大直径管线钢管的U成形工艺研究
摘要
管线钢管UOE成形工艺是目前国际上广泛采用的大直径直缝埋弧焊管成形工艺之一。UOE成形过程是一个复杂的变形过程,涉及的工艺路线长,工艺参数和模具结构参数多,各种参数对最终的质量影响各不相同。其中U成形过程是一个典型的中间过程,也是唯一一个两次成形的工序,对其进行理论分析、有限元模拟和工艺参数分析对消化吸收国外技术,优化工艺参数和提高制品质量有重要意义。
本文对UOE成形工艺过程及其国内外的发展和研究情况进行了阐述。论文对U成形过程进行理论分析,并根据现行成形工艺推导了垂直方向和水平方向的弯曲力及模具行程计算公式,近似给出弯曲回弹的表示方法。
针对UOE成形过程,在有限元分析软件MARC平台上,基于研究小组开发的大直径管线钢管UOE成形工艺过程的连续仿真模型,对不同规格的管线钢管的U成形过程进行了数值模拟,分析了U成形过程的变形特点,应力应变分布规律。
U成形的工艺参数主要有:弯曲凸模工作行程Su、水平辊工作行程Ss和左右水平辊间距Ds。这些参数不仅对中间毛坯形状有所影响,而且对成形载荷也有一定程度的影响。论文通过有限元数值模拟,详细分析了这些工艺参数对中间毛坯的几何形状以及成形载荷的影响,为整体工艺的参数优化奠定了基础。
UOE line-pipe forming process is one of the widely used processes internationally in large-diameter LSAW pipe forming.UOE forming process is a complex deformation process involving a long line of technology, many process parameters and mold structure parameters, and various parameters impact the quality of the ultimate pipe differently. In the forming process, U-forming is a typical intermediate process, and also the only process with two forming processes, their theoretical analysis, finite element modeling and analysis of process parameters is very important to help people digesting and absorbing foreign technology, optimizing the process parameters and improving the quality of products.
The development of UOE forming process and its studies at home and abroad is described. The theoretical analysis of U-forming process was done in this paper, and according to the current forming process, the bending formula at the vertical and horizontal direction is derived, as well as the expression method about the rebound analogously.
For the process of UOE, with the MARC finite element analysis software platform, basing on the continuous simulation model of UOE forming process, the process of the U-forming for different steel pipe is stimulated, the deformation characteristics of U-forming process and distribution of the stress and strain is analysed.
The main parameters of U-forming process including the work stroke of U-punch: Su、the work stroke of: Ss and the spacing of the two level-rollers: Ds. These parameters not only have an impact on the shape of intermediate rough, but also on the forming load to a certain extent. In the article, through the finite element numerical simulation, the process parameters’impact on the geometry and forming load of intermediate rough are analyzed which laid the foundation of parameter optimization of the overall process.
本文对UOE成形工艺过程及其国内外的发展和研究情况进行了阐述。论文对U成形过程进行理论分析,并根据现行成形工艺推导了垂直方向和水平方向的弯曲力及模具行程计算公式,近似给出弯曲回弹的表示方法。
针对UOE成形过程,在有限元分析软件MARC平台上,基于研究小组开发的大直径管线钢管UOE成形工艺过程的连续仿真模型,对不同规格的管线钢管的U成形过程进行了数值模拟,分析了U成形过程的变形特点,应力应变分布规律。
U成形的工艺参数主要有:弯曲凸模工作行程Su、水平辊工作行程Ss和左右水平辊间距Ds。这些参数不仅对中间毛坯形状有所影响,而且对成形载荷也有一定程度的影响。论文通过有限元数值模拟,详细分析了这些工艺参数对中间毛坯的几何形状以及成形载荷的影响,为整体工艺的参数优化奠定了基础。
UOE line-pipe forming process is one of the widely used processes internationally in large-diameter LSAW pipe forming.UOE forming process is a complex deformation process involving a long line of technology, many process parameters and mold structure parameters, and various parameters impact the quality of the ultimate pipe differently. In the forming process, U-forming is a typical intermediate process, and also the only process with two forming processes, their theoretical analysis, finite element modeling and analysis of process parameters is very important to help people digesting and absorbing foreign technology, optimizing the process parameters and improving the quality of products.
The development of UOE forming process and its studies at home and abroad is described. The theoretical analysis of U-forming process was done in this paper, and according to the current forming process, the bending formula at the vertical and horizontal direction is derived, as well as the expression method about the rebound analogously.
For the process of UOE, with the MARC finite element analysis software platform, basing on the continuous simulation model of UOE forming process, the process of the U-forming for different steel pipe is stimulated, the deformation characteristics of U-forming process and distribution of the stress and strain is analysed.
The main parameters of U-forming process including the work stroke of U-punch: Su、the work stroke of: Ss and the spacing of the two level-rollers: Ds. These parameters not only have an impact on the shape of intermediate rough, but also on the forming load to a certain extent. In the article, through the finite element numerical simulation, the process parameters’impact on the geometry and forming load of intermediate rough are analyzed which laid the foundation of parameter optimization of the overall process.
引文
1郭宝锋,金淼,任运来,等.大口径直缝焊管UOE成形技术及发展策略.锻压技术, 2000, 25(3):22-25
2朝日均(日).超高强度管线钢管X120的开发.鞍钢技术, 2006, 2: 57-61
3陈宝林.我国建设直缝埋弧焊管机组的前景.钢管, 2000, 29(2): 5-9
4潘家华.我国管道钢管的发展方向.焊管, 1998, 21(4): 16-20, 27
5严圣样.我国应发展大口径直缝焊管技术[J].钢铁, 2001, 36(5): 73-7
6肖冶,李卡.对发展直缝埋弧焊管机组的建议.焊管, 1995, 18(2): 4-7
7李国栋,张浩.大口径直缝焊管的排辊成型工艺[J].钢管, 2002, 31(2): 43–49
8黄克坚,刘京雷,阮锋. UOE成形工艺在大直缝焊接钢管生产中的应用.锻压技术, 2006, 1: 18-21
9张远生,李延丰.大口径直缝埋弧焊钢管生产线简介.焊管, 2001, 24 (6)2: 35-37
10孙瑞华. UOE焊管生产及其现状[J].焊管, 2000, 23(5): 24-39
11杨秀琴.我国钢管工业的现状、问题与发展前景(上).钢管, 2008, 37(1): 12-17
12金淼,郭宝锋,任运来,等.大口径管线钢管机械扩径工艺实验研究.锻压技术, 2001, 26(3): 44-46
13王三云.国外大口径直缝埋弧焊管生产技术发展概况.焊管, 2000, 23(6): 50-58
14肖曙红,郑时雄.大口径直缝焊管机械扩径成形机理研究.锻压装备与制造技术, 2004, 39(5): 81-84
15段志伟,仝天永.钢管机械扩径工艺研究.锻压技术, 2003,28(1): 44-44, 47
16 M.D.HERYNK, S.KYRIAKIDES, A.ONOUFRIOU,H.D.Yun. Effects of the UOE/UOC Pipe Manufacturing Processeson PipeCollapse Pressure[J]. International Journal of Mechanical Sciences, 2007(49): 533-553
17吴坚. UOE成型大直径直缝焊管生产.钢管, 2000, 29(5): 13-16
18王啸修,王小宝.大口径直缝埋弧焊管工程评析.世界钢铁, 2006, (6): 28-31
19 J. Afaganis Alex, R. Barnes Keith, E. Hanson George. Development and Production of Large Diameter, High Toughness Gr.550(X80) Linepipe at Stelco. Mechanical Working and Steel Processing Conference. Indianapolis. 1997, 10: 535-544
20 Ishikawa Nobuyuki, Endo Shigeru, Kondo Joe. High performance UOE Line pipe. JFE Technical Report. 2006, (1): 20-26
21近藤丈. TLPテザー用高強度厚肉UOE鋼管. NKK技報, 1991,№134: 51-60
22長江守康.ごみ輸送用耐摩耗鋼管. NKK技報, 1993,№144: 40-47
23 Duren, Niederhoff K. Recommended procedure for girth welding of large diameter pipes. [J][M]. Europipe. 1990, (1): 1-6
24 Chaudhary V. German ges pipeline first to use new generation linepipe. Oil & Gas, Jan,1995, (1): 45-60
25 Katsumi Kawada, Yasuhisa Tozawa, Hideo Koyama. An Analysis for Optimum Condition in C-U-O-E Forming Method.塑性与加工, 1984, (25): 1014-1020
26 HUANG Y M, LCU D K. An elasto-plastic finite-element simulation of successive UO-bending processes of sheet metal. J Mater Proc Tech, 1995, 53: 643-661
27 YASUHISA T, KATSUMI K. Effect of the diameter of U-forming punch on the deformation process in forming of tube.塑性と加工, 1972, 13(134): 171-177
28技術研究所,福山製鉄所. UOE造管方式による厚肉鋼管.日本鋼管技報, 1979,№80: 89-94
29刘京雷,谢仕强,阮锋.弯曲回弹逆解公式及其在焊管预弯机组设计中的应用.锻压技术, 2005, (2): 36-43
30刘京雷,黄克坚,阮锋.预弯工艺参数UOE焊管O成形的影响.塑性工程学报, 2005, 12(3): 71-75
31刘京雷,黄克坚,阮锋.大口径直缝焊管O成形过程的有限元分析.材料科学与工艺, 2007, 15(5): 693-396
32郭宝锋,聂绍珉,金淼.扩径力与扩径行程的主要影响因素和计算方法.塑性工程学报, 2002, 9(3): 31-34
33郭宝锋,聂绍珉,金淼,等.管筒形件的机械扩径成形条件.中国有色金属学报, 2002, 12(6): 1149-1153
34郭宝峰,金淼,吴生富,等.扩径率和重叠量对机械扩径制品品质的影响.中国机械工程, 2004, 15(12): 1111-1114
35 Guo Baofeng, Jin Miao, Nie Shaomin, et al. Deformation characteristics of mechanical expanding thin-walled cylindrical parts. Trans. Nonferrous Met. Soc. China, 2003, 13(6): 1342-1347
36郭宝峰,王建新,贾薇,等.模具扇形角对机械扩径成形过程的影响.塑性工程学报, 2002, 9(1): 59-61
37郭宝峰,贾薇,聂绍珉,等.扩径模具直径对成形件品质的影响.塑性工程学报, 2003, 10(4): 52-57
38郭宝峰,吴生富,聂绍珉,等.扩径模具形状参数对制品质量的影响.塑性工程学报, 2004, 11(1): 46-51
39郭宝峰,金淼,李群,等.筒形零件在机械扩径过程中的回弹预测方法.塑性工程学报, 2006, 13(1): 8-12
40郭宝峰.管线钢管机械扩径工艺的数值模拟与实验研究. [燕山大学博士学位论文]. 2001,9:25-46
41周维海,宋清玉,王忠玉,等. UOE大直径直缝埋弧焊管U成形回弹量分析.重型机械. 2002(3): 51-54
42陈昌,王利树,刘世泽,等.我国首条UOE焊管机组的引进、应用及其意义.中国国际钢管研讨会论文集, 2004(5): 445-446
43李长穆.现在钢管生产.北京:冶金工业出版社, 1982: 24-27
44曾攀.有限元分析及应用.北京:清华大学出版社, 2004: 1-5
45梁清香,张根全.有限元与MARC实现.北京:机械工业出版社, 2003: 58-99
46嘉木工作室. ANSYS5.7有限元实例分析教程.北京:机械工业出版社, 2002: 2-4
47 E.Harpell, C.Lamontagne, M.J.Worswick, P.Martin,M.Finn,&C.Galbraith.Deep drawing and stretching of Al 5754 sheet LS-DYNA3D simulation and validation.In:Proceedings of the 3rd International Conference:NUMISHEET’96 Numerical Simulation of 3-d SheetForming PROCESSES-Verification of Simulations with Experiments, J.K.Lee, Kinzel, &R.H.Wagoner(eds.), 2005: 386~393
48 MARC-CDC. General purpose finite element analysis program. MARC analysis. Corp. Providence RI, 1990: 196~202
49陈火红. Marc有限元实例分析教程.北京:机械工业出版社, 2002, 4: 255-276
50李生智.金属压力加工概论.北京:冶金工业出版社. 1984: 1-27. 148-155
51 Katsumi kawada, Yasuhusa Tozawa. Effects of mechanical properties of the materials on the forming of tube [J]. Journal of JSTP, 1979, 20(219): 299~306
52 Kyriakides S, Corona E, Fischer FJ. On the effect of the UOE manufacturing process on the collapse pressure of long tubes. ASMEJournal of Engineering for Industry, 1994, 11: 93-100
53 Katsumi KAWADA, Yasuhisa TOZAWA. Effects of Mechanical Properties of the Materials on the Forming of Tube[J]. Journal of JSTP. 1979,20(219): 299～306
2朝日均(日).超高强度管线钢管X120的开发.鞍钢技术, 2006, 2: 57-61
3陈宝林.我国建设直缝埋弧焊管机组的前景.钢管, 2000, 29(2): 5-9
4潘家华.我国管道钢管的发展方向.焊管, 1998, 21(4): 16-20, 27
5严圣样.我国应发展大口径直缝焊管技术[J].钢铁, 2001, 36(5): 73-7
6肖冶,李卡.对发展直缝埋弧焊管机组的建议.焊管, 1995, 18(2): 4-7
7李国栋,张浩.大口径直缝焊管的排辊成型工艺[J].钢管, 2002, 31(2): 43–49
8黄克坚,刘京雷,阮锋. UOE成形工艺在大直缝焊接钢管生产中的应用.锻压技术, 2006, 1: 18-21
9张远生,李延丰.大口径直缝埋弧焊钢管生产线简介.焊管, 2001, 24 (6)2: 35-37
10孙瑞华. UOE焊管生产及其现状[J].焊管, 2000, 23(5): 24-39
11杨秀琴.我国钢管工业的现状、问题与发展前景(上).钢管, 2008, 37(1): 12-17
12金淼,郭宝锋,任运来,等.大口径管线钢管机械扩径工艺实验研究.锻压技术, 2001, 26(3): 44-46
13王三云.国外大口径直缝埋弧焊管生产技术发展概况.焊管, 2000, 23(6): 50-58
14肖曙红,郑时雄.大口径直缝焊管机械扩径成形机理研究.锻压装备与制造技术, 2004, 39(5): 81-84
15段志伟,仝天永.钢管机械扩径工艺研究.锻压技术, 2003,28(1): 44-44, 47
16 M.D.HERYNK, S.KYRIAKIDES, A.ONOUFRIOU,H.D.Yun. Effects of the UOE/UOC Pipe Manufacturing Processeson PipeCollapse Pressure[J]. International Journal of Mechanical Sciences, 2007(49): 533-553
17吴坚. UOE成型大直径直缝焊管生产.钢管, 2000, 29(5): 13-16
18王啸修,王小宝.大口径直缝埋弧焊管工程评析.世界钢铁, 2006, (6): 28-31
19 J. Afaganis Alex, R. Barnes Keith, E. Hanson George. Development and Production of Large Diameter, High Toughness Gr.550(X80) Linepipe at Stelco. Mechanical Working and Steel Processing Conference. Indianapolis. 1997, 10: 535-544
20 Ishikawa Nobuyuki, Endo Shigeru, Kondo Joe. High performance UOE Line pipe. JFE Technical Report. 2006, (1): 20-26
21近藤丈. TLPテザー用高強度厚肉UOE鋼管. NKK技報, 1991,№134: 51-60
22長江守康.ごみ輸送用耐摩耗鋼管. NKK技報, 1993,№144: 40-47
23 Duren, Niederhoff K. Recommended procedure for girth welding of large diameter pipes. [J][M]. Europipe. 1990, (1): 1-6
24 Chaudhary V. German ges pipeline first to use new generation linepipe. Oil & Gas, Jan,1995, (1): 45-60
25 Katsumi Kawada, Yasuhisa Tozawa, Hideo Koyama. An Analysis for Optimum Condition in C-U-O-E Forming Method.塑性与加工, 1984, (25): 1014-1020
26 HUANG Y M, LCU D K. An elasto-plastic finite-element simulation of successive UO-bending processes of sheet metal. J Mater Proc Tech, 1995, 53: 643-661
27 YASUHISA T, KATSUMI K. Effect of the diameter of U-forming punch on the deformation process in forming of tube.塑性と加工, 1972, 13(134): 171-177
28技術研究所,福山製鉄所. UOE造管方式による厚肉鋼管.日本鋼管技報, 1979,№80: 89-94
29刘京雷,谢仕强,阮锋.弯曲回弹逆解公式及其在焊管预弯机组设计中的应用.锻压技术, 2005, (2): 36-43
30刘京雷,黄克坚,阮锋.预弯工艺参数UOE焊管O成形的影响.塑性工程学报, 2005, 12(3): 71-75
31刘京雷,黄克坚,阮锋.大口径直缝焊管O成形过程的有限元分析.材料科学与工艺, 2007, 15(5): 693-396
32郭宝锋,聂绍珉,金淼.扩径力与扩径行程的主要影响因素和计算方法.塑性工程学报, 2002, 9(3): 31-34
33郭宝锋,聂绍珉,金淼,等.管筒形件的机械扩径成形条件.中国有色金属学报, 2002, 12(6): 1149-1153
34郭宝峰,金淼,吴生富,等.扩径率和重叠量对机械扩径制品品质的影响.中国机械工程, 2004, 15(12): 1111-1114
35 Guo Baofeng, Jin Miao, Nie Shaomin, et al. Deformation characteristics of mechanical expanding thin-walled cylindrical parts. Trans. Nonferrous Met. Soc. China, 2003, 13(6): 1342-1347
36郭宝峰,王建新,贾薇,等.模具扇形角对机械扩径成形过程的影响.塑性工程学报, 2002, 9(1): 59-61
37郭宝峰,贾薇,聂绍珉,等.扩径模具直径对成形件品质的影响.塑性工程学报, 2003, 10(4): 52-57
38郭宝峰,吴生富,聂绍珉,等.扩径模具形状参数对制品质量的影响.塑性工程学报, 2004, 11(1): 46-51
39郭宝峰,金淼,李群,等.筒形零件在机械扩径过程中的回弹预测方法.塑性工程学报, 2006, 13(1): 8-12
40郭宝峰.管线钢管机械扩径工艺的数值模拟与实验研究. [燕山大学博士学位论文]. 2001,9:25-46
41周维海,宋清玉,王忠玉,等. UOE大直径直缝埋弧焊管U成形回弹量分析.重型机械. 2002(3): 51-54
42陈昌,王利树,刘世泽,等.我国首条UOE焊管机组的引进、应用及其意义.中国国际钢管研讨会论文集, 2004(5): 445-446
43李长穆.现在钢管生产.北京:冶金工业出版社, 1982: 24-27
44曾攀.有限元分析及应用.北京:清华大学出版社, 2004: 1-5
45梁清香,张根全.有限元与MARC实现.北京:机械工业出版社, 2003: 58-99
46嘉木工作室. ANSYS5.7有限元实例分析教程.北京:机械工业出版社, 2002: 2-4
47 E.Harpell, C.Lamontagne, M.J.Worswick, P.Martin,M.Finn,&C.Galbraith.Deep drawing and stretching of Al 5754 sheet LS-DYNA3D simulation and validation.In:Proceedings of the 3rd International Conference:NUMISHEET’96 Numerical Simulation of 3-d SheetForming PROCESSES-Verification of Simulations with Experiments, J.K.Lee, Kinzel, &R.H.Wagoner(eds.), 2005: 386~393
48 MARC-CDC. General purpose finite element analysis program. MARC analysis. Corp. Providence RI, 1990: 196~202
49陈火红. Marc有限元实例分析教程.北京:机械工业出版社, 2002, 4: 255-276
50李生智.金属压力加工概论.北京:冶金工业出版社. 1984: 1-27. 148-155
51 Katsumi kawada, Yasuhusa Tozawa. Effects of mechanical properties of the materials on the forming of tube [J]. Journal of JSTP, 1979, 20(219): 299~306
52 Kyriakides S, Corona E, Fischer FJ. On the effect of the UOE manufacturing process on the collapse pressure of long tubes. ASMEJournal of Engineering for Industry, 1994, 11: 93-100
53 Katsumi KAWADA, Yasuhisa TOZAWA. Effects of Mechanical Properties of the Materials on the Forming of Tube[J]. Journal of JSTP. 1979,20(219): 299～306