大直径厚壁管制造工艺与技术
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摘要
管道运输已经成为当前能源运输的主要方式。直缝埋弧焊钢管具有高强度高韧性的特点,新建的管线主要采用直缝埋弧焊管。本文以大直径厚壁直缝埋弧焊管的成形工艺为对象,对整个生产过程做了模拟分析。
分析了模压式预弯模,并利用MSC.MARC软件的回弹计算功能进行数值模拟。研究了模具形状、预弯卷角、预弯宽度等因素对最终成形半径的影响。以弯曲回弹逆解公式为基础,设计正交试验,分析了板料厚度对回弹的影响。研究了多道次渐进折弯制管技术的工艺特点及其优势:将钢管的成形过程分解为多个步长,每步只对钢板的一部分进行弯曲,这时所需的折弯成形力较小,降低了对设备能量的要求。
将3-D实体模型简化为2-D平面模型,选取凸模半径、凹模圆角半径、凹模开口量和凸模进入凹模深度等因素为对象进行优化。分析了以上因素对回弹的影响,通过选取合理工艺参数,实现了对回弹量的预测控制。
研究了O形圆管的焊接工艺,采取气体保护预焊及内外双层埋弧焊的多层焊接工艺。根据母材性能及管材规格,选取焊丝,焊剂、温度、焊接电流、焊接电压等参数值。
设计了管径在线测试系统,对钢管圆度进行检测和整形。利用激光传感器采集信号,通过计算机进行数据处理和直接显示,提高了管径的成形精度。研究了用多个扇形块对焊管进行机械扩径的方法,实现管材端口管一一管对接的要求。
本文的研究工作给大直径厚壁管的生产提供了从毛坯到成品的全面完整的成形技术,对实际生产有较大的指导意义。
Pipeline transportation has currently become the main form of energy transport. As the LSAW pipe has high strength and high toughness, some of the new-constructed pipelines were required to mainly use LSAW pipes. The entire production process was analyzed in this paper based on thick-walled large diameter LSAW pipe forming process.
Pre-bending mode after die pressing is analyzed and simulated using the spring back calculation block of MSC.MARC software. The influences of the mold shape, pre-curved corner, pre-curved width, etc, to the radius of the final forming were studied. Perpendicular experiment was designed based on Bending Spring back formula for inverse kinematics. The impact of thickness of sheet metal on the spring back was analyzed..
The technological feathers and advantages of multi-pass progressive bending pipe technology were studied. The pipe forming process was divided into several steps, and only part of the plate was bent during each step. The requirements to the equipment capacities were reduced due to the lower bending force.
3-D solid model was simplified to 2-D plane model. Factors such as the punch radius, die radius, die opening volume, the depth of punch into the die and so on were optimized. Predictive control of the amount of spring back was realized by choosing the reasonable parameters, through analysis of the impact of the above factors on the rebound.
The welding process of the O-shaped tube was researched through the pre-gas-shielded welding and submerged arc welding of internal and external layer with multi-layer welding process. The welding wire, solder, temperature, current, voltage and other parameters were selected according to parent metal properties and pipe specifications.
A set of pipe-line testing system was designed to test and reshape the roundness of pipe. The forming accuracy of diameter was improved through the data processing and direct display by computer, using a laser sensor to collect the signal.
The method using multiple fan-shaped die to expand the pipe was researched. The docking requirements of tube ports were satisfied after mechanical expanding.
A very comprehensive and complete technical guidance of the production of large diameter thick-walled tube from the blank to the finished product is provided in this research work. It also provides a larger referential significance to the actual production.
分析了模压式预弯模,并利用MSC.MARC软件的回弹计算功能进行数值模拟。研究了模具形状、预弯卷角、预弯宽度等因素对最终成形半径的影响。以弯曲回弹逆解公式为基础,设计正交试验,分析了板料厚度对回弹的影响。研究了多道次渐进折弯制管技术的工艺特点及其优势:将钢管的成形过程分解为多个步长,每步只对钢板的一部分进行弯曲,这时所需的折弯成形力较小,降低了对设备能量的要求。
将3-D实体模型简化为2-D平面模型,选取凸模半径、凹模圆角半径、凹模开口量和凸模进入凹模深度等因素为对象进行优化。分析了以上因素对回弹的影响,通过选取合理工艺参数,实现了对回弹量的预测控制。
研究了O形圆管的焊接工艺,采取气体保护预焊及内外双层埋弧焊的多层焊接工艺。根据母材性能及管材规格,选取焊丝,焊剂、温度、焊接电流、焊接电压等参数值。
设计了管径在线测试系统,对钢管圆度进行检测和整形。利用激光传感器采集信号,通过计算机进行数据处理和直接显示,提高了管径的成形精度。研究了用多个扇形块对焊管进行机械扩径的方法,实现管材端口管一一管对接的要求。
本文的研究工作给大直径厚壁管的生产提供了从毛坯到成品的全面完整的成形技术,对实际生产有较大的指导意义。
Pipeline transportation has currently become the main form of energy transport. As the LSAW pipe has high strength and high toughness, some of the new-constructed pipelines were required to mainly use LSAW pipes. The entire production process was analyzed in this paper based on thick-walled large diameter LSAW pipe forming process.
Pre-bending mode after die pressing is analyzed and simulated using the spring back calculation block of MSC.MARC software. The influences of the mold shape, pre-curved corner, pre-curved width, etc, to the radius of the final forming were studied. Perpendicular experiment was designed based on Bending Spring back formula for inverse kinematics. The impact of thickness of sheet metal on the spring back was analyzed..
The technological feathers and advantages of multi-pass progressive bending pipe technology were studied. The pipe forming process was divided into several steps, and only part of the plate was bent during each step. The requirements to the equipment capacities were reduced due to the lower bending force.
3-D solid model was simplified to 2-D plane model. Factors such as the punch radius, die radius, die opening volume, the depth of punch into the die and so on were optimized. Predictive control of the amount of spring back was realized by choosing the reasonable parameters, through analysis of the impact of the above factors on the rebound.
The welding process of the O-shaped tube was researched through the pre-gas-shielded welding and submerged arc welding of internal and external layer with multi-layer welding process. The welding wire, solder, temperature, current, voltage and other parameters were selected according to parent metal properties and pipe specifications.
A set of pipe-line testing system was designed to test and reshape the roundness of pipe. The forming accuracy of diameter was improved through the data processing and direct display by computer, using a laser sensor to collect the signal.
The method using multiple fan-shaped die to expand the pipe was researched. The docking requirements of tube ports were satisfied after mechanical expanding.
A very comprehensive and complete technical guidance of the production of large diameter thick-walled tube from the blank to the finished product is provided in this research work. It also provides a larger referential significance to the actual production.
引文
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[7]刘智慧.国内外原油管道技术发展概述.石油规划设计,2006,第3期.
[8]艾福奇.大直径厚壁弯管步进成形法.管道技术与设备,2002,第2期.
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[12]刘京雷,谢仕强,阮锋.弯曲回弹逆解公式及其在焊管预弯机组设计中的应用[J].锻压技术,2005,(2):36-38.
[13]艾福奇.大直径厚壁弯管步进成形法.管道技术与设备,2002,第2期.
[14]李延丰,孙奇.JCOE直缝埋弧焊钢管生产线的研发和应用.焊管,2004,第6期.
[15]甄立冬.数控板料折弯机工艺数据的确定[J].机械工艺师,2001,第2期.
[16]张国铭.挤压法生产大直径钢管的工艺和模具[J].模具技术,1990,第4期.
[17]刘庆才,陈淑荣.卷曲式JCOE钢管成形芯轴直径和开口量的计算方法[J].锻压技术,2007,32卷第2期.
[18]徐天发,陈作柄,胡潥,叶泽刚,易振民,常建娥.C形管筒折弯成形预测模型研究[J].中国机械工程,第15卷15期,2004.8.
[19]王震溅.气体保护焊工艺和设备[M].北京:国防工业出版社,1981.
[20]贾安东.焊接结构及生产设计[M].天津:天津大学出版社,1989.
[21]冯曰海,周方明,蒋成禹.双弧焊接工艺研究现状及发展[J].焊接,2002(1):5-9.
[22]张清辉.焊接材料研制理论与技术[M].冶金工业出版社:2005.
[23]杨广臣,薛忠明,张彦华.厚板多层多道焊角变形分析方法[J].焊接学报,2004(2):115-118.
[24]周桂芬.埋弧焊焊接参数对单面焊双面成形质量的影响[J].焊接质量控制与管理,2007(8):71-74.
[25]霍光瑞,朱丙坤,姚润钢.双丝埋弧焊工艺参数与焊道成形关系研究[J].热加工工艺,2007,第36卷,15期:27-36.
[26]王少青,任中京.激光三角位移法原理与结构参数优化研究.山东建材学院学报,1994.12.
[27]李兰君,喻寿益.单点激光三角法测距及其标定.研究与开发,2003.10.
[28]何道清,传感器与传感器技术.北京:科学出版社,2004.8.
[29]孟立凡,郑宾.传感器原理与技术.北京:国防出版社,2005.1.
[30]章小兵.激光三角形法板材在线测厚系统设计.测控技术与设备,2002.8.
[31]肖曙红.管线用直缝焊管机械扩径及其影响因素研究[J].石油机械,2007 35(3):1-4.
[32]张绍庆.直缝埋弧焊钢管的扩径[J].焊管,2000,23(5):42-43.
[33]郭宝锋,聂绍珉,金淼.管筒形件机械扩径的变形特征与规律[A].《制造业与未来中国》,2002CMES论文集,北京.机械工业出版社,2002:83.
[34]郭宝锋,金森,任运来等.模具扇形角对机械扩径成形过程的影响[J].塑性过程学报,2002.9 (1):59-61.
[35]吴鹏,郭宝锋,聂绍珉.大直径螺旋焊管管端扩径的数值模拟与实验研究[D].秦皇岛:燕山大学机械工程学院.
[36]郭宝锋,吴生富等.扩径模具形状参数对制品质量的影响[J].塑性过程学报,2004.11(1):46-50.
[37]郭宝锋,聂绍珉等.扩径模具直径对成形件品质的影响[J].塑性过程学报,2003.10(4):52-57.
[38]李聚群等.管材扩径时摩擦对变形状态的影响[J].锻压技术,2008.33(1):133-135.
[39]王利树,黎剑峰.焊接钢管机械扩径工艺和水压扩径工艺技术分析[J].焊管,2006.29(4) :60-63.
[2]杨太阳,廖卫团,温志红.输油气管线钢X52的开发.南方金属,2008,总第162期.
[3]彭在美.石油天然气输送用钢管的生产技术及发展方向.钢管,2004.33卷第2期.
[4]李良福.制造大直径厚壁管的工艺特点.金属成形工艺,2000,第11期.
[5]李鹤林,吉玲康.中国石油钢管的发展前景展望.河北科技大学学报,2006,第2期.
[6]罗先登.世界钢管生产发展的主要趋势.钢管,2006,第3期.
[7]刘智慧.国内外原油管道技术发展概述.石油规划设计,2006,第3期.
[8]艾福奇.大直径厚壁弯管步进成形法.管道技术与设备,2002,第2期.
[9]张正修.厚板冲压技术[J].模具技术,1997,(4):62-75.
[10]张士宏,王忠堂,周立新.板材零件局部体积成形技术研究[J].塑性工程学报,2008,15(2):31-36.
[11]金属塑性成形原理.北京:机械工业出版社,1982.
[12]刘京雷,谢仕强,阮锋.弯曲回弹逆解公式及其在焊管预弯机组设计中的应用[J].锻压技术,2005,(2):36-38.
[13]艾福奇.大直径厚壁弯管步进成形法.管道技术与设备,2002,第2期.
[14]李延丰,孙奇.JCOE直缝埋弧焊钢管生产线的研发和应用.焊管,2004,第6期.
[15]甄立冬.数控板料折弯机工艺数据的确定[J].机械工艺师,2001,第2期.
[16]张国铭.挤压法生产大直径钢管的工艺和模具[J].模具技术,1990,第4期.
[17]刘庆才,陈淑荣.卷曲式JCOE钢管成形芯轴直径和开口量的计算方法[J].锻压技术,2007,32卷第2期.
[18]徐天发,陈作柄,胡潥,叶泽刚,易振民,常建娥.C形管筒折弯成形预测模型研究[J].中国机械工程,第15卷15期,2004.8.
[19]王震溅.气体保护焊工艺和设备[M].北京:国防工业出版社,1981.
[20]贾安东.焊接结构及生产设计[M].天津:天津大学出版社,1989.
[21]冯曰海,周方明,蒋成禹.双弧焊接工艺研究现状及发展[J].焊接,2002(1):5-9.
[22]张清辉.焊接材料研制理论与技术[M].冶金工业出版社:2005.
[23]杨广臣,薛忠明,张彦华.厚板多层多道焊角变形分析方法[J].焊接学报,2004(2):115-118.
[24]周桂芬.埋弧焊焊接参数对单面焊双面成形质量的影响[J].焊接质量控制与管理,2007(8):71-74.
[25]霍光瑞,朱丙坤,姚润钢.双丝埋弧焊工艺参数与焊道成形关系研究[J].热加工工艺,2007,第36卷,15期:27-36.
[26]王少青,任中京.激光三角位移法原理与结构参数优化研究.山东建材学院学报,1994.12.
[27]李兰君,喻寿益.单点激光三角法测距及其标定.研究与开发,2003.10.
[28]何道清,传感器与传感器技术.北京:科学出版社,2004.8.
[29]孟立凡,郑宾.传感器原理与技术.北京:国防出版社,2005.1.
[30]章小兵.激光三角形法板材在线测厚系统设计.测控技术与设备,2002.8.
[31]肖曙红.管线用直缝焊管机械扩径及其影响因素研究[J].石油机械,2007 35(3):1-4.
[32]张绍庆.直缝埋弧焊钢管的扩径[J].焊管,2000,23(5):42-43.
[33]郭宝锋,聂绍珉,金淼.管筒形件机械扩径的变形特征与规律[A].《制造业与未来中国》,2002CMES论文集,北京.机械工业出版社,2002:83.
[34]郭宝锋,金森,任运来等.模具扇形角对机械扩径成形过程的影响[J].塑性过程学报,2002.9 (1):59-61.
[35]吴鹏,郭宝锋,聂绍珉.大直径螺旋焊管管端扩径的数值模拟与实验研究[D].秦皇岛:燕山大学机械工程学院.
[36]郭宝锋,吴生富等.扩径模具形状参数对制品质量的影响[J].塑性过程学报,2004.11(1):46-50.
[37]郭宝锋,聂绍珉等.扩径模具直径对成形件品质的影响[J].塑性过程学报,2003.10(4):52-57.
[38]李聚群等.管材扩径时摩擦对变形状态的影响[J].锻压技术,2008.33(1):133-135.
[39]王利树,黎剑峰.焊接钢管机械扩径工艺和水压扩径工艺技术分析[J].焊管,2006.29(4) :60-63.