护环液压胀形加载路径优化设计方法
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摘要
以600 MW护环为例,研究了外补液液压胀形加载路径确定方法。把连续的胀形强化过程离散为多个子加载段,将各子加载段锥模作用力和环坯腔内液体压力的关系简化为线性关系,采用分段匹配的方法确定各加载段的合理子加载路径,再叠加为完整的合理加载路径,确定了加载路径的形式和关键参数。将环坯液压胀形质量作为目标,两段加载路径斜率、加载路径拐点液体压力和胀形终了液体压力为设计变量,采用遗传优化算法对护环液压胀形加载路径进行优化,并进行了缩比实验。研究结果表明,外补液护环液压胀形加载路径可近似为两段线性线形,拐点对应的环坯腔内液体压力在使环坯外层完全屈服的液体压力值附近,且通过优化获得加载路径的最优参数组合能够保证护环液压胀形制品的质量。
Taking 600 MW retaining ring as an example,the method of determining loading paths of retaining ring hydraulic bulging with additional liquid was analyzed. The continuous hydraulic bulging strengthening process was dispersed into limited interval,and a linear relationship between the axial force and liquid pressure was supposed in limited interval. The form and key parameters of the loading paths were determined by the sectional matching method in limited interval and the superposition principle. The loading paths of retaining ring hydraulic bulging was optimized according to genetic algorithm with the quality of retaining ring after hydraulic bulging as the optimal objective and the slopes of the linear loading paths,the pressure of inflection points in loading path and the maximum pressure as the design variables. And the simulative experiments of retaining ring hydraulic bulging was finished based on the result of the study. The results show that the loading paths of retaining ring hydraulic bulging with additional liquid can be approximated as two segments linear,and the pressure of inflection points is approximately equal to the wholly yields pressure of the outer-layer of retaining ring. The optimal parameters of optimized loading paths can ensure the quality of retaining ring products.
Taking 600 MW retaining ring as an example,the method of determining loading paths of retaining ring hydraulic bulging with additional liquid was analyzed. The continuous hydraulic bulging strengthening process was dispersed into limited interval,and a linear relationship between the axial force and liquid pressure was supposed in limited interval. The form and key parameters of the loading paths were determined by the sectional matching method in limited interval and the superposition principle. The loading paths of retaining ring hydraulic bulging was optimized according to genetic algorithm with the quality of retaining ring after hydraulic bulging as the optimal objective and the slopes of the linear loading paths,the pressure of inflection points in loading path and the maximum pressure as the design variables. And the simulative experiments of retaining ring hydraulic bulging was finished based on the result of the study. The results show that the loading paths of retaining ring hydraulic bulging with additional liquid can be approximated as two segments linear,and the pressure of inflection points is approximately equal to the wholly yields pressure of the outer-layer of retaining ring. The optimal parameters of optimized loading paths can ensure the quality of retaining ring products.
引文
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[15]田晓佳.护环外补液胀形的过程控制参数研究[D].秦皇岛:燕山大学,2016.TIAN Xiaojia.Study on the process control parameters for hydraulic expansion with additional liquid of retaining ring[D].Qinhuangdao:Yanshan University,2016.
[16]倪洪启,宋荣发,杨兵.护环液压胀形变形规律的研究[J].大型铸锻件,2002,(4):26-28.NI Hongqi,SONG Rongfa,YANG Bing.Research for retaining ring deforming rule[J].Heavy Castings and Forgings,2002,(4):26-28.
[17]魏庆亮,张旭东,王树立,等.液压胀形模具结构改进及材料代用研究[J].大型铸锻件,2014,(6):41-42.WEI Qingliang,ZHANG Xudong,WANG Shuli,et al.Research on structure improvement and material alternative for hydraulic bulging die[J].Heavy Castings and Forgings,2014,(6):41-42.
[18]王晓晶.护环液压胀形加载路径的数值模拟及实验研究[D].秦皇岛:燕山大学,2014.WANG Xiaojing.Simulation and experimental research on loading paths of retaining ring hydraulic bulging[D].Qinhuangdao:Yanshan University,2014.
[2]熊东旭.护环设计中的几个问题浅析[J].东方电机,1999,(2):28-32.XIONG Dongxu.Analysis of several problems in the design of retaining ring[J].Dongfang Electrical Machine,1999,(2):28-32.
[3]BALITSKII A,KROHMALNY O,RIPEY I.Hydrogen cooling of turbogenerators and the problem of rotor retaining ring materials degradation[J].International Journal of Hydrogen Energy,2000,25(2):167-171.
[4]刘建生,陈慧琴,郭会光.护环扩挤复合成形新工艺的模拟研究[J].机械工程学报,1998,34(1):21-26.LIU Jiansheng,CHEN Huiqin,GUO Huiguang.Simulation study on new process of expanding and extrusion composite forming of retaining ring[J].Journal of Mechanical Engineering,1998,34(1):21-26.
[5]DREW M W.Assessment of overheated generator end bells[J].Engineering Failure Analysis,2004,11(2):191-198.
[6]任运来,牛龙江,任杰,等.护环液压胀形尺寸与性能预测[J].塑性工程学报,2014,21(6):1-6.REN Yunlai,NIU Longjiang,REN Jie,et al.Dimesion and property prediction of retainning ring in hydraulic expansion[J].Journal of Plasticity Engineering,2014,21(6):1-6.
[7]ZHAO X L,LIU J S,HE W W.Research of deformation process control of generator's retaining rings on hydraulic bulging strengthening technology[J].Advanced Materials Research,2010,139-141:970-974.
[8]HE W W,LIU J S,GUO H G,et al.Deformation pattern of the large generator's retaining rings during hydraulic bulging strengthening[J].Materials Science Forum,2008,575-578:606-611.
[9]朱磊.300MWMn18Cr18N护环外补液胀形工艺及设备研究[D].秦皇岛:燕山大学,2005.ZHU Lei.Study on the technique and equipment of300MWMn18Cr18N retaining ring hydraulic expansion with additional liquid[D].Qinhuangdao:Yanshan University,2005.
[10]墨静.600MW护环NTA液压胀形工艺研究[D].秦皇岛:燕山大学,2012.MO Jing.Study on technique of 600MW retaining ring hydraulic bulging with NTA method[D].Qinhuangdao:Yanshan University,2012.
[11]杨兵,曲东方,郭宝强,等.600MW1Mn18Cr18N护环的制造[J].大型铸锻件,2010,(6):31-34.YANG Bing,QU Dongfang,GUO Baoqiang,et al.The manufacture of 600MW retaining ring of 1Mn18Cr18N steel[J].Heavy Castings and Forgings,2010,(6):31-34.
[12]李媛,许焕宾,曲东方,等.600 MW 1Mn18Cr18N护环外补液压胀形的数值模拟与试验研究[J].锻压技术,2015,40(2):65-69.LI Yuan,XU Huanbin,QU Dongfang,et al.Research on numerical simulation and experiment of hydraulic expansion with additional liquid for 60MW retaining ring of Mn18Cr18N steel[J].Forging&Stamping Technology,2015,40(2):65-69.
[13]董立三.大型护环液压胀形的加载路径研究[D].秦皇岛:燕山大学,2013.DONG Lisan.Study on the loading path of hydroforming process for retaining ring[D].Qinhuangdao:Yanshan University,2013.
[14]王潇钰.护环液压胀形工艺参数研究及成形质量预测[D].秦皇岛:燕山大学,2015.WANG Xiaoyu.Researches on the technological parameters and the prediction of porming quality for retaining ring hydraulic bulging[D].Qinhuangdao:Yanshan University,2015.
[15]田晓佳.护环外补液胀形的过程控制参数研究[D].秦皇岛:燕山大学,2016.TIAN Xiaojia.Study on the process control parameters for hydraulic expansion with additional liquid of retaining ring[D].Qinhuangdao:Yanshan University,2016.
[16]倪洪启,宋荣发,杨兵.护环液压胀形变形规律的研究[J].大型铸锻件,2002,(4):26-28.NI Hongqi,SONG Rongfa,YANG Bing.Research for retaining ring deforming rule[J].Heavy Castings and Forgings,2002,(4):26-28.
[17]魏庆亮,张旭东,王树立,等.液压胀形模具结构改进及材料代用研究[J].大型铸锻件,2014,(6):41-42.WEI Qingliang,ZHANG Xudong,WANG Shuli,et al.Research on structure improvement and material alternative for hydraulic bulging die[J].Heavy Castings and Forgings,2014,(6):41-42.
[18]王晓晶.护环液压胀形加载路径的数值模拟及实验研究[D].秦皇岛:燕山大学,2014.WANG Xiaojing.Simulation and experimental research on loading paths of retaining ring hydraulic bulging[D].Qinhuangdao:Yanshan University,2014.