Abstract: The car-body processing parts of aluminum alloy rail vehicle are normally large profiles. In case of any over-machining，the invalid repair work arrangement will cause great economic loss and directly influence the cycle time. In this article，different over-machining cases of large aluminum alloy profile are studied，through the functions analysis before and after the car-body parts rework and via finite element analysis （FEA），5 kinds of common repair process schemes and their application scopes are discussed.