高压弯头等径等厚管坯热推温压成形工艺研究
|
摘要
近年来随着工业的快速发展，高压弯管作为航空、航天、汽车、石油化工工业中气体、液体的输送管路和结构件，得到了广泛应用。通过不同弯曲成形工艺生产的管材，其内外壁的承载能力有较大的差异，成形后各处的壁厚不同，弯头质量参差不齐。要提高管材的使用安全性及使用寿命，则需先提高管道的韧性，抗冲击性，及耐磨性。为研究高效率、高质量的弯头成形工艺，本文以近年来企业研发的热点“热推制弯头成形工艺”为基础进行创新研究。进而建立高压弯头等径等厚管坯热推温压成形工艺研究模型。
新工艺主要由中频感应热推椭圆形弯头预制坯和温压整形终成形两部分组成。本文借助有限元模拟软件Deform对热推制成形过程、温压成形过程进行数值模拟。
首先以预制坯椭圆弯头温压缩颈量和弯头截面椭圆度为影响因素分析温压成形弯头质量，得出最优的预制坯弯头尺寸，进而返求热推的牛角形芯棒尺寸并加以优化。
然后对热推弯成形进行正交实验，以热推弯生产的椭圆弯头的壁厚均匀性、弯头截面椭圆度、弯头截面周长和外弧弯曲半径四个评价指标分析推制速度、摩擦系数及热推制中频感应加热的温度三个因素对成形影响的主次顺序，以及总结这三个因素对其成形质量的影响规律，并最终确定出了最佳工艺参数组合。
最后通过正交试验得到的热推的最佳工艺参数结合温压成形工艺参数建立完整的高压弯头等径等厚热推温压工艺有限元模型，并通过测量成形后弯头的壁厚、弯曲半径等一系列尺寸参数，验证了在此工艺下生产的弯头的质量是合格的，从而进一步确定了工艺的可行性，为以后的生产实践提供了依据。
Presently, with the rapid development of industry，as the pipeline and configurableparts of the transportation of gas and liquid，the elbow has been widely used in theaviation, spaceflight, automobile, petroleum and chemical industry. Through differentbending forming process for the production of pipes, the inner wall and the outer wall ofthe bearing capacity have bigger difference, after forming the thickness of different quality.Elbow quality uneven. In consideration of use safety，service life，toughness propertiesand impact resistence and abrasion resistance of pipeline.As the main connector of thepressure pipeline , pipe has been widely used.For the high efficiency and quality elbowforming process of study,the paper give creative research on developmental focuses ofenterprises in rencent years. Furthermore high pressure elbow equal-diameter formingprocess model is proposed.
The new process by medium frequency induction heated pushing elliptic elbowpreform and final forming temperature and pressure shaping is composed of two parts.
First, the process of the heat pushing and warmly compaction is simulated by thefinite element software called Deform. Through simulation of warmly compaction，tocalculate the size of ox-core.
Then, making orthogonal test to the heat pushing. Through analyzing thicknessuniformity , ellipticity, expanding diameter ratio and bending radius of external arc, thenobtaining the important order of the effect of three factors to index and the law of effect ofthree factors to formability. The three factors are pushing velocity, friction coefficient,friction style and temperature. Ultimately determine the best combination of parameters.
Through the best combination of parameters and parameters of warmly compaction,the model process of the heat pushing and warmly compaction. Through measuring wallthickness and bending radius of the elbow, verifing quality of the elbow by theprocess.The process was demonstrated in the industrial experiments. The aim is to provideenough theories to instruct practice.
新工艺主要由中频感应热推椭圆形弯头预制坯和温压整形终成形两部分组成。本文借助有限元模拟软件Deform对热推制成形过程、温压成形过程进行数值模拟。
首先以预制坯椭圆弯头温压缩颈量和弯头截面椭圆度为影响因素分析温压成形弯头质量，得出最优的预制坯弯头尺寸，进而返求热推的牛角形芯棒尺寸并加以优化。
然后对热推弯成形进行正交实验，以热推弯生产的椭圆弯头的壁厚均匀性、弯头截面椭圆度、弯头截面周长和外弧弯曲半径四个评价指标分析推制速度、摩擦系数及热推制中频感应加热的温度三个因素对成形影响的主次顺序，以及总结这三个因素对其成形质量的影响规律，并最终确定出了最佳工艺参数组合。
最后通过正交试验得到的热推的最佳工艺参数结合温压成形工艺参数建立完整的高压弯头等径等厚热推温压工艺有限元模型，并通过测量成形后弯头的壁厚、弯曲半径等一系列尺寸参数，验证了在此工艺下生产的弯头的质量是合格的，从而进一步确定了工艺的可行性，为以后的生产实践提供了依据。
Presently, with the rapid development of industry，as the pipeline and configurableparts of the transportation of gas and liquid，the elbow has been widely used in theaviation, spaceflight, automobile, petroleum and chemical industry. Through differentbending forming process for the production of pipes, the inner wall and the outer wall ofthe bearing capacity have bigger difference, after forming the thickness of different quality.Elbow quality uneven. In consideration of use safety，service life，toughness propertiesand impact resistence and abrasion resistance of pipeline.As the main connector of thepressure pipeline , pipe has been widely used.For the high efficiency and quality elbowforming process of study,the paper give creative research on developmental focuses ofenterprises in rencent years. Furthermore high pressure elbow equal-diameter formingprocess model is proposed.
The new process by medium frequency induction heated pushing elliptic elbowpreform and final forming temperature and pressure shaping is composed of two parts.
First, the process of the heat pushing and warmly compaction is simulated by thefinite element software called Deform. Through simulation of warmly compaction，tocalculate the size of ox-core.
Then, making orthogonal test to the heat pushing. Through analyzing thicknessuniformity , ellipticity, expanding diameter ratio and bending radius of external arc, thenobtaining the important order of the effect of three factors to index and the law of effect ofthree factors to formability. The three factors are pushing velocity, friction coefficient,friction style and temperature. Ultimately determine the best combination of parameters.
Through the best combination of parameters and parameters of warmly compaction,the model process of the heat pushing and warmly compaction. Through measuring wallthickness and bending radius of the elbow, verifing quality of the elbow by theprocess.The process was demonstrated in the industrial experiments. The aim is to provideenough theories to instruct practice.
引文
[1]苑世剑,朗利辉.内高压成形技术研究与应用进展[J].哈尔滨工业大学学报, 2000, 32(5):60-63.
[2]王同海.管材塑性加工技术[M].北京机械工业出版社, 1997, 12: 1-5.
[3]张文生,孙娈芬,陈建忠.热推弯头制造工艺的改进[J].管道技术与设备, 2007, (05):28-29.
[4] E. D. X, He. H H,Liu X Y,et al.Experimental study and finiteelement analysis ofspring-backdeformation in tube bending[J]. International Journal of Mineral, Metallurgy andMaterials, 2009, (2): 177-183.
[7]张君斗,何养民,杨合.加热弯管工艺研究[J].重型机械. 2002(1): 45-47.
[8]邵靖利.推制工艺对推制弯头几何形状的影响[J].机械工人(热加工), 2007, (06): 78-80.
[9]宋树康.热推制弯头壁厚不减薄理论[J].大型铸锻件, 2010, (06): 29-31.
[10]刘学,白绍桐,张东黎,等.超超临界机组再热蒸汽管道热推弯头强度分析[J].华电技术,2008, (02): 22-25.
[11]张骁勇,高惠临. X70管线钢感应加热弯管工艺参数的热模拟实验[J].热加工工艺, 2005,34(9): 34-38.
[12]鹿晓阳,韩善灵,杨乐宇,等.等强度弯管成形工艺及工艺参数CAD系统[J].锻压机械,2001(4): 16-17.
[13]王华林. RSφ377碳钢弯管的中频推制[J].广东造船, 2008/02: 60-62.
[14]李恒,杨合,詹梅,等.大口径薄壁小弯曲半径数控弯管有限元建模和实验[J].锻压技术,2006, (05): 136-139.
[15]鹿晓阳,徐秉业,岑章志,等.牛角芯棒热推弯管成形过程力学原理及分析求解方法[J].塑性工程学报, 1999(3): 31-36.
[16]杨合,孙志超,林艳.面向21世纪的先进塑性加工技术与管成形研究发展[J].塑性工程学报, 2001, 8(2): 86-88.
[17]曹雷.大直径中频感应加热弯管机的研究[J].焊管, 2010, (10): 52-56.
[18]顾煜炯,芮晓明,张丽文,等.感应加热小半径弯管技术的研究[J].电力建设, 1994(3): 5-7.
[19] A1·Qureshi H A.Elastic—plastic analysis of tube bending[J]. International Journal of MachineTools&Manufacture, 1999.3 9: 87-104.
[20]杜伟,王长安,程敦华.川气东送管道工程用Φ1016mm×26.2mm感应加热弯管的性能分析[J].钢管, 2010(5): 51-54.
[21]鹿晓阳,徐秉业,路立平,等.模糊数学在中频热推弯管工艺参数优化设计中的应用[J].塑性工程学报, 1994(4): 21-28.
[22]李建湘.中频电源在天津大无缝钢管厂的应用[J].冶金自动化, 2006, (06): 45-47.
[23]刘进军,郭红霞.弯头外观与芯轴形状[J].石油化工设备, 2004, (33): 57-58.
[24]张尧武,曾卫东,周义刚,等.基于虚拟正交试验的热推弯管工艺参数优化设计[J].焊管,2009, (06): 91-95.
[25]王增辉,彭立山,郭宗堂,等.国内外1.5D弯头壁厚设计标准对比[J]. 2011, (08): 56-58.
[26]赵彬,杨英丽,赵恒章,等.高强钛合金环形管热推弯曲工艺研究[J].材料工程, 2009:167-171.
[27]张小昂,鄂大辛,何花卉.弯管壁厚变形试验及有限元模拟分析[J].现代制造工程, 2007,(11): 56-58.
[28] Kinsey Brad, Viswanathan Vikram, and Cao Jian. Forming of Aluminum Tailor-weldedBlanks[J]. SAE 2001 World Congress Detroit, Michigan, 2001, 4:5-8.
[29] Heo Youngmoo, Choi Youho, Heon Young Kim, et al. Characteristics of Weld Line Movementsfor the Deep Drawing With Drawbeads of Tailor-Welded Blanks[J]. Journal of MaterialsProcessing Technology, 2001, 4: 111-120.
[30] Heo Young Moo, Wang Sung Ho, Kim Heon Young et al1. The Effect of the DrawbeadDimensions on the Weld-line Movements in the Deep Drawing of Tailor-Welded Blanks[J].Journal of Materials Processing Technology, 2001, 5: 113-119.
[31] Zinmiak Z, et a1. Finite Element Analysis of a Tailored Blanks Stamping Process[J]. Journal ofMaterials Processing Technology, 2000, 106: 254-260.
[32] X G Qiu,W L Chen.The study on numerical simulation of the laser tailor-welded blanksstamping[J]. Journal of Materials Processing Technology,2007,178-188:128-131.
[33] Shi Y L, et a1. Impact Modeling of the Weld Line of Tailor-Welded[J]. Blank.Materials &Design, 2008, 29: 232-238.
[34] Sung H C.Young M H.Dae G S. Springback Characteristics of the Tailor-welded Strips inU-draw Bending[J]. NUMISHEET’2002 Korea, 2002: 183-187.
[35] Moslemi Naeini, G. H Liaghat, etc. Analysis of deformation behavior of the large diameter pipeby U-O bending process[J]. Journal of Materials Processing Technology, 2006, 177(1-3):179-182.
[36]鹿晓阳,徐秉业,岑章志,等.牛角芯棒热推弯管成形过程力学原理及分析求解方法[J].塑性工程学报, 1999(3): 31-36.
[37]李林涛,曾卫东,殷京瓯,等.中频感应加热纯钛弯管成形过程中的有限元模拟[J].锻压技术,2006(6): 131-134.
[38]张小昂,鄂大辛,何花卉.弯管壁厚变形试验及有限元模拟分析[J].现代制造工程, 2007,(11): 56-58.
[39]何花卉,鄂大辛,李延民,等.管材弯曲成形中横截面畸变的试验及有限元分析[J].现代制造工程, 2006(11): 40-42.
[40]詹艳然.金属体积成形过程中的温度场的分析[J].塑性工程学报, 2001, 8(4): 3-16.
[41] T.S.Kawk, Y.J.Kim, M.K.Seo, W.B.Bae.The effect of V-ringindenter on the sheared surface inthe fineblanking process ofpawl[J]. Journal of Materials processing Technology143-144(2003):656-661.
[42]鹿晓力.中频热推弯管加热温度的测量方法[J].郑州轻工业学院学报, 12(3): 57-60.
[43]苗天德,等.用牛角芯棒推制弯管的塑性分析[J].力学学报, 1979(3): 230-238.
[44] Hu Z, Li J Q, Computer simulation of pipe bending processes with small bending radius usinglocal induction heating[J]. Journal of Materials Processing Technology, 1999(91): 75-79.
[45] Zhang Sen, Yao Zheng.The relation of CMM and sofeware lifecycle modle[J]. ArtificialIntelligence, 2007: 864-869.
[46] M.Abbe, K.Takamasu, S.Ozono.Reliability on calibration of CMM[J]. The Journal of ChemicalPhysics, 2002, 117(23): 827-836.
[2]王同海.管材塑性加工技术[M].北京机械工业出版社, 1997, 12: 1-5.
[3]张文生,孙娈芬,陈建忠.热推弯头制造工艺的改进[J].管道技术与设备, 2007, (05):28-29.
[4] E. D. X, He. H H,Liu X Y,et al.Experimental study and finiteelement analysis ofspring-backdeformation in tube bending[J]. International Journal of Mineral, Metallurgy andMaterials, 2009, (2): 177-183.
[7]张君斗,何养民,杨合.加热弯管工艺研究[J].重型机械. 2002(1): 45-47.
[8]邵靖利.推制工艺对推制弯头几何形状的影响[J].机械工人(热加工), 2007, (06): 78-80.
[9]宋树康.热推制弯头壁厚不减薄理论[J].大型铸锻件, 2010, (06): 29-31.
[10]刘学,白绍桐,张东黎,等.超超临界机组再热蒸汽管道热推弯头强度分析[J].华电技术,2008, (02): 22-25.
[11]张骁勇,高惠临. X70管线钢感应加热弯管工艺参数的热模拟实验[J].热加工工艺, 2005,34(9): 34-38.
[12]鹿晓阳,韩善灵,杨乐宇,等.等强度弯管成形工艺及工艺参数CAD系统[J].锻压机械,2001(4): 16-17.
[13]王华林. RSφ377碳钢弯管的中频推制[J].广东造船, 2008/02: 60-62.
[14]李恒,杨合,詹梅,等.大口径薄壁小弯曲半径数控弯管有限元建模和实验[J].锻压技术,2006, (05): 136-139.
[15]鹿晓阳,徐秉业,岑章志,等.牛角芯棒热推弯管成形过程力学原理及分析求解方法[J].塑性工程学报, 1999(3): 31-36.
[16]杨合,孙志超,林艳.面向21世纪的先进塑性加工技术与管成形研究发展[J].塑性工程学报, 2001, 8(2): 86-88.
[17]曹雷.大直径中频感应加热弯管机的研究[J].焊管, 2010, (10): 52-56.
[18]顾煜炯,芮晓明,张丽文,等.感应加热小半径弯管技术的研究[J].电力建设, 1994(3): 5-7.
[19] A1·Qureshi H A.Elastic—plastic analysis of tube bending[J]. International Journal of MachineTools&Manufacture, 1999.3 9: 87-104.
[20]杜伟,王长安,程敦华.川气东送管道工程用Φ1016mm×26.2mm感应加热弯管的性能分析[J].钢管, 2010(5): 51-54.
[21]鹿晓阳,徐秉业,路立平,等.模糊数学在中频热推弯管工艺参数优化设计中的应用[J].塑性工程学报, 1994(4): 21-28.
[22]李建湘.中频电源在天津大无缝钢管厂的应用[J].冶金自动化, 2006, (06): 45-47.
[23]刘进军,郭红霞.弯头外观与芯轴形状[J].石油化工设备, 2004, (33): 57-58.
[24]张尧武,曾卫东,周义刚,等.基于虚拟正交试验的热推弯管工艺参数优化设计[J].焊管,2009, (06): 91-95.
[25]王增辉,彭立山,郭宗堂,等.国内外1.5D弯头壁厚设计标准对比[J]. 2011, (08): 56-58.
[26]赵彬,杨英丽,赵恒章,等.高强钛合金环形管热推弯曲工艺研究[J].材料工程, 2009:167-171.
[27]张小昂,鄂大辛,何花卉.弯管壁厚变形试验及有限元模拟分析[J].现代制造工程, 2007,(11): 56-58.
[28] Kinsey Brad, Viswanathan Vikram, and Cao Jian. Forming of Aluminum Tailor-weldedBlanks[J]. SAE 2001 World Congress Detroit, Michigan, 2001, 4:5-8.
[29] Heo Youngmoo, Choi Youho, Heon Young Kim, et al. Characteristics of Weld Line Movementsfor the Deep Drawing With Drawbeads of Tailor-Welded Blanks[J]. Journal of MaterialsProcessing Technology, 2001, 4: 111-120.
[30] Heo Young Moo, Wang Sung Ho, Kim Heon Young et al1. The Effect of the DrawbeadDimensions on the Weld-line Movements in the Deep Drawing of Tailor-Welded Blanks[J].Journal of Materials Processing Technology, 2001, 5: 113-119.
[31] Zinmiak Z, et a1. Finite Element Analysis of a Tailored Blanks Stamping Process[J]. Journal ofMaterials Processing Technology, 2000, 106: 254-260.
[32] X G Qiu,W L Chen.The study on numerical simulation of the laser tailor-welded blanksstamping[J]. Journal of Materials Processing Technology,2007,178-188:128-131.
[33] Shi Y L, et a1. Impact Modeling of the Weld Line of Tailor-Welded[J]. Blank.Materials &Design, 2008, 29: 232-238.
[34] Sung H C.Young M H.Dae G S. Springback Characteristics of the Tailor-welded Strips inU-draw Bending[J]. NUMISHEET’2002 Korea, 2002: 183-187.
[35] Moslemi Naeini, G. H Liaghat, etc. Analysis of deformation behavior of the large diameter pipeby U-O bending process[J]. Journal of Materials Processing Technology, 2006, 177(1-3):179-182.
[36]鹿晓阳,徐秉业,岑章志,等.牛角芯棒热推弯管成形过程力学原理及分析求解方法[J].塑性工程学报, 1999(3): 31-36.
[37]李林涛,曾卫东,殷京瓯,等.中频感应加热纯钛弯管成形过程中的有限元模拟[J].锻压技术,2006(6): 131-134.
[38]张小昂,鄂大辛,何花卉.弯管壁厚变形试验及有限元模拟分析[J].现代制造工程, 2007,(11): 56-58.
[39]何花卉,鄂大辛,李延民,等.管材弯曲成形中横截面畸变的试验及有限元分析[J].现代制造工程, 2006(11): 40-42.
[40]詹艳然.金属体积成形过程中的温度场的分析[J].塑性工程学报, 2001, 8(4): 3-16.
[41] T.S.Kawk, Y.J.Kim, M.K.Seo, W.B.Bae.The effect of V-ringindenter on the sheared surface inthe fineblanking process ofpawl[J]. Journal of Materials processing Technology143-144(2003):656-661.
[42]鹿晓力.中频热推弯管加热温度的测量方法[J].郑州轻工业学院学报, 12(3): 57-60.
[43]苗天德,等.用牛角芯棒推制弯管的塑性分析[J].力学学报, 1979(3): 230-238.
[44] Hu Z, Li J Q, Computer simulation of pipe bending processes with small bending radius usinglocal induction heating[J]. Journal of Materials Processing Technology, 1999(91): 75-79.
[45] Zhang Sen, Yao Zheng.The relation of CMM and sofeware lifecycle modle[J]. ArtificialIntelligence, 2007: 864-869.
[46] M.Abbe, K.Takamasu, S.Ozono.Reliability on calibration of CMM[J]. The Journal of ChemicalPhysics, 2002, 117(23): 827-836.