测量值较为吻合，故该方法可对动车组侧墙窗口模块的焊接装配偏差进行有效且准确的预测.
Welding is the most widely used connection mode in the assembly process of the electric multiple unit (EMU) while the deformation induced by welding will have a great influence on the assembly precision. The influence of welding deformation on the assembly precision of the sidewall window module is discussed in this paper. Firstly, the inherent strain of three typical welded joints in the sidewall window module of the EMU is extracted by the thermal elastic-plastic finite element method. Then, the deformation of the sidewall window module is obtained by the finite element simulation based on the inherent strain method. The obtained deformation is considered as a mean shift to amend the 3D assembly variation simulation results of the window module. Finally, the amended simulation results are compared with the measured data. The simulation results of assembly variation considering welding deformation have a good agreement with the actual measured data which indicates that the proposed method is more accurate and feasible for predicting the assembly variation of the sidewall window module of the EMU.
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