摘要
在波纹管管坯生产过程中，由于受到材料成形极限的限制，大多数波纹管管坯不可能顺利地一次成形，还需要增添中间辅助工序，如热处理等。这就需要考虑各工序之间的相互联系和影响，合理设计工艺流程，合理选择模具参数和变形环境条件，尽量减少工序次数，提高生产效率，满足大批量生产的要求。
本文建立了多模变薄拉深过程的力学模型，对多模变薄拉深过程进行了详细分析。在多模变薄拉深过程中，变薄凹模数量、凹模半锥角、摩擦系数对变薄拉深工艺过程有重要影响。
实践证明，多模变薄拉深工艺可以充分发挥材料的塑性变形能力，使本需经过几次单模变薄拉深才能制成的管坯，一次即可完成。减少了中间工序，提高了生产效率。
本文分析了波纹管管坯壁厚不均匀产生的原因极其后果，采用措施以减少波纹管管坯壁厚不均匀程度。
本文提出单只管坯平均壁厚概念，描述整批波纹管管坯壁厚分散程度的概念：批平均值和对批平均值分散度。在波纹管管坯生产中，通过测量整批波纹管管坯的批平均值和对批平均值分散度，调整变薄拉深模具的尺寸，通过控制波纹管管坯壁厚的分散来保证整批波纹管刚度的一致性。
通过分析波纹管管坯壁厚精度与其刚度之间的对应关系，探讨了管坯壁厚精度对波纹管刚度一致性的影响，为确定波纹管管坯壁厚精度提供理论依据。
由于温度控制器用波纹管的管坯壁厚仅0.1mm，且长度为54mm，属于超薄壁、小直径超长筒形件，其壁厚精度要求高，加工难度大，生产批量大，所以选其作为本研究项目的对象。
设计出一种新型卸料装置。在多模变薄拉深过程中，避免了管坯外表面划伤，使管坯顺利的从凸模上退下，保证生产顺利运行。
本文在对多模变薄拉深变形过程进行分析的基础上，将多模变薄拉深工艺技术应用于波纹管管坯大批量生产中，提高了我国波纹管管坯的生产技术水平。
提出的管坯壁厚精度概念极其控制方法具有普遍性，对于其它薄壁筒形件的制造工艺具有参考作用。
During the production of pipe material for bellows, the pipe can not be finished in just once of processing in most cases without adding auxiliary processes such as heating treatment due to the restriction of material malleability limit. Therefore some considerations become necessary, for example the relationship and the influence among the different production processes, rational design of production line, making the right choice bf moulding set parameter and environment conditions in order to reduce unnecessary procedures so that high efficiency of mass production can be achieved.
In this dissertation, a mechanics module is established for multi-die ironing process, of which, the analysis is also going to be discussed in details. It has been found that the ironing procedures are affected in big style by the factors like the quantity of ironing moulds, semi cone angle and friction factors.
Tests have showed that with this technology improvement the full use of material malleability can be made. This makes the ironing process being able to be completed in just one go which used to take several steps with single die ironing technology. The efficiency is therefore increased by the reduction of redundant middle processes.
This article has analysed the causes and the consequences of unevenness of wall thickness and recommended measures for corrections.
This article has also introduced the concept of average thickness of single pipe wall, the wall distribution degree of batch bellows pipe material, batch mean and the distribution of batch mean. By measuring batch mean of wall thickness of
the whole batch of bellows pipe and feeding back the information for the accuracy adjustment to ironing mould, the consistency of the rigidity of the whole batch bellows can be assured.
The thermal controller use bellows with the wall thickness of just 0.1mm and the length up to 54mm, which falls into the category of super thin, super slim and super long tube like products, has been chosen as the target of the research project because of the requirement of high degree of accuracy, the difficulty of deformation process and the wide usefulness of its products in industry.
A new unloading apparatus is going to be designed so. that die tube material can be smoothly unloaded from ironing mould without having the tube surface scratched during the multi-die ironing process.
Further to the analysis of multi-die ironing process, this research is trying to apply the successful engineering system to mass production of bellows material with the purpose of technology improvement for bellows production in our country.
This article has also discussed the influence of wall thickness of the bellows for temperature controller on the coincidence with the rigidity based on the analysis of the relationship between bellows wall thickness and its rigidity, which provide a theory foundation for determining the accuracy of bellows wall thickness.
The introduction of the concept of bellows wall thickness accuracy has the universal significance and reference value for manufacturing technology of other thin wall tube like products.
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