Manufacturing Technology
Friction Stir Welding
Car body assembly by friction stir welding (FSW)
Fig.1 Fix pin tool
Fig.2 Self-reacting pin tool
Friction Stir Welding(FSW) is adopted in assembling of aluminium carbody.
The material is not melted during this joining process. The stronger
strength and the smaller distortion due to the low heat input from
friction take the advantages to the joint design over the conventional
arc welding.
We are using the fix pin tool (Fig.1) and self-reacting pin tool
(Fig.2). Simple, strong, and lightweight for the structure are served
with this welding method.
Fig.3 FSW facility
Fig.3 shows the manufacturing facility of FSW and macro photography of the joint.
Fig.4 Numerical simulation
Fig.4 shows numerical simulation of
self-reacting pin tool.
Fig.5 Lap joint sample
Fig.5 shows the sample of the lap joint between a sheet of aluminum alloy(JIS A5083) of 2.0 mm thick and aluminum alloy extrusions(JIS A6N01) of 3.0 mm thick.
Laser Welding
Car body assembly by laser welding
Laser welding is an next generation welding method that uses high density energy laser beam. Continuous laser welding gives stainless-steel carbody structure more strength and rigidity. Laser-MIG hybrid welding runs 6 times as fast as MIG welding. It also makes stiffer and lighter structure.
stainless steel carbody panel
hollow extrusion
Sheet Forming
Forming Press
Aerodynamics require that train cars have more and more complex shape. Sheet forming is introduced in order to meet such a trend.The machine stretches the sheet, and pushes it against the shape.
Photo by courtesy of ACB, France (https://www.acb-ps.com)
Numerical Simulation
Structual AnalysysFluid AnalysysAcoustic AnalysysTesting＆Phototyping
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