CN116748409A - Integrated window frame structure, preparation mold, method and railway vehicle - Google Patents
Integrated window frame structure, preparation mold, method and railway vehicle Download PDFInfo
- Publication number
- CN116748409A CN116748409A CN202310678529.8A CN202310678529A CN116748409A CN 116748409 A CN116748409 A CN 116748409A CN 202310678529 A CN202310678529 A CN 202310678529A CN 116748409 A CN116748409 A CN 116748409A
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- window frame
- window
- area
- frame structure
- integrally formed
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- 238000000034 method Methods 0.000 title claims abstract description 32
- 238000002360 preparation method Methods 0.000 title claims abstract description 8
- 239000000463 material Substances 0.000 claims abstract description 45
- 238000000465 moulding Methods 0.000 claims abstract description 18
- 240000004282 Grewia occidentalis Species 0.000 claims abstract description 11
- 238000003825 pressing Methods 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 238000012545 processing Methods 0.000 claims description 12
- 238000000748 compression moulding Methods 0.000 claims description 8
- 238000002474 experimental method Methods 0.000 claims description 7
- 239000011324 bead Substances 0.000 claims description 3
- 230000035882 stress Effects 0.000 abstract description 18
- 230000032683 aging Effects 0.000 abstract description 4
- 239000003292 glue Substances 0.000 abstract description 4
- 230000008569 process Effects 0.000 description 20
- 238000003466 welding Methods 0.000 description 15
- 229910001220 stainless steel Inorganic materials 0.000 description 10
- 239000010935 stainless steel Substances 0.000 description 10
- 238000009434 installation Methods 0.000 description 6
- 238000012795 verification Methods 0.000 description 4
- 239000010410 layer Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000005357 flat glass Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000003698 laser cutting Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/74—Making other particular articles frames for openings, e.g. for windows, doors, handbags
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
- B21D37/12—Particular guiding equipment, e.g. pliers; Special arrangements for interconnection or cooperation of dies
Abstract
The invention provides an integrally formed window frame structure, a preparation mold, a method and a railway vehicle, wherein the window frame structure and a wallboard of the railway vehicle are integrally formed by stamping; the preparation mould comprises an upper mould component and a lower mould component, wherein a forming gap of a window frame is formed between the upper mould component and the lower mould component, wherein the gap corresponding to a main stress area of the window frame is equal to the material thickness of the window frame, and the gap corresponding to the area outside the main stress area of the window frame is gradually increased; the gaps corresponding to the multi-material areas which are positioned at the inner side of the main stress area of the window frame and formed during the four-corner molding of the window frame are smaller than the material thickness of the window frame. The problem of traditional wallboard and window frame connected area glue line thickness little, lead to the ageing inefficacy of top layer in the operation in-process rain leakage is avoided.
Description
Technical Field
The invention belongs to the field of window frame structures of railway vehicles, and particularly relates to an integrally formed window frame structure of a railway vehicle and a preparation method thereof.
Background
Currently, most of stainless steel car body wallboards and window frames of railway vehicles are in split form, and the stainless steel car body wallboards and the window frames are connected through spot welding or laser welding technology; a window frame with a structure surrounded by a beam and an upright post, wherein the window corner area needs to be reinforced; the other is an integral window frame, which is formed by welding multiple components by laser.
The patent with the patent application number of CN202010785006.X discloses a built-in window frame side wall module of a railway vehicle and the railway vehicle, wherein a rectangular window area is formed by encircling a B-shaped cross beam X2 and a cap-shaped upright column X2, and a connecting piece is adopted for reinforcing the connecting part of the two; the upright posts and the cross beam flanging are connected with the wallboard by lap spot welding or laser welding, the boards cannot be sealed, the thickness of the window bonding sealing layer is only the thickness of the wallboard (t=1.5 mm), and the problem of ageing, failure and rain leakage of the rubber layer easily occurs in the operation process; in addition, the window angle area of the window frame structure is not high in strength, and under the limiting working condition, the instability deformation of the window angle is easy to occur.
The patent with the patent application number of CN201821301237.3 discloses a window frame structure and a train carriage with the window frame structure, the window frame structure is an integral window frame structure, a beam B is formed by welding a beam X4 and a window angle X4 in a tailor-welding mode by adopting a laser welding process, an assembly gap is controlled in a grinding mode to meet the requirement of less than or equal to 0.2mm, the weld seam surplus height is required to be removed by grinding after welding, and the integral flatness is controlled by repairing; under the condition of the treatment measures, the problems of spot welding splashing, poor laser welding fusion, glue layer aging failure, rain leakage and the like still occur in the connection of the wallboard and the window frame; in addition, the window frame has complex manufacturing process and higher manufacturing cost.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide an integrally formed window frame structure of a railway vehicle and a preparation method thereof.
In order to achieve the above object, the present invention is realized by the following technical scheme:
in a first aspect, the present invention provides an integrally formed window frame structure, the window frame structure being integrally formed by stamping with a wall panel of a rail car vehicle; the window depth of the window frame is 15-25 mm, the arc angle R (radius) of the window is 100-150 mm, and the flanging length of the window is 20-30mm.
In a second aspect, an embodiment of the present invention provides an integrally formed window frame structure manufacturing mold, including an upper mold assembly and a lower mold assembly, where a forming gap of a window frame is formed between the upper mold assembly and the lower mold assembly, where a gap corresponding to a main stress area of the window frame is equal to a material thickness of the window frame, and a gap corresponding to an area located outside the main stress area of the window frame is gradually increased; the corresponding gap of the multi-material area formed during the four-corner molding of the window frame is smaller than the material thickness of the window frame.
As a further technical scheme, the gap between the outermost peripheries of the upper die assembly and the lower die assembly is equal to 1.25 times of the thickness of the window frame.
As a further technical scheme, the gap corresponding to the multi-material area is equal to 10% of the thickness of the window frame.
As a further technical scheme, the preparation mould also comprises a blank holder assembly which is matched with the outer ring of the upper mould assembly and used for pressing the window frame in the window frame forming process.
In a third aspect, the present invention also provides a method for manufacturing an integrally formed window frame structure, including the steps of:
step 1, processing a plate for forming a window frame;
step 2, designing a compression molding die, wherein the die comprises an upper die assembly and a lower die assembly, and a molding gap of a window frame is formed between the upper die assembly and the lower die assembly, wherein the gap corresponding to a main stress area of the window frame is equal to the thickness of a material of the window frame, and the gap corresponding to an area outside the main stress area of the window frame is gradually increased; gaps corresponding to the multi-material areas formed during the four-corner forming of the window frame are smaller than the material thickness of the window frame;
and 3, placing the plate in the step 1 into the die in the step 2, and pressing the window flanging shape by applying pressure to the upper die assembly through a press.
As a further technical scheme, before the implementation of the step 3, the rebound angle of the plane area of the window and the rebound angle of the round corner area of the window are obtained through experiments, rebound compensation processing is carried out during molding through experimental data, and the requirement of the size of a workpiece can be met after profile compensation processing.
As a further technical scheme, the approximate range of the rebound angle of the stainless steel plate is experimentally measured by using a flat plate material, and then the range of the rebound angle is further reduced by experimental verification according to the shape of a window.
As a further technical scheme, a main material pressing stress area during forming of a workpiece window is measured through a blank holder material pressing experiment.
In a fourth aspect, the present invention also provides a rail vehicle having a body on which the integrated sash structure described above is mounted.
The beneficial effects of the embodiment of the invention are as follows:
1. the invention discloses an integrated stamping forming structure of a wallboard and a window frame, which solves the problems of ageing, failure and rain leakage of a surface layer in the operation process caused by small thickness of a glue line of a connecting area of the traditional wallboard and the window frame; the window corner area is high in three-dimensional structural strength, does not need to be reinforced, and cannot be unstable and deformed; the flatness of the window area, particularly four corners, is less than or equal to 1.5mm, so that the accuracy requirement of window installation is met; the window frame is manufactured by adopting a stamping forming process instead of a welding process, so that the manufacturing efficiency, precision and product consistency of the window frame are greatly improved, and the manufacturing cost and period are reduced.
2. The invention provides an integrated forming window frame structure, which has the phenomena of stress concentration and distortion deformation in the forming process, so that the problems of window flatness, window perpendicularity exceeding and window four corner wrinkling occur to a workpiece; according to the method, stress generated in the process of forming the workpiece can be uniformly dispersed, and the problem of flatness of the formed window body is avoided; gaps corresponding to the multi-material areas which are positioned at the inner side of the main stress area of the window frame and formed during the four-corner forming of the window frame are smaller than the material thickness of the window frame; the wrinkling is eliminated, the molding manufacturability is improved, the product quality is improved, and meanwhile, the rigidity of the product is increased; and the rebound compensation processing is carried out through experimental data, and the size requirement of the workpiece can be met after the profile compensation processing.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention.
FIG. 1 is a schematic view of a prior art installation of a window frame and wall panel of a rail vehicle;
FIG. 2 is a schematic view of an integrally formed window frame of a rail vehicle;
FIG. 3 is a cross-sectional view A-A of FIG. 1;
FIG. 4 is a sectional view B-B of FIG. 1;
FIG. 5 is a schematic view of the installation of a window frame and wall panel of a rail vehicle of the present invention;
FIG. 6 is a schematic view of an upper mold assembly for forming an integrally formed window frame structure;
FIG. 7 is a schematic view of a lower mold assembly for forming an integrally formed window frame structure;
FIG. 8 is a schematic view of a bead assembly forming an integrally formed window frame structure;
FIG. 9 is a cross-sectional view of a mold for molding an integrally formed window frame structure;
FIG. 10 is a schematic view of a steel sheet after blanking;
FIG. 11 is a schematic illustration of the gap formed by the upper and lower mold plates of the present invention;
in the figure: the mutual spacing or dimensions are exaggerated for the purpose of showing the positions of the various parts, and the schematic illustrations are used for illustration only.
The upper die comprises an upper die base, an upper die insert, a guide plate 3, a lower die base, a lower die insert, a 7-blank holder base, an 8-blank holder insert, a guide plate 9, a guide plate 10, a wall plate 11, a window frame 12, a passenger room side window 13, a welding point 14 and a window frame 15.
Detailed Description
It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular forms also are intended to include the plural forms unless the present invention clearly dictates otherwise, and furthermore, it should be understood that when the terms "comprise" and/or "include" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof;
as described in the background art, the window frame and the wall panel structure of the railway vehicle in the prior art are shown in fig. 1, and are connected together by welding, so as to solve the technical problems as described above, the invention provides an integrally formed window frame structure of the railway vehicle.
In a typical implementation mode of the invention, as shown in fig. 2, 3 and 4, the integral forming window frame structure of the railway vehicle disclosed in the embodiment has the advantages that as shown in fig. 1, the wallboard and the window frame are of an integral structure, wherein the depth of a window is= (15-25) mm, the arc angle R of the window is= (100-150) mm, the flanging size L= (20-30) mm, and the integral forming window frame structure of the railway vehicle in the embodiment avoids the problems that the glue joint thickness of the connecting area of the traditional wallboard and the window frame is small, and the surface layer is aged, failed and leaked in the operation process; the window corner area is high in three-dimensional structural strength, does not need to be reinforced, and cannot be unstable and deformed; the flatness of the window area, particularly four corners, is less than or equal to 1.5mm, so that the accuracy requirement of window installation is met; the window frame is manufactured by adopting a stamping forming process instead of a welding process, so that the manufacturing efficiency, precision and product consistency of the window frame are greatly improved, and the manufacturing cost and period are reduced. Fig. 5 is a schematic view showing an installation state of an integrally formed window frame structure of a railway vehicle according to the present invention; the invention does not change the installation mode of the window frame, but improves the sealing performance of the window area.
Further, in view of the fact that the stainless steel car body wallboard material in the railway car industry mostly adopts EN1.4318+2g material with yield strength rp 0.2=350 Mpa, the cross beam and the upright post mostly adopt SUS 301L-HT material with yield strength rp 0.2=685 Mpa, and in the embodiment, EN1.4318+2g is adopted as the material of the integrally formed window frame from the aspects of car appearance effect, material strength, elongation index and the like.
The embodiment also discloses a mold for molding the integrally molded window frame structure, as shown in fig. 6, 7, 8 and 9, comprising an upper mold assembly, a blank holder assembly and a lower mold assembly;
wherein the upper die assembly comprises an upper die base 1 and an upper die insert 2, the upper die insert 2 is embedded in the upper die base 1, the upper die base 1 and the upper die insert 2 are connected through bolts to form the upper die assembly,
the lower die assembly comprises a lower die base 4, a lower die insert base 5 and a lower die insert 6, and the lower die base 4, the lower die insert base 5 and the lower die insert 6 are connected through bolts to form the lower die assembly;
the blank holder assembly comprises a blank holder base 7 and a blank holder insert 8; the blank holder base 7 and the blank holder insert 8 are connected through bolts to form a blank holder assembly,
the upper die assembly and the blank holder assembly are guided by the guide plate 3, the guide plate 9 and the upper die assembly are guided by the guide plate 10;
forming a forming gap of the window frame between the upper die assembly and the lower die assembly, wherein the gap corresponding to the main stress area of the window frame is equal to the material thickness of the window frame, and the gap corresponding to the area outside the main stress area of the window frame is gradually increased; the gaps corresponding to the multi-material areas which are positioned at the inner side of the main stress area of the window frame and formed during the four-corner molding of the window frame are smaller than the material thickness of the window frame.
The embodiment also provides a method for forming the integrally formed window frame structure, which comprises the following steps: the window frame has the problems and technical difficulties in the forming process: because the stainless steel car body window frame is a car body appearance piece and window glass is required to be installed, visual defects in appearance are not allowed, the problems of window flatness and window perpendicularity exceeding after product compression molding are required to be overcome, and the phenomenon of four corner wrinkling of the window is not allowed to occur after compression molding.
1. And (3) blanking:
a whole stainless steel plate is selected, the material of the stainless steel plate is EN1.4318+2G, and the thickness of the stainless steel plate material is 1.5mm. After discharging, processing the material into a unfolded shape without folding edges by a laser cutting machine, wherein the edge of the unfolded material needs to be provided with folding edge quantity, and the periphery needs to be provided with processing allowance;
2. and a molding simulation platform is adopted to analyze and evaluate the molding performance of the integrated window frame, guide part structures, mold designs and molding process designs, and four corners of the window are areas with the maximum material drawing and deformation.
3. Compression molding:
in the compression molding process, the mold is adopted for compression molding, and specifically, the compression molding machine comprises an upper mold assembly, a blank holder assembly and an upper mold assembly; the upper die assembly comprises an upper die base 1 and an upper die insert 2, the upper die insert 2 is embedded in the upper die base 1, the upper die base 1 and the upper die insert 2 are connected through bolts to form an upper die assembly, the upper die assembly comprises a lower die base 4, a lower die insert base 5 and a lower die insert 6, and the lower die base 4, the lower die insert base 5 and the lower die insert 6 are connected through bolts to form an upper die assembly; the blank holder assembly comprises a blank holder base 7 and a blank holder insert 8; the blank holder base 7 and the blank holder insert 8 are connected through bolts to form a blank holder assembly, the upper die assembly and the blank holder assembly are guided through the guide plate 3, and the blank holder assembly and the upper die assembly are guided through the guide plate 10;
4. the molding process comprises the following steps: and (3) placing the processed stainless steel plate into a pressing die, placing the pressing die into a positioning area of the blank holder, and simultaneously applying pressure to the upper die and the blank holder through a press machine to press the window flanging shape. The phenomena of stress concentration and distortion exist in the forming process of the unfolded plate obtained according to the part graph, so that the problems of window flatness, window perpendicularity out-of-tolerance and window four corner wrinkling appear in a workpiece, and in order to improve the forming quality and solve the problems in the forming process, the problems are solved by adopting the following means through process verification and forming analysis:
first, regarding the window flatness problem solving method: the main material pressing stress area during forming of the workpiece window is measured through a blank holder material pressing experiment, the upper and lower model surface gaps are processed according to the workpiece material thickness (t=1.5 mm), the molded surfaces outside the material pressing stress area are increased gradually according to the radial shape, the molded surfaces of the upper die insert 2 and the molded surfaces of the lower die insert 6, the molded surfaces of the outermost upper die insert 2 and the gaps of the lower die insert 6 are increased to 25% of the workpiece material thickness, stress is generated in the workpiece forming process can be evenly dispersed according to the method, and the problem of flatness of the formed window is avoided.
Secondly, regarding the window perpendicularity problem solving method: firstly, a rough range of rebound angles of the stainless steel plate is detected by using a flat plate material experiment, then, the rebound angle range is further narrowed by carrying out experiment verification according to the shape of the window, the rebound angle of a plane area of the window is 37% and the rebound angle of a round angle area of the window is 16% according to the experiment verification, rebound compensation processing is carried out through experimental data, and the requirement of the size of a workpiece can be met after profile compensation processing.
Finally, the solution to the problem of window four corner wrinkling is as follows: in the window frame forming process, an intrados surface is formed at the top, excessive materials cannot be digested, so that top surface wrinkling is serious and cannot be eliminated, gaps between the profile of the upper die insert 2 and the profile of the lower die insert 6 corresponding to the multi-material area are adjusted to be 10% of the thickness of the materials, the excessive materials are absorbed, wrinkling is eliminated, forming manufacturability is improved, product quality is improved, and meanwhile, product rigidity is improved.
The embodiment also provides a railway vehicle, which comprises the integrated window frame structure. The rail vehicle also has all the advantages described above, since the integrated sash structure as described above is provided in the rail vehicle. In some embodiments, the rail vehicle provided by the present invention may be any suitable type of vehicle, such as a general speed train, a motor car, a subway vehicle, a city rail vehicle, etc., and the present invention is not limited to a particular rail vehicle type or types.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. An integrated into one piece window frame structure, its characterized in that, window frame structure and the wallboard integrated into one piece stamping forming of railcar vehicle.
2. The integrally formed window frame structure of claim 1, wherein the window depth of the window frame is 15-25 mm, the window arc angle R is 100-150 mm, and the window flange length is 20-30mm.
3. The integrally formed window frame structure manufacturing mold according to any one of claims 1-2, comprising an upper mold assembly and a lower mold assembly, wherein a molding gap of a window frame is formed between the upper mold assembly and the lower mold assembly, wherein a gap corresponding to a main stress area of the window frame is equal to a material thickness of the window frame, and a gap corresponding to an area located outside the main stress area of the window frame is gradually increased; the corresponding gap of the multi-material area formed during the four-corner molding of the window frame is smaller than the material thickness of the window frame.
4. The integrally formed window frame structure preparation mold of claim 3, wherein the gap between the outermost peripheries of the upper mold member and the lower mold member is equal to 1.25 times the thickness of the window frame.
5. The mold for manufacturing an integrally formed window frame structure of claim 3, wherein said multi-material regions have a gap corresponding to 10% of the thickness of the window frame.
6. The mold for manufacturing the integrally formed window frame structure of claim 3, wherein the mold further comprises a bead ring assembly which is engaged with the outer ring of the upper mold assembly for pressing the window frame during the molding of the window frame.
7. A method of making an integrally formed window frame structure according to any one of claims 1-2, comprising the steps of:
step 1, processing a plate for forming a window frame;
step 2, designing a compression molding die, wherein the die comprises an upper die assembly and a lower die assembly, and a molding gap of a window frame is formed between the upper die assembly and the lower die assembly, wherein the gap corresponding to a main stress area of the window frame is equal to the thickness of a material of the window frame, and the gap corresponding to an area outside the main stress area of the window frame is gradually increased; the corresponding gap of the multi-material area formed during the four-corner molding of the window frame is smaller than the material thickness of the window frame.
And 3, placing the plate in the step 1 into the die in the step 2, and pressing the window flanging shape by applying pressure to the upper die assembly through a press.
8. The method for manufacturing an integrally formed window frame structure according to claim 7, wherein the rebound angle of the planar area of the window and the rebound angle of the rounded corner area of the window are obtained through experiments before the step 3 is implemented, and the rebound compensation processing is performed during the forming through experimental data, so that the size requirement of the workpiece can be met after the profile compensation processing.
9. The method of claim 7, wherein the main pressing force area of the workpiece window during molding is measured by a bead pressing test.
10. A rail vehicle having a body provided with an integrally formed window frame structure as claimed in any one of claims 1 to 2.
Priority Applications (1)
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CN202310678529.8A CN116748409A (en) | 2023-06-08 | 2023-06-08 | Integrated window frame structure, preparation mold, method and railway vehicle |
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CN202310678529.8A CN116748409A (en) | 2023-06-08 | 2023-06-08 | Integrated window frame structure, preparation mold, method and railway vehicle |
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CN116748409A true CN116748409A (en) | 2023-09-15 |
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CN202310678529.8A Pending CN116748409A (en) | 2023-06-08 | 2023-06-08 | Integrated window frame structure, preparation mold, method and railway vehicle |
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