车用双层卷焊管制造技术研究
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摘要
车用双层卷焊管由于其优越的性能,自问世以来,备受汽车行业的青睐,主要用于汽车的制动系统中,作为制约汽车安全性能的关键部件,其性能的好坏直接影响整车安全性。由于车用双层卷焊管外资制造商的不断涌入、国内一些低端车型用管增多、国际及国内钢材价格提高,中国的车用管路管材行业竞争日趋激烈,提高生产线效率及产品性能是企业可持续发展的必然选择。因此,对车用双层卷焊管加工工艺进行研究具有重要的现实意义。
本文以车用双层卷焊管为对象,对其制造技术进行研究。论文主要研究工作如下：
(1)在研究国内外车用双层卷焊管的发展现状的基础上,分析车用双层卷焊管生产线基本构成和加工工艺流程,研究车用双层卷焊管关键制造工艺,选择合理成型方案,研究成型机组布置形式,对车用双层卷焊管关键工艺参数进行分析。
(2)深入分析车用双层卷焊管生产线关键设备,研究设备工作原理及特点,分析设备关键控制参数,为车用双层卷焊管成型的模型建立及生产线控制奠定基础。
(3)建立车用双层卷焊管管筒成型有限元分析模型,应用显式动力学有限元分析软件ANSYS/LS-DYNA对车用双层卷焊管管筒成型应力特性及其对加工质量影响进行仿真模拟,分析其管筒成型的应变状态和应力分布情况,从而为研究车用双层卷焊管辊弯成型结构优化提供研究分析依据。
(4)研究生产线关键设备动作的协调控制,包括车用双层卷焊管生产线总体控制方案的确定、信息集成控制系统的硬件平台和软件设计。
本文的研究工作促使车用双层卷焊管企业对双层卷焊管生产线及生产工艺进行改造,以提升车用双层卷焊管制造工艺和技术水平,增强企业竞争力。
Automotive Double-wall Curly Brazed Tubes are pretty popular in the automotive industry due to the superior performance since they were appeared in the market. They are mainly used in automobile braking systems, as the key components of the constraints of vehicle safety performance, their performance have a direct impact on vehicle safety. Therefore, the study of processing technology in Automotive Double-wall Curly Brazed Tubes has important practical significance. China's vehicle pipe industry has fierce competition, since the foreign manufacturer of Automotive Double-wall Curly Brazed Tubes flood into China, some domestic low-end vehicles rise, and the increase in price of international and domestic steel, the improvement of product line efficiency and production performance is the inevitable choice for sustainable development of enterprises. Therefore, it is highly significant to conduct researches on the manufacturing technology of Automotive Double-wall Curly Brazed Tubes.
Based on the Automotive Double-wall Curly Brazed Tubes, their manufacturing technology is studied. In this paper, the major research contents are as follows:
On a basis of studying on the present situation of domestic and foreign Auto-motive Double-wall Curly Brazed Tubes. The basic ingredients of production line and manufacture process are analyzed. It is concerned with the manufacturing process, the reasonable form-solution, the basic layout types of formation machinery and the cri-tical process parameters of Automotive Double-wall Curly Brazed Tubes.
More thorough analysis on the key equipment of production line of Automotive Double-wall Curly Brazed Tubes is conducted, the operation principle and character-istics are studied, the key control parameters are analyzed. Thus, a foundation is provided for establishing the forming models and controlling production line.
The finite element models of Automotive Double-wall Curly Brazed Tubes are established. The stress-strain characteristics of divided edge forming processes and its influence on processing quality are simulated using explicit code LS-DYNA based on 3D elastic-plastic finite element method, and the strain state and stress distribution are analyzed. Thus, a foundation is provided for optimizing the forming structure of Automotive Double-wall Curly Brazed Tubes.
The coordination control of key equipment action is studied, including confirming the whole production line's control scheme of Automotive Double-wall Curly Brazed Tubes, and designing the hardware platform and software of the information integrated control.
The study makes the enterprises to reform the production line and its manufacturing technique of Automotive Double-wall Curly Brazed Tubes, aiming at improving its manufacturing technology and enhancing the competition of enterprises.
本文以车用双层卷焊管为对象,对其制造技术进行研究。论文主要研究工作如下：
(1)在研究国内外车用双层卷焊管的发展现状的基础上,分析车用双层卷焊管生产线基本构成和加工工艺流程,研究车用双层卷焊管关键制造工艺,选择合理成型方案,研究成型机组布置形式,对车用双层卷焊管关键工艺参数进行分析。
(2)深入分析车用双层卷焊管生产线关键设备,研究设备工作原理及特点,分析设备关键控制参数,为车用双层卷焊管成型的模型建立及生产线控制奠定基础。
(3)建立车用双层卷焊管管筒成型有限元分析模型,应用显式动力学有限元分析软件ANSYS/LS-DYNA对车用双层卷焊管管筒成型应力特性及其对加工质量影响进行仿真模拟,分析其管筒成型的应变状态和应力分布情况,从而为研究车用双层卷焊管辊弯成型结构优化提供研究分析依据。
(4)研究生产线关键设备动作的协调控制,包括车用双层卷焊管生产线总体控制方案的确定、信息集成控制系统的硬件平台和软件设计。
本文的研究工作促使车用双层卷焊管企业对双层卷焊管生产线及生产工艺进行改造,以提升车用双层卷焊管制造工艺和技术水平,增强企业竞争力。
Automotive Double-wall Curly Brazed Tubes are pretty popular in the automotive industry due to the superior performance since they were appeared in the market. They are mainly used in automobile braking systems, as the key components of the constraints of vehicle safety performance, their performance have a direct impact on vehicle safety. Therefore, the study of processing technology in Automotive Double-wall Curly Brazed Tubes has important practical significance. China's vehicle pipe industry has fierce competition, since the foreign manufacturer of Automotive Double-wall Curly Brazed Tubes flood into China, some domestic low-end vehicles rise, and the increase in price of international and domestic steel, the improvement of product line efficiency and production performance is the inevitable choice for sustainable development of enterprises. Therefore, it is highly significant to conduct researches on the manufacturing technology of Automotive Double-wall Curly Brazed Tubes.
Based on the Automotive Double-wall Curly Brazed Tubes, their manufacturing technology is studied. In this paper, the major research contents are as follows:
On a basis of studying on the present situation of domestic and foreign Auto-motive Double-wall Curly Brazed Tubes. The basic ingredients of production line and manufacture process are analyzed. It is concerned with the manufacturing process, the reasonable form-solution, the basic layout types of formation machinery and the cri-tical process parameters of Automotive Double-wall Curly Brazed Tubes.
More thorough analysis on the key equipment of production line of Automotive Double-wall Curly Brazed Tubes is conducted, the operation principle and character-istics are studied, the key control parameters are analyzed. Thus, a foundation is provided for establishing the forming models and controlling production line.
The finite element models of Automotive Double-wall Curly Brazed Tubes are established. The stress-strain characteristics of divided edge forming processes and its influence on processing quality are simulated using explicit code LS-DYNA based on 3D elastic-plastic finite element method, and the strain state and stress distribution are analyzed. Thus, a foundation is provided for optimizing the forming structure of Automotive Double-wall Curly Brazed Tubes.
The coordination control of key equipment action is studied, including confirming the whole production line's control scheme of Automotive Double-wall Curly Brazed Tubes, and designing the hardware platform and software of the information integrated control.
The study makes the enterprises to reform the production line and its manufacturing technique of Automotive Double-wall Curly Brazed Tubes, aiming at improving its manufacturing technology and enhancing the competition of enterprises.
引文
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[3]王德林.新型制动管—邦迪管[J].汽车与配件,1996,(3)：14.
[4]Bert L. Copper Coating and Welding Process. U S, Inventor 2092557[P]. Sept.7,1937.
[5]赵明修.双层卷焊管的生产[J].钢管,1994,(1)：10-17.
[6]刘承杰,于恩林,吴坚.双层卷焊管的生产研究[J].鞍钢技术,1994,(5)：42-44.
[7]Yu, EI Wu, J I Lai, M. Comprehensive Measurement of WDCT Machines. Iron and Steel [J]. Vol.27, no.5, pp.24-27. May 1992.
[8]何勇智.双层卷焊管在汽车制动硬管方面的应用及制动硬管的制造工艺[J].航天工艺,1997,(6)：37-39.
[9]于恩林,刘兴阁.双层卷焊管管筒层间紧密度的研究[J].力学与实践,1995,17(5)：28-30.
[10]杰夫·史沃滋.邦迪管[J].汽车与配件,1991,(1)：80-82.
[11]程循刚.汽车制动管及燃料管的工艺处理[J].天津汽车,2002,(2)：30-32.
[12]徐飞.邦迪管用高精密冷轧钢带的生产特点[J].轧钢,1994,(1)：30-35.
[13]张伯勋,郭斌.双层铜钎焊管用冷轧薄钢带的研制[J].钢铁研究,1995,(2)：30-35.
[14]王军杰,蒋劲茂,彭颖红等.ERW焊管辊弯成型过程的动态仿真研究[J].塑料工程学报,2007,14(5)：23-26.
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[16]于恩林,赖明道,吴坚.双层卷焊管成型质量的理论分析及实验研究[J].钢铁,1996,31(1)：40-44.
[17]杨宾峰.脉冲涡流无损检测若干关键技术研究[D].北京：国防科技大学.2006,10.
[18]邵泽波.无损检测技术[M].北京：化学工业出版社.2003,1.
[19]王广丰,钟海娜.发展中的涡流无损检测技术[J].煤矿机械,2005,(7)：7-8.
[20]刘宝,徐彦霖,王增勇.涡流检测技术及进展[J].测控技术,2006,25(3)：80-82.
[21]B. A. Auld,J. C. Moulder. Review of Advances in Quantitative Eddy Current Nondestructive Evaluation[J]. Journal of Nondestructive Evaluation,1999,18(1).
[22]Brunet M,Mguil S,Pol P. Modeling of a roll2forming process wit h a combined 2D and 3D FEM code[J].Journal of Material Processing Technology,1998,(80-81):213-219.
[23]Naksoo Kim,Byungseok Kang,Seungyoo n Lee. Prediction and design of edge shape of initial-strip for thick tube roll forming using finite element method[J].Journal of Material Processing Technology,2003,142:479-486.
[24]Jinmao Jiang,Dayong Li,Yinghong Peng,Jianxin Li. Research on strip deformation in the cage roll-forming process of ERW round pipes[J]. Journal of Materials Processing Technology,209(2009)4850-4856.
[25]李大永,蒋劲茂,彭颖红,尹纪龙.辊弯成形过程仿真与参数优化[J].系统仿真学报,2007,19(4)：893-896.
[26]牛洪军.直缝焊管成型新方法与轧辊设计的研究[D].天津：天津理工大学,2006,12.
[27]于恩林.双层卷焊管的成型理论及实践研究[D].燕山：燕山大学,1990,06：5-6.
[28]孙凤文.一次成型四层卷焊管的成型理论及试验研究[D].燕山：燕山大学.1999,06.
[29]Yu Enlin et al. Quality Control in forming double wall brazed tube[J],Tube International, 1995,No.l.
[30]李云江.奇数多层卷焊管试验及理论研究[D].燕山：燕山大学,1992,06.
[31]赖明道,于恩林,吴学礼等.焊管机组的研究与进展[M].北京：国防工业出版社,2006,10.
[32]唐鼎,李大永,彭颖红.芯棒形式对铜管绕弯成形质量影响的仿真研究[J].中国机械工程增刊,2006,(17)：80-82.
[33]睿驰达咨询.2010年中国汽车油管总成产业研究及展望[EB/OL]. [2009-04-05].http://www.cndata100.com/show/1/101518.html.
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[35]米俊如.双层卷焊管连续焊接工艺与设备[J].焊管,1994,(1)：28-30.
[36]于恩林,赖明道,吴坚.双层卷焊管定径辊减壁区轧制压力及芯棒轴向力的研究[J].钢管,1991,(5)：31-36.
[37]周湛通.双层卷焊管焊接过程神经网络自适应控制方法研究[D].河北：河北科技大学,2009,5.
[38]陶军.轧辊自动涡流探伤系统的研制[D].上海：上海交通大学,2008,09.
[39]谢永生,李永生.金属塑性成形的有限元模拟技术及应用[M].北京：科学出版社,2008.
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