Simulation analysis and optimization of welding deformation for load wheel flange plate of special vehicle body

Objective The load-bearing wheel flange is one of the main components connecting the load-bearing wheel and the vehicle body. It can reduce the impact generated when driving over uneven ground or at high speeds, thereby protecting the load-bearing wheel, axle, and vehicle body system. The aim of the paper is to reduce welding deformation of the load-bearing wheel flange. Methods This study uses 6060 aluminum alloy material to establish a finite element analysis (FEA) model of the load-bearing wheel flange, and analyzes the distribution of welding deformation based on the finite element method. To verify the accuracy of the finite element simulation, a three-dimensional laser scanner was used to conduct multiple experiments and multi-point measurements on the welded load-bearing wheel flange. Results The results show that the simulated welding deformation fits the experimental results well, with a relative error controlled within 10%. Therefore, the finite element simulation method in this paper can effectively reflect the actual welding deformation. This paper investigated the deformation of corner joints of the load-bearing wheel flange at different groove angles and then analyzed the deformation changes under different welding speeds and welding sequences, leading to the optimal welding scheme. Conclusion With a corner joint groove angle of 40°, welding speed of 10 mm/s, and welding sequence of Scheme 1, that is welding counterclockwise from both ends to the middle, the welding deformation is minimal.