ERW中口径直缝焊管排辊成型工艺优化的研究
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摘要
ERW中口径直缝焊管是一种高附加值的带钢二次加工产品,以其尺寸精度高,表面质量好以及生产成本低的优点被广泛应用于油气输送、建筑结构等领域,有着广阔的市场前景。近年来,市场对ERW焊管的表面质量以及二次加工性能要求越来越高,主要表现在耐腐蚀和超低温冲击韧性。为了顺应市场,ERW工艺装备技术也在同步发展,最有代表性的是德国MEER的URD技术和日本中田的FFX成型技术。在制管方面,辊弯成型技术逐步向柔性化方向发展,其特点是轧辊的共用性强,换辊和辊位调整的工作量小,效率高,成本低。成型工艺对制管过程至关重要,直接影响到其后的焊接,这要求成型孔型必须精确且柔性过渡,否则鼓包、错边和褶皱等缺陷将不可避免,如何经济有效地得到成型工艺参数是论文研究的关键。
本文着重研究宝钢MEER成型机组,从排辊成型缺陷机理解析的角度出发,借助数字化成型仿真模拟平台,深挖典型缺陷的诱因,对排辊成型工艺的调整优化具有指导意义,同时也为宝钢ERW成型工艺的自主开发指明方向。
ERW(Electrical Resistance Welded) Mid-size pipe is a kind of high value-addedproduct which is secondary processed with strip. With its high precision size, goodsurface and the advantages of low production cost, ERW pipe is widely used in oil andgas transportation, building structure and other fields, having a broad market prospect.In recent years, the market for ERW welded pipe's surface quality and secondaryprocessing performance requirements is being more and more high, mainly displays incorrosion resistance and impact peformance in ultra-low temperature. In order to meetthe market, ERW equipment technology is also in the synchronous development, themost representative of which are the German MEER URD technology and the JapanNAKATA FFX Forming technology. On the manufacturing, roll forming technologygradually go to a flexible direction, its characteristic is roll Shared, little adjustment ofroll change, high efficiency, and low cost. Forming technology is extremely importantto the process, and directly affects the welding. Precise caliber and flexible formingare required to avoid forming defects like strip bump, offset and drape. The key ofstudy is to get forming parameters economically and effectively.
This thesis focused on the study of ERW mill of Baosteel from the point of defectmechanism, with the help of the simulation platform, finding root causes of defects,the way of which not only guide the optimization of forming process, but also directthe forming technology of independent development in Baosteel.
本文着重研究宝钢MEER成型机组,从排辊成型缺陷机理解析的角度出发,借助数字化成型仿真模拟平台,深挖典型缺陷的诱因,对排辊成型工艺的调整优化具有指导意义,同时也为宝钢ERW成型工艺的自主开发指明方向。
ERW(Electrical Resistance Welded) Mid-size pipe is a kind of high value-addedproduct which is secondary processed with strip. With its high precision size, goodsurface and the advantages of low production cost, ERW pipe is widely used in oil andgas transportation, building structure and other fields, having a broad market prospect.In recent years, the market for ERW welded pipe's surface quality and secondaryprocessing performance requirements is being more and more high, mainly displays incorrosion resistance and impact peformance in ultra-low temperature. In order to meetthe market, ERW equipment technology is also in the synchronous development, themost representative of which are the German MEER URD technology and the JapanNAKATA FFX Forming technology. On the manufacturing, roll forming technologygradually go to a flexible direction, its characteristic is roll Shared, little adjustment ofroll change, high efficiency, and low cost. Forming technology is extremely importantto the process, and directly affects the welding. Precise caliber and flexible formingare required to avoid forming defects like strip bump, offset and drape. The key ofstudy is to get forming parameters economically and effectively.
This thesis focused on the study of ERW mill of Baosteel from the point of defectmechanism, with the help of the simulation platform, finding root causes of defects,the way of which not only guide the optimization of forming process, but also directthe forming technology of independent development in Baosteel.
引文
[1].彭在美,中国钢管50年的回顾与未来技术发展战略的探讨[J].南方金属,2005,144(3):1-8.
[2].孙永喜,我国ERW钢管生产现状与经营发展策略(上)[J].钢管2002,31(1):5-8.
[3].孙永喜,我国ERW钢管生产现状与经营发展策略(下)[J].钢管2002,31(2):1-4.
[4].李云江,赖明道,焊管成型分析方法(Ⅰ)[J].钢管1993,第一期:40-43.
[5].李云江,赖明道,焊管成型分析方法(Ⅱ)[J].钢管1993,第一期:39-42.
[6].冶金部劳动公司编,高频直缝电焊管生产[M].北京冶金工业出版社1985
[7].李云江,赖明道,周庆田,焊管自然柔性成型过程理论研究[J].焊管,1999,22(3):9-13.
[8].佟连勋,φ508直缝焊管机组工艺的选进性[J].焊管,1996,19(4):34-36.
[9].胡松林,从日本焊管制造技术的发展看国内HFW焊管的技术创新[J].焊管,2006,29(6):53-57.
[10].温殿英等,直缝焊管成型第一,二架应变分布的实验研究[J].焊管,1997,20(3):18-21.
[11].石京,王先进,国内外冷弯成型研究最新进展[J].轧钢,1998,NO.5:45-48.
[12].梁炳文,胡世光,弹塑性稳定理论[M].北京国防工业出版社,1983:24-34
[13].熊建辉,宝钢Φ610mmERW柔性成型辊位参数的确定[J].钢管,2009,38(2):33-38.
[14].彭在美,我国焊管的市场形势和发展趋向[J].焊管,2009,32(10):5-8.
[15].冯耀荣等,油气输送焊管残余应力测试与安全评价方法研究[D].中国安全科学报,2007.
[16].张曙华,残余应力对ERW管线管制造过程的影响分析[J]钢管,2007(12):25-28.
[17].张喜庆,高压厚壁ERW直缝油井焊管应用前景分析[J].石油矿物机械,2001,30(1):26-29.
[18].李大永等,辊弯成形数值数值研究综述及全流程仿真研究现状[J].机械科学与技术,2004,23(12):1466~1469.
[19].周瑛,姜文光,刘才,辊式成形过程的样条有限元分析[J].机械工程学报,1997,33(2):82-87.
[20].蒋劲茂,直缝焊管排辊成型有限元仿真研究[J].中国机械工程第17卷增刊,2006:5-7.
[21].张定潮,计算机辅助周期轧机孔型优化设计[D].重庆大学学报,2002.
[22].童明生,直缝焊管成型的非线性有限元分析程序设计[J].电脑开发与应用,1995,8(4):13-20.
[23].于思林,赖明道,蔡松庆,薄板大位移弹塑性有限元分析[J].焊管,1994,17(5):1-4
[24].花江,焊管辊弯成形过程的计算机仿真[J].钢铁1997,32(7):38-42.
[25].石油天然气工业输送钢管交货技术条件[S]. GB/T 9711.1:1997 .
[26].李辉,张宇平,半圆形焊管轧辊的孔型设计[J].焊管,2004,27(5):38-40.
[27].冯耀荣,李鹤林,ERW钢管焊缝未熔合缺陷及其对性能的影响[J].焊管,1994,17(2):24-28.
[28].覃源等,X52管线钢焊接时鼓包原因分析[J].四川冶金,1998,2:32-39.
[29].赵坤,浅谈ERW钢管错边缺陷[J].焊管,2008,31(2):67-68.
[30].闵祥玲等,应变时效对高强度管线钢管的影响[J].焊管,2010,33(4):66-71.
[31].API SPEC 5L-2004, LinePipes Specification[S], American Petroleum Institution, 2004.
[32].API SPEC 5CT-2005, Tubing and Casing Specification[S], American Petroleum Institution, 2005.
[33].Liu C , Zhou Y, Lu W. Numerical Simulation of Roll-forming by B-spline Finite Strip Method[J] . J . Mater. Process. Technol. , 1996 ,60 :215-218.
[34].Han Z W, Liu C,Lu W P. Experimental Investigation and Theoretical Analysis of Roll Forming ofElect rical Resistance Welded Pipes [J] . J . Mater. Process. Technol. ,2004 ,145 :311-316.
[35].Kim N , Kang B , Lee S. Prediction and Design of Edge Shape of Initial St rip for Thick Tube RollForming Using Finite Element Method [J] . J . Mater. Process. Technol. , 2003 ,142 : 479-486.
[36].Kiuchi M , Wang F Z. FEM Simulation of Roll-forming of ERW Pipes and Mill/ ProcessDesign[C]/ / Proceedings of NUMISHEET’99. Besancon France ,1999 :529-534.
[2].孙永喜,我国ERW钢管生产现状与经营发展策略(上)[J].钢管2002,31(1):5-8.
[3].孙永喜,我国ERW钢管生产现状与经营发展策略(下)[J].钢管2002,31(2):1-4.
[4].李云江,赖明道,焊管成型分析方法(Ⅰ)[J].钢管1993,第一期:40-43.
[5].李云江,赖明道,焊管成型分析方法(Ⅱ)[J].钢管1993,第一期:39-42.
[6].冶金部劳动公司编,高频直缝电焊管生产[M].北京冶金工业出版社1985
[7].李云江,赖明道,周庆田,焊管自然柔性成型过程理论研究[J].焊管,1999,22(3):9-13.
[8].佟连勋,φ508直缝焊管机组工艺的选进性[J].焊管,1996,19(4):34-36.
[9].胡松林,从日本焊管制造技术的发展看国内HFW焊管的技术创新[J].焊管,2006,29(6):53-57.
[10].温殿英等,直缝焊管成型第一,二架应变分布的实验研究[J].焊管,1997,20(3):18-21.
[11].石京,王先进,国内外冷弯成型研究最新进展[J].轧钢,1998,NO.5:45-48.
[12].梁炳文,胡世光,弹塑性稳定理论[M].北京国防工业出版社,1983:24-34
[13].熊建辉,宝钢Φ610mmERW柔性成型辊位参数的确定[J].钢管,2009,38(2):33-38.
[14].彭在美,我国焊管的市场形势和发展趋向[J].焊管,2009,32(10):5-8.
[15].冯耀荣等,油气输送焊管残余应力测试与安全评价方法研究[D].中国安全科学报,2007.
[16].张曙华,残余应力对ERW管线管制造过程的影响分析[J]钢管,2007(12):25-28.
[17].张喜庆,高压厚壁ERW直缝油井焊管应用前景分析[J].石油矿物机械,2001,30(1):26-29.
[18].李大永等,辊弯成形数值数值研究综述及全流程仿真研究现状[J].机械科学与技术,2004,23(12):1466~1469.
[19].周瑛,姜文光,刘才,辊式成形过程的样条有限元分析[J].机械工程学报,1997,33(2):82-87.
[20].蒋劲茂,直缝焊管排辊成型有限元仿真研究[J].中国机械工程第17卷增刊,2006:5-7.
[21].张定潮,计算机辅助周期轧机孔型优化设计[D].重庆大学学报,2002.
[22].童明生,直缝焊管成型的非线性有限元分析程序设计[J].电脑开发与应用,1995,8(4):13-20.
[23].于思林,赖明道,蔡松庆,薄板大位移弹塑性有限元分析[J].焊管,1994,17(5):1-4
[24].花江,焊管辊弯成形过程的计算机仿真[J].钢铁1997,32(7):38-42.
[25].石油天然气工业输送钢管交货技术条件[S]. GB/T 9711.1:1997 .
[26].李辉,张宇平,半圆形焊管轧辊的孔型设计[J].焊管,2004,27(5):38-40.
[27].冯耀荣,李鹤林,ERW钢管焊缝未熔合缺陷及其对性能的影响[J].焊管,1994,17(2):24-28.
[28].覃源等,X52管线钢焊接时鼓包原因分析[J].四川冶金,1998,2:32-39.
[29].赵坤,浅谈ERW钢管错边缺陷[J].焊管,2008,31(2):67-68.
[30].闵祥玲等,应变时效对高强度管线钢管的影响[J].焊管,2010,33(4):66-71.
[31].API SPEC 5L-2004, LinePipes Specification[S], American Petroleum Institution, 2004.
[32].API SPEC 5CT-2005, Tubing and Casing Specification[S], American Petroleum Institution, 2005.
[33].Liu C , Zhou Y, Lu W. Numerical Simulation of Roll-forming by B-spline Finite Strip Method[J] . J . Mater. Process. Technol. , 1996 ,60 :215-218.
[34].Han Z W, Liu C,Lu W P. Experimental Investigation and Theoretical Analysis of Roll Forming ofElect rical Resistance Welded Pipes [J] . J . Mater. Process. Technol. ,2004 ,145 :311-316.
[35].Kim N , Kang B , Lee S. Prediction and Design of Edge Shape of Initial St rip for Thick Tube RollForming Using Finite Element Method [J] . J . Mater. Process. Technol. , 2003 ,142 : 479-486.
[36].Kiuchi M , Wang F Z. FEM Simulation of Roll-forming of ERW Pipes and Mill/ ProcessDesign[C]/ / Proceedings of NUMISHEET’99. Besancon France ,1999 :529-534.