ERW管的成型过程分析仿真及机械性能试验研究
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摘要
ERW直缝焊管以其尺寸精度高、壁厚均匀、生产率高、抗压性能和综合力学性能好以及射孔不裂等优点而具有很大的发展潜力和市场竞争力。目前,ERW管已正在向原属无缝钢管应用的领域进军,已广泛应用于石油、天然气、水、煤气和矿浆等流体长距离输送和油井套管。因此,对ERW管的生产工艺和成型过程的研究,以及成型工艺对ERW焊管质量及机械性能的影响的研究,有着重要的意义。
本文综述了ERW焊管的特点,国内外应用、生产发展情况;对ERW管成型机组进行了简单介绍;分析研究了ERW管的成型工艺及各项参数,ERW管成型原理和板料参数的确定,并对成型过程中可能出现的影响情况做出介绍分析;利用样条有限条法,通过将连续体的离散化,构造位移函数,对由刚度矩阵、载荷矩阵得到的平衡方程求解,从而由理论上分析ERW焊管成型过程中的应力应变情况;运用ANSYS/LS-DYNA动态模块,对ERW焊管的成型过程进行建模、模拟,进行全流程的仿真,结合仿真结果分析研究ERW管成型过程的应力应变情况;最后,对成品ERW管取样进行压扁试验、拉伸试验和弯曲试验,并根据数理统计的方法处理实验数据,求得各项数据的概率密度曲线,得到较为精确的试验结果,对试验结果进行分析研究成品管的各项机械性能。
本文将ERW管成型过程的理论分析,过程仿真以及成品管的机械性能试验研究相结合,对ERW焊管生产的全流程进行分析研究,为ERW焊管生产工艺的改进发展打下基础。
ERW longitudinally welded pipe has great development potential and market competitiveness for its excellence of great dimensional precision, symmetrical wall thickness, high productivity, good compression resistance capability and comprehensive mechanical properties and without perforation cracks. Now the ERW pipe is coming into the field seamless steel tube is used before, and has been used in long distance transportation of petroleum,natural gas, water, gas, pulp, etc. , and oil well casing. So it is important to study the production process of ERW pipe and how the process affects quality and mechanical properties of ERW pipe.
This paper summarized characteristics, applications at home and abroad, situation of production and development of ERW pipe; Introduced the generating unit; analyzed and studied the forming process and parameter of the pipe; Studied the forming principle and how to confirm sheet metals’parameters, analyzed the situation may appear in the production process and the effects of it; Studied the situation of stress and strain in the forming process in the abstract by spline finite strip method through continuum discretization, structuring displacement function, solving balance equation confirmed by stiffness matrix and loading matrix; Modeling for forming process of ERW pipe and study the result of simulation made by ANSYS/LS-DYNA dynamic module. Analyzed the stress and strain in the forming process by simulation; Selected samples of ERW pipe, then made flattening test, tensile test and bending test. Deal with the test date in mathematical statistics method, in this way the probability density curve of the date can be made. According to the probability density curve, accurate test date can be got. Study and analyze mechanical properties of ERW pipe through the accurate test date.
The theoretical analysis of forming process, simulation of forming process and mechanical property test hang together in this paper, the whole forming process was studied and analyzed. That made foundations for the development of ERW pipe’s production process.
本文综述了ERW焊管的特点,国内外应用、生产发展情况;对ERW管成型机组进行了简单介绍;分析研究了ERW管的成型工艺及各项参数,ERW管成型原理和板料参数的确定,并对成型过程中可能出现的影响情况做出介绍分析;利用样条有限条法,通过将连续体的离散化,构造位移函数,对由刚度矩阵、载荷矩阵得到的平衡方程求解,从而由理论上分析ERW焊管成型过程中的应力应变情况;运用ANSYS/LS-DYNA动态模块,对ERW焊管的成型过程进行建模、模拟,进行全流程的仿真,结合仿真结果分析研究ERW管成型过程的应力应变情况;最后,对成品ERW管取样进行压扁试验、拉伸试验和弯曲试验,并根据数理统计的方法处理实验数据,求得各项数据的概率密度曲线,得到较为精确的试验结果,对试验结果进行分析研究成品管的各项机械性能。
本文将ERW管成型过程的理论分析,过程仿真以及成品管的机械性能试验研究相结合,对ERW焊管生产的全流程进行分析研究,为ERW焊管生产工艺的改进发展打下基础。
ERW longitudinally welded pipe has great development potential and market competitiveness for its excellence of great dimensional precision, symmetrical wall thickness, high productivity, good compression resistance capability and comprehensive mechanical properties and without perforation cracks. Now the ERW pipe is coming into the field seamless steel tube is used before, and has been used in long distance transportation of petroleum,natural gas, water, gas, pulp, etc. , and oil well casing. So it is important to study the production process of ERW pipe and how the process affects quality and mechanical properties of ERW pipe.
This paper summarized characteristics, applications at home and abroad, situation of production and development of ERW pipe; Introduced the generating unit; analyzed and studied the forming process and parameter of the pipe; Studied the forming principle and how to confirm sheet metals’parameters, analyzed the situation may appear in the production process and the effects of it; Studied the situation of stress and strain in the forming process in the abstract by spline finite strip method through continuum discretization, structuring displacement function, solving balance equation confirmed by stiffness matrix and loading matrix; Modeling for forming process of ERW pipe and study the result of simulation made by ANSYS/LS-DYNA dynamic module. Analyzed the stress and strain in the forming process by simulation; Selected samples of ERW pipe, then made flattening test, tensile test and bending test. Deal with the test date in mathematical statistics method, in this way the probability density curve of the date can be made. According to the probability density curve, accurate test date can be got. Study and analyze mechanical properties of ERW pipe through the accurate test date.
The theoretical analysis of forming process, simulation of forming process and mechanical property test hang together in this paper, the whole forming process was studied and analyzed. That made foundations for the development of ERW pipe’s production process.
引文
[1]徐学利,辛希贤.ERW直缝套管残余应力分布规律的研究[J].石油机械,2003,31(3):1—3
[2]肖绍嵩.石油套管及钻杆生产现状及发展趋势[J].石油矿场机械,2002,31(6):19-22.
[3]张居勤,丁晓军,田小龙,等.ERW直焊缝套管的开发和应用[J].焊管,2000,23(4):1-8.
[4]孙永喜.ERW钢管在长输管道建设中的应用[J].油气储运,2001,20(1):47-49.
[5]贾十周.直缝电阻焊钢管与无缝管对比[J].焊管,1995,18(3):12-15.
[6]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.
[7]丁作礼.大直径直缝焊管生产现状与发展(三)[J].鞍钢技术,1996,2:1-3.
[8]刘志俭.ERW直缝焊管成型装置的发展[J].钢管,2007,36(1):1-8
[9]王先进.冷弯型钢生产及应用[M].北京:冶金工业出版社,1994,11
[10]五弓勇雄.金属塑性加工技术[M] .北京:冶金工业出版社,1987:1
[11]王军杰,蒋劲茂.ERW焊管辊弯成型过程的动态仿真研究[J].塑性工程学报,2007,14(5):23—25
[12]李大永,蒋劲茂.辊弯成型过程仿真与参数优化[J].系统仿真学报,2007,19(4):893—895
[13]古恩著,赵志业,王国栋译.金属压力加工理论基础[M] .北京:冶金工业出版社,1989:127
[14]彭在美.关于ERW焊管机组国内外发展趋势评述[J].钢铁设计,1997,3:9-14
[15]胡建英.冷拔钢管与焊管成型过程的非线性有限元分析[D].天津:天津理工大学, 2005
[16]吴凤桐等.国外高频直缝焊管生产[M].北京:冶金工业出版社,1985:35
[17]王仕杰.大直径ERW直缝焊管排辊成型工艺研究[D].太原:太原科技大学,2007
[18]赖明道,吴学礼等.焊管机组的研究与进展[M].北京:国防工业出版社,2006:259
[19] R.T.Angle. Iron Age[M].1949,3:83
[20]加藤健三.冷間ロ_ル成型[N]。日刊工业新闻。1971
[21] B.N.达维多夫,М.П.马科萨柯夫等.穆东生译.薄壁冷弯型钢生产[M].北京:中国工业出版社,1962:115
[22]小奈弘,神馬敬.塑性と加工[J].生产研究,1983,24(270):32-33
[23]周瑛.辊式成型过程的塑性大变形样条有限条模拟[D].秦皇岛:燕山大学,1996
[24]林时宪.国外冷弯型钢[M].北京:北京冶金工业出版社,1984:87-89
[25] K.Nakajime, W.Miznutani. Development of new vertical roll forming process foe ERW pipe[R]. Nippon Steel Technical Report.1980,(15):127—144.
[26] Terrv R. Walker,Roy J. Pick. APPROXIMATION OG THE AXIAL STRAINS DEVELOPED DURING THE ROLL FORMING OF PIPE[J]. Journal of Materials Processing Technology. 1990; 22: 29—44
[27] T.R.Walker,R.J.Pick. Developments in the geometric modeling of an ERW pipe skelp[J]. Journal of Materials Processing Technology,1991,25:35—54
[28]木内学,千葉和裕.ロ-ルフォ-ミソゲ汎用シミエレ-タの開凳に關する研究[J].生产研究,1989,41(8),33—36
[29]小野田義富,长町拓夫.正方形角钢管のエケスドロ-ルフォ-ミソゲにする舉動の有限要素シミニレ-ショソ[J].塑性と加工.1995,36(409):149—154.
[30]张必强.焊管成型的回弹[J].焊管.1993,(6):1—3
[31]张全根.制管时带钢的纵向变形分析[J].焊管.1989;12(3): 24-30
[32]蔡松庆.直缝焊管力能参数研究[D] .齐齐哈尔:东北重型机械学院,1983
[33]徐树成.辊弯成型的三维大变形有限元模拟[D].秦皇岛:燕山大学.1997
[34]李强,韩志武,刘才.复杂断面型钢辊弯成型数值模拟[J].机械工程学报.2000,36(7):96—98
[35]韩志武,徐树成,刘才,等.冷弯成型过程的实验研究[J].钢铁.1999,34(11):37—40
[36] C. Liu, Y. Zhou. Numerical simulation of roll-forming by B-spline finite strip method[J]. Journal of Materials Processing Technology.1996,60:215—218
[37]王先进,石京.国内外冷弯技术的发展与趋势[J].冷弯型钢十年发展成果及展望.1995:235-239 76
[38] M. Brunet,S. Ronel. FINITE ELEMENT ANALYSIS OF ROLL-FORMING OF THIN SHEET METAL[J]. Journal of Materials Processing Technology.1994,45:255—260
[39]王军杰.基于材料混合硬化模型的辊弯成型过程仿真研究[D].上海:上海交通大学.2007
[40]李春夏.冷弯成型力学理论模拟及试验研究[D].昆明:昆明理工大学.2005
[41] Y. K. Cheung著,谢秀松译.结构分析的有限条法[M].北京:人民交通出版社.1978:17-19
[42]曹志远,张耀勤.非线性弹性有限条分析[J].上海力学.1992,13(1): 30-37
[43]殷有泉.固体力学非线性有限元引论[M].北京:清华大学出版社.1986:117-121
[44]张乐乐.基于样条有线条法的辊弯成型过程可视化仿真研究[D].秦皇岛:燕山大学,2001
[45]周瑛.辊式成型过程的弹塑性大变形样条有限条模拟[D].秦皇岛:燕山大学.1996
[46]郭彦林.薄壳结构的样条有限条非线性分析[J].西安冶金建筑学院学报.1990,22(4):366—373
[47]韩志武.基于大变形有限条法的冷弯成型计算机模拟与专家系统技术的研究[D].秦皇岛:燕山大学.1998
[48]段进,倪栋.ANSYS10.0结构分析从入门到精通[D].北京:兵器工业出版社,2-3
[49]尚小江.ANSYS/LS-DYNA动力分析方法与工程实例[D].北京:中国水利水电出版社,2006:5-7
[50]赵海峰,蒋迪.ANSYS8.0工程结构实例分析.北京:中国铁道出版社,2004, 11
[51]何涛,杨竞.ANSYS10.0/LS-DYNA非线性有限元分析实例指导教程.北京:机械工业出版社:256
[52]邓凡平.ANSYS10.0有限元分析.北京:人民邮电出版社:343
[53]胡晓伦,陈艾荣.ANSYS路径映射技术在结构分析中的应用[J].交通与计算,2004,3(22):86-88.
[54]陈卫东,刘旭华.同一试验多组数据处理方法研究[J].兵工学报,2007,28(1):42-45.
[2]肖绍嵩.石油套管及钻杆生产现状及发展趋势[J].石油矿场机械,2002,31(6):19-22.
[3]张居勤,丁晓军,田小龙,等.ERW直焊缝套管的开发和应用[J].焊管,2000,23(4):1-8.
[4]孙永喜.ERW钢管在长输管道建设中的应用[J].油气储运,2001,20(1):47-49.
[5]贾十周.直缝电阻焊钢管与无缝管对比[J].焊管,1995,18(3):12-15.
[6]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.
[7]丁作礼.大直径直缝焊管生产现状与发展(三)[J].鞍钢技术,1996,2:1-3.
[8]刘志俭.ERW直缝焊管成型装置的发展[J].钢管,2007,36(1):1-8
[9]王先进.冷弯型钢生产及应用[M].北京:冶金工业出版社,1994,11
[10]五弓勇雄.金属塑性加工技术[M] .北京:冶金工业出版社,1987:1
[11]王军杰,蒋劲茂.ERW焊管辊弯成型过程的动态仿真研究[J].塑性工程学报,2007,14(5):23—25
[12]李大永,蒋劲茂.辊弯成型过程仿真与参数优化[J].系统仿真学报,2007,19(4):893—895
[13]古恩著,赵志业,王国栋译.金属压力加工理论基础[M] .北京:冶金工业出版社,1989:127
[14]彭在美.关于ERW焊管机组国内外发展趋势评述[J].钢铁设计,1997,3:9-14
[15]胡建英.冷拔钢管与焊管成型过程的非线性有限元分析[D].天津:天津理工大学, 2005
[16]吴凤桐等.国外高频直缝焊管生产[M].北京:冶金工业出版社,1985:35
[17]王仕杰.大直径ERW直缝焊管排辊成型工艺研究[D].太原:太原科技大学,2007
[18]赖明道,吴学礼等.焊管机组的研究与进展[M].北京:国防工业出版社,2006:259
[19] R.T.Angle. Iron Age[M].1949,3:83
[20]加藤健三.冷間ロ_ル成型[N]。日刊工业新闻。1971
[21] B.N.达维多夫,М.П.马科萨柯夫等.穆东生译.薄壁冷弯型钢生产[M].北京:中国工业出版社,1962:115
[22]小奈弘,神馬敬.塑性と加工[J].生产研究,1983,24(270):32-33
[23]周瑛.辊式成型过程的塑性大变形样条有限条模拟[D].秦皇岛:燕山大学,1996
[24]林时宪.国外冷弯型钢[M].北京:北京冶金工业出版社,1984:87-89
[25] K.Nakajime, W.Miznutani. Development of new vertical roll forming process foe ERW pipe[R]. Nippon Steel Technical Report.1980,(15):127—144.
[26] Terrv R. Walker,Roy J. Pick. APPROXIMATION OG THE AXIAL STRAINS DEVELOPED DURING THE ROLL FORMING OF PIPE[J]. Journal of Materials Processing Technology. 1990; 22: 29—44
[27] T.R.Walker,R.J.Pick. Developments in the geometric modeling of an ERW pipe skelp[J]. Journal of Materials Processing Technology,1991,25:35—54
[28]木内学,千葉和裕.ロ-ルフォ-ミソゲ汎用シミエレ-タの開凳に關する研究[J].生产研究,1989,41(8),33—36
[29]小野田義富,长町拓夫.正方形角钢管のエケスドロ-ルフォ-ミソゲにする舉動の有限要素シミニレ-ショソ[J].塑性と加工.1995,36(409):149—154.
[30]张必强.焊管成型的回弹[J].焊管.1993,(6):1—3
[31]张全根.制管时带钢的纵向变形分析[J].焊管.1989;12(3): 24-30
[32]蔡松庆.直缝焊管力能参数研究[D] .齐齐哈尔:东北重型机械学院,1983
[33]徐树成.辊弯成型的三维大变形有限元模拟[D].秦皇岛:燕山大学.1997
[34]李强,韩志武,刘才.复杂断面型钢辊弯成型数值模拟[J].机械工程学报.2000,36(7):96—98
[35]韩志武,徐树成,刘才,等.冷弯成型过程的实验研究[J].钢铁.1999,34(11):37—40
[36] C. Liu, Y. Zhou. Numerical simulation of roll-forming by B-spline finite strip method[J]. Journal of Materials Processing Technology.1996,60:215—218
[37]王先进,石京.国内外冷弯技术的发展与趋势[J].冷弯型钢十年发展成果及展望.1995:235-239 76
[38] M. Brunet,S. Ronel. FINITE ELEMENT ANALYSIS OF ROLL-FORMING OF THIN SHEET METAL[J]. Journal of Materials Processing Technology.1994,45:255—260
[39]王军杰.基于材料混合硬化模型的辊弯成型过程仿真研究[D].上海:上海交通大学.2007
[40]李春夏.冷弯成型力学理论模拟及试验研究[D].昆明:昆明理工大学.2005
[41] Y. K. Cheung著,谢秀松译.结构分析的有限条法[M].北京:人民交通出版社.1978:17-19
[42]曹志远,张耀勤.非线性弹性有限条分析[J].上海力学.1992,13(1): 30-37
[43]殷有泉.固体力学非线性有限元引论[M].北京:清华大学出版社.1986:117-121
[44]张乐乐.基于样条有线条法的辊弯成型过程可视化仿真研究[D].秦皇岛:燕山大学,2001
[45]周瑛.辊式成型过程的弹塑性大变形样条有限条模拟[D].秦皇岛:燕山大学.1996
[46]郭彦林.薄壳结构的样条有限条非线性分析[J].西安冶金建筑学院学报.1990,22(4):366—373
[47]韩志武.基于大变形有限条法的冷弯成型计算机模拟与专家系统技术的研究[D].秦皇岛:燕山大学.1998
[48]段进,倪栋.ANSYS10.0结构分析从入门到精通[D].北京:兵器工业出版社,2-3
[49]尚小江.ANSYS/LS-DYNA动力分析方法与工程实例[D].北京:中国水利水电出版社,2006:5-7
[50]赵海峰,蒋迪.ANSYS8.0工程结构实例分析.北京:中国铁道出版社,2004, 11
[51]何涛,杨竞.ANSYS10.0/LS-DYNA非线性有限元分析实例指导教程.北京:机械工业出版社:256
[52]邓凡平.ANSYS10.0有限元分析.北京:人民邮电出版社:343
[53]胡晓伦,陈艾荣.ANSYS路径映射技术在结构分析中的应用[J].交通与计算,2004,3(22):86-88.
[54]陈卫东,刘旭华.同一试验多组数据处理方法研究[J].兵工学报,2007,28(1):42-45.