小直径厚壁管产品Roll forming FEA仿真研究
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摘要
小直径厚壁焊管在生产生活中有着广泛的应用,但是由于其直径小、壁厚较厚的特点,在实际的辊弯成型生产中出现了许多困难。工程中要实现合理的辊型设计,多是以实际经验为参考,依赖试错法进行设计,需要从设计到实践和从实践到设计多次反复才能完成,因而新产品的研发周期较长成本较高。随着有限元技术的成熟,通过商业化有限元软件进行计算机仿真,对其成型过程进行系统的理论分析,为实际生产应用提供指导,这样既可以缩短周期也可以节省费用。
本文从《实用钢铁材料手册》根据不同的厚径比选择了一些尺寸规格,通过轧辊专业设计软件copra进行了辊花图设计,以便于有限元仿真软件的建模和仿真。用非线性有限元软件Msc.Marc,将copra生成的dxf格式图形导入其中,建立合理的小直径厚壁焊管成型过程的三维模型,对小直径厚壁焊管多道次辊弯成型工艺的整个过程进行了数值模拟,分析了模拟后焊管的圆度误差,给出了外径不变与壁厚不变两种情况下误差的多项式方程,总结了成型后小直径厚壁焊管壁厚的变化规律,找出了壁厚变化的峰值点,提出了依据壁厚变化规律对轧辊原始外轮廓进行修正以减少壁厚误差的设想。
文中内容为小直径厚壁焊管的生产应用做出了有益的探索;为高精度焊管设计方法提供了新的理论依据。
Small-diameter thick-walled tube has a wide application in the production, but it has a lot of difficulties in the process of roll forming. In order to realize reasonable cambering in practice, we need more experience and trial-error design, the development of new products are repeated many times between design and practice , therefore, it is a longer cycle and also has a higher cost. With the finite element software is adopted to simulate the roll-forming process, the process is analyzed with the purpose of providing guidance on the application in actual production; it can cut down the cycle length and save cost.
A number of sizes are selected from the "Practical Handbook of Iron and Steel" in this article, roll flowers are designed through the professional software COPRA. Using the method of elastic-plastic finite element analysis, nonlinear finite element software Msc.Marc is used for simulating the small-diameter thick-walled tube in roll-forming process. The roundness error is analyzed, and the polynomial equation is summed up according to the same diameter and the same wall thickness. The tube wall thickness changing is stated after roll-forming, and the peak point of the changing error is given.
In the article, the conclusions can be used for high-precision welded tube roll forming process. A new conception for modifying the roller gap contour by the wall thickness changes is disclosed.
本文从《实用钢铁材料手册》根据不同的厚径比选择了一些尺寸规格,通过轧辊专业设计软件copra进行了辊花图设计,以便于有限元仿真软件的建模和仿真。用非线性有限元软件Msc.Marc,将copra生成的dxf格式图形导入其中,建立合理的小直径厚壁焊管成型过程的三维模型,对小直径厚壁焊管多道次辊弯成型工艺的整个过程进行了数值模拟,分析了模拟后焊管的圆度误差,给出了外径不变与壁厚不变两种情况下误差的多项式方程,总结了成型后小直径厚壁焊管壁厚的变化规律,找出了壁厚变化的峰值点,提出了依据壁厚变化规律对轧辊原始外轮廓进行修正以减少壁厚误差的设想。
文中内容为小直径厚壁焊管的生产应用做出了有益的探索;为高精度焊管设计方法提供了新的理论依据。
Small-diameter thick-walled tube has a wide application in the production, but it has a lot of difficulties in the process of roll forming. In order to realize reasonable cambering in practice, we need more experience and trial-error design, the development of new products are repeated many times between design and practice , therefore, it is a longer cycle and also has a higher cost. With the finite element software is adopted to simulate the roll-forming process, the process is analyzed with the purpose of providing guidance on the application in actual production; it can cut down the cycle length and save cost.
A number of sizes are selected from the "Practical Handbook of Iron and Steel" in this article, roll flowers are designed through the professional software COPRA. Using the method of elastic-plastic finite element analysis, nonlinear finite element software Msc.Marc is used for simulating the small-diameter thick-walled tube in roll-forming process. The roundness error is analyzed, and the polynomial equation is summed up according to the same diameter and the same wall thickness. The tube wall thickness changing is stated after roll-forming, and the peak point of the changing error is given.
In the article, the conclusions can be used for high-precision welded tube roll forming process. A new conception for modifying the roller gap contour by the wall thickness changes is disclosed.
引文
[1]Peter A.J.van der Veer et al.刘丹[译],纪常杰[校]小直径厚壁管线内部腐蚀的检测.国外油田工程.2001.9
[2]电缆金属电气有限公司,制造小直径厚壁管的方法和装置:德国,CN1032758A[P],1989.5.10
[3]赵金龙.大型方矩形管直接成型的仿真研究.北方工业大学.2008.5.16
[4]中小直径电焊钢管技术,冶金工业部钢铁司编.100-110
[5]牛洪军,胡建英,叶金铎.直缝焊管管坯双半径成型的非线性有限元分析,天津理工大学学报,2006.8
[6]小奈 弘[日].刘继英[中],Roll forming Technology,北京:化学工业出版社,2008.18-24
[7]George T.Halmos.刘继英.艾正青[译].冷弯成型技术手册.北京:化学工业出版社,2008.6
[8]李鹤林.中国焊管50年。西安:陕西科学技术出版社,2008.8.
[9]杨明珠,李涛.冷弯成型工艺分析及问题,辽宁,考试周刊,2008年第45期.
[10]唐继明.浅析高频直缝焊管用坯料及成型要求.河北冶金报.2006年第4期.
[11]朱春华,梁永生.中小直径厚壁电焊钢管生产工艺初探,河北建筑工程学院学报,2003.3.第21卷第1期.
[12]胡松林.我国焊管技术今后发展趋势刍议.钢管.1996.2
[13]郑申白,杨勇,范世军,龙跃.轧制过程仿真现状及展望.河南冶金报,2007.2
[14]曾攀.有限元分析及应用.北京:清华大学出版社,2004.6
[15]虞莲莲.曾正明.实用钢铁材料手册.北京:机械工业出版社,2001.2
[16]陈火红.Marc有限元实例分析教程.机械工业出版社.2002.4
[17]阚前华.常志宇.Msc.Marc工程应用实例分析与二次开发.北京:中国水利水电出版社,2005.1-7
[18]梁清香.张根全.有限元与Marc实现.北京:机械工业出版社,2003.2.4-7
[19]陈火红.于军泉.席源山等.Msc.Marc/Mentat 2003基础与应用实例.北京:科学出版社,2004.20-24
[20]韩志武,徐树成,刘才,周瑛,陆卫平.冷弯型钢成型过程的实验研究.钢铁,1999.11
[21]崔银会,张冰.冷弯结构焊管生产的技术特点焊管,2004年5月
[22]艾正青.冷弯成型计算机辅助辊花设计.北方工业大学学报,2000.3
[23]D.J.Mynorsl,M.English 1,M.Castelluccil.Controlling the Cold Roll Forming Design Process.Annals of the CIRP Vol.55/1/2006
[24]Hiroshi Ona.Cold roll forming for high tensile strength steel sheet proposition on forming of thin spring steel sheet pipe.Materials Processing Technology.2004.4
[25]M.English a,b,M.Castellucci,D.J.Mynors.Eco-efficiency of the cold roll formed product supply chain.Materials Processing Technology.2006.3
[26]K.Abrirtia,H.R.Farahmand.An upper bound analysis for the reshaping of thick tubes with experimental verification.Mechanical sciences.2007.7
[27]H.Moslemi Naeini,M.Kiuchi,T.Kitawaki,R.Kuromatsu.Design method of rolls for reshaping processes of pipes with pentagonal cross-sections.Materials Processing Technology.2002.7
[28]B.Radi,A.El Hami.Reliability analysis of the metal forming process.MATHEMATICAL AND COMPUTER MODELLING.2006.5
[29]B.V.Popovskii and Engineer G.V.Linevich.ROLL FORMING OF PROCESS EQUIPMENT.Candidate Engineer of Science.1965.11
[30]Han Zhi-wu,Liu Cai,LU Wei-ping.NUMERICAL SIMULATION OF ROLL FORMING FOR CHANNEL SECTION WITH OUTER EDGE.Applied Mathematics and Mechanics.2002.3
[31]李远光.抛物线型面Roll forming成型研究.北方工业大学.2008.5
[32]卜高乐.变截面冷弯成型的FRA仿真研究。北方工业大学,2007.5.27
[33]李凯.法国DIRICK× A×IS70冷弯成型工艺的计算机仿真.北方工业大学.2006.5.20
[34]夏雁宾.冷弯成型计算机仿真及在预冲孔板料中的应用研究.北方工业大学.2002.4
[35]王春新.冷弯成型过程的计算机仿真在工程实例中的应用研究.北方工业大学.2003.5
[36]史永凌.先进高强度钢辊弯成型仿真研究,北方工业大学.2006.5
[37]石京,王先进.国内外冷弯成型研究最新进展.轧钢,1998.10
[38]刘继英.冷弯成型CAD/CAM的一体化技术.北方工业大学学报,1996.9
[391 Z.-W.Han,L.-Q.Ren,C.Liu,W.-P.Lu.Modeling of cold roll forming of steel strip.Materials Science and Technology,2001.4
[40]韩志武,李强,刘才.多道次直缝焊管连续成形有限条分析
[41]韩志武,任露泉,刘才,陆卫平.冷弯成形数值模拟与孔型CAD集成系统.钢铁,2001.7
[42]花江,木内学.焊管成形过程的计算机仿真.钢铁,1997.10
[43]花江,木内学.带材辊型的计算机仿真模型研究.钢铁,1996.3
[44]小奈弘,神马敬,小园东雄.冷弯成形的计算机辅助设计系统.小奈弘教授论文选.北方工业大学机电工程研究所,1996.8
[45]王先进,涂厚道.冷弯型钢生产及应用.冶金工业出版社,1994.8
[46]刘鸿文.材料力学.高等教育出版社,1992.9
[47]陈国强,赵俊伟。基于MATLAB的圆度误差精确评定,焦作:河南理工大学,2005.9
[48]林璨.圆度误差测量软件.广东省计量科学研究所,1994年第二期
[49]郝宏伟,刘顺芳,范淑果.最小区域法评定圆度误差的计算机实现方法.河北科技大学学报,2006年6月
[2]电缆金属电气有限公司,制造小直径厚壁管的方法和装置:德国,CN1032758A[P],1989.5.10
[3]赵金龙.大型方矩形管直接成型的仿真研究.北方工业大学.2008.5.16
[4]中小直径电焊钢管技术,冶金工业部钢铁司编.100-110
[5]牛洪军,胡建英,叶金铎.直缝焊管管坯双半径成型的非线性有限元分析,天津理工大学学报,2006.8
[6]小奈 弘[日].刘继英[中],Roll forming Technology,北京:化学工业出版社,2008.18-24
[7]George T.Halmos.刘继英.艾正青[译].冷弯成型技术手册.北京:化学工业出版社,2008.6
[8]李鹤林.中国焊管50年。西安:陕西科学技术出版社,2008.8.
[9]杨明珠,李涛.冷弯成型工艺分析及问题,辽宁,考试周刊,2008年第45期.
[10]唐继明.浅析高频直缝焊管用坯料及成型要求.河北冶金报.2006年第4期.
[11]朱春华,梁永生.中小直径厚壁电焊钢管生产工艺初探,河北建筑工程学院学报,2003.3.第21卷第1期.
[12]胡松林.我国焊管技术今后发展趋势刍议.钢管.1996.2
[13]郑申白,杨勇,范世军,龙跃.轧制过程仿真现状及展望.河南冶金报,2007.2
[14]曾攀.有限元分析及应用.北京:清华大学出版社,2004.6
[15]虞莲莲.曾正明.实用钢铁材料手册.北京:机械工业出版社,2001.2
[16]陈火红.Marc有限元实例分析教程.机械工业出版社.2002.4
[17]阚前华.常志宇.Msc.Marc工程应用实例分析与二次开发.北京:中国水利水电出版社,2005.1-7
[18]梁清香.张根全.有限元与Marc实现.北京:机械工业出版社,2003.2.4-7
[19]陈火红.于军泉.席源山等.Msc.Marc/Mentat 2003基础与应用实例.北京:科学出版社,2004.20-24
[20]韩志武,徐树成,刘才,周瑛,陆卫平.冷弯型钢成型过程的实验研究.钢铁,1999.11
[21]崔银会,张冰.冷弯结构焊管生产的技术特点焊管,2004年5月
[22]艾正青.冷弯成型计算机辅助辊花设计.北方工业大学学报,2000.3
[23]D.J.Mynorsl,M.English 1,M.Castelluccil.Controlling the Cold Roll Forming Design Process.Annals of the CIRP Vol.55/1/2006
[24]Hiroshi Ona.Cold roll forming for high tensile strength steel sheet proposition on forming of thin spring steel sheet pipe.Materials Processing Technology.2004.4
[25]M.English a,b,M.Castellucci,D.J.Mynors.Eco-efficiency of the cold roll formed product supply chain.Materials Processing Technology.2006.3
[26]K.Abrirtia,H.R.Farahmand.An upper bound analysis for the reshaping of thick tubes with experimental verification.Mechanical sciences.2007.7
[27]H.Moslemi Naeini,M.Kiuchi,T.Kitawaki,R.Kuromatsu.Design method of rolls for reshaping processes of pipes with pentagonal cross-sections.Materials Processing Technology.2002.7
[28]B.Radi,A.El Hami.Reliability analysis of the metal forming process.MATHEMATICAL AND COMPUTER MODELLING.2006.5
[29]B.V.Popovskii and Engineer G.V.Linevich.ROLL FORMING OF PROCESS EQUIPMENT.Candidate Engineer of Science.1965.11
[30]Han Zhi-wu,Liu Cai,LU Wei-ping.NUMERICAL SIMULATION OF ROLL FORMING FOR CHANNEL SECTION WITH OUTER EDGE.Applied Mathematics and Mechanics.2002.3
[31]李远光.抛物线型面Roll forming成型研究.北方工业大学.2008.5
[32]卜高乐.变截面冷弯成型的FRA仿真研究。北方工业大学,2007.5.27
[33]李凯.法国DIRICK× A×IS70冷弯成型工艺的计算机仿真.北方工业大学.2006.5.20
[34]夏雁宾.冷弯成型计算机仿真及在预冲孔板料中的应用研究.北方工业大学.2002.4
[35]王春新.冷弯成型过程的计算机仿真在工程实例中的应用研究.北方工业大学.2003.5
[36]史永凌.先进高强度钢辊弯成型仿真研究,北方工业大学.2006.5
[37]石京,王先进.国内外冷弯成型研究最新进展.轧钢,1998.10
[38]刘继英.冷弯成型CAD/CAM的一体化技术.北方工业大学学报,1996.9
[391 Z.-W.Han,L.-Q.Ren,C.Liu,W.-P.Lu.Modeling of cold roll forming of steel strip.Materials Science and Technology,2001.4
[40]韩志武,李强,刘才.多道次直缝焊管连续成形有限条分析
[41]韩志武,任露泉,刘才,陆卫平.冷弯成形数值模拟与孔型CAD集成系统.钢铁,2001.7
[42]花江,木内学.焊管成形过程的计算机仿真.钢铁,1997.10
[43]花江,木内学.带材辊型的计算机仿真模型研究.钢铁,1996.3
[44]小奈弘,神马敬,小园东雄.冷弯成形的计算机辅助设计系统.小奈弘教授论文选.北方工业大学机电工程研究所,1996.8
[45]王先进,涂厚道.冷弯型钢生产及应用.冶金工业出版社,1994.8
[46]刘鸿文.材料力学.高等教育出版社,1992.9
[47]陈国强,赵俊伟。基于MATLAB的圆度误差精确评定,焦作:河南理工大学,2005.9
[48]林璨.圆度误差测量软件.广东省计量科学研究所,1994年第二期
[49]郝宏伟,刘顺芳,范淑果.最小区域法评定圆度误差的计算机实现方法.河北科技大学学报,2006年6月