DIC Measurement of Welding-Induced Deformation on a Train Bogie Moving Bolster Subassembly

Abstract

The experimental evaluation of welding-induced distortion is a topic of great interest to both the scientific and industrial communities. With the aim of addressing a specific need in an industrial context, this paper investigates the capabilities of a stereo–Digital Image Correlation (stereo–DIC) system to measure the weld-induced distortion of the front-plate of a bogie train bolster subassembly. Currently, the deviation from planarity of this surface is measured at less than five points using a CMM in the post-weld cooled state. An additional machining process is then used to bring the surface within the tolerance required to join the welded assembly to the train body through a threaded flange. The paper shows that DIC can provide accurate full-field distortion and strain maps over the entire 588 mm × 308 mm surface of the front plate. The distinct strength of DIC over the currently used inspection technique is its ability to provide highly spatially dense data that are unaffected by rigid body motion. This can be advantageous in terms of saving time in the post-weld inspection and reducing errors in the finishing process. In addition, DIC capabilities revealed important information that was not available from the CMM, such as the full-surface map of the initial deviation of the plate from its nominal geometry and its asymmetric deformation after welding. Finally, the full-field nature of the experimental data obtained allows for seamless integration with FE thermo-mechanical simulations for numerical model validation, stress calculation, and optimization of geometry and technological processes.