基于弹性体的三通管复合胀形技术研究
发布时间：2018-11-03 20:40
【摘要】：多通管在工业领域应用广泛,是各种中高压管路系统中必不可少的基础元件之一,而多通管的生产却一直是最困难的工艺之一。多通管的生产,已逐渐由传统的焊接、机加工和铸造等方法,过渡到胀形成形方法。多通管胀形是在压力作用下使管材沿径向扩张的成形工艺,是一种少无切削加工,半精/精成形技术,属于先进制造技术范畴。本文以三通管为典型零件,对以橡胶弹性体为胀形介质的多通管胀形工艺进行研究。由于多通管胀形过程既包含材料非线性,又有几何非线性和边界非线性的特点,选取非线性显式有限元分析程序ANSYS/LS-DYNA为数值模拟平台,对成形工艺参数和加载路径进行优化。 工艺参数优化。管坯参数优化:建立三通管胀形有限元模型,结合正交设计的思想获取训练、测试样本;采用Elman人工神经网络构建管坯料参数预测模型,以管坯长度、管坯壁厚和模具过渡圆角半径为网络输入参数,壁厚增减量不超过30%时的最大支管长度为输出参数;在MATLAB软件平台上完成预测网络的建立、训练、测试和管坯参数预测优化,得到圆角半径R=7 mm,壁厚t=1.5 mm,长度l0=100 mm的坯料参数。分析摩擦对成形影响:对管坯与模具摩擦系数μ1、橡胶棒与管坯摩擦系数μ2进行方案设计,引入评价函数并结合橡胶寿命考虑,得到最优组合μ1 = 0.1,μ2 = 0.35。 复合胀形加载路径优化。对复合胀形反压的施加方式和加载路径进行了设计。对轴向加压胀形时支管高度随时间变化进行线性简化,选择反压冲头与支管开始接触时高度h0和反压冲头移动速度V3代替反压F3的施加,确定了h0 = 6 mm、反压冲压速度V3与轴向挤压冲头V1的速度比值V3/V1 = 1,轴压冲头小端长度l1 = 5mm的复合胀形方案,并得到较理想支管长度的三通管件。通过三通管轴向加压和复合胀形的壁厚分析、应变应力分析及支长度分析,表明复合胀形管件壁厚减薄更缓慢,壁厚分布更均匀,最终得到更大的支管长度,验证了复合胀形工艺的优越性。
[Abstract]:Multi-way pipe is widely used in industrial field and is one of the essential basic components in various medium-high pressure pipeline systems, but the production of multiway pipe has been one of the most difficult processes. The production of multiway pipe has gradually changed from traditional welding, machining and casting to bulging forming method. Multipass tube bulging is a kind of forming technology which makes the tube expand along the radial direction under the action of pressure. It is a kind of less cutting and semi-fine / fine forming technology, which belongs to the advanced manufacturing technology category. In this paper, the bulging process of multipass tube with rubber elastomer as bulging medium is studied. Because the bulging process of multichannel tube includes material nonlinearity, geometric nonlinearity and boundary nonlinearity, the nonlinear explicit finite element analysis program ANSYS/LS-DYNA is chosen as the numerical simulation platform. The process parameters and loading path are optimized. Optimization of process parameters. Optimization of tube billet parameters: the finite element model of tube bulging was established, and the training and test samples were obtained based on the idea of orthogonal design. The Elman artificial neural network is used to build the prediction model of pipe billet parameters. The network input parameters are the length of the billet, the wall thickness of the billet and the radius of the transition corner of the die, and the maximum length of the branch pipe when the increase or decrease of the wall thickness is not more than 30 is the output parameter. The prediction network was established, trained, tested and optimized on the platform of MATLAB software, and the billet parameters of r-7 mm, wall thickness t _ (1.5) mm, ~ (-1) mm, ~ (100) mm were obtained. The influence of friction on forming was analyzed. The scheme design of friction coefficient 渭 1 between tube and die and friction coefficient 渭 2 between rubber rod and tube blank was carried out. The optimum combination 渭 1 = 0.1, 渭 2 = 0.35 was obtained by introducing evaluation function and considering rubber life. Compound bulging loading path optimization. The application mode and loading path of compound bulging back pressure are designed. The variation of branch height with time during axial pressure bulging is linear simplified. The height h _ 0 and the moving speed V _ 3 of the back pressure punch are chosen to replace the applied of the back pressure F _ 3 when the back pressure punch and the branch pipe are in contact with the branch tube, and the H _ 0 = 6 mm, is determined. The ratio of the velocity of V3 to V1 of the axial extrusion punch is V3/V1 = 1, the length of the small end of the axial press punch is 1 = 5mm, and the tri-way pipe fitting with ideal branch length is obtained. Through the wall thickness analysis, strain stress analysis and support length analysis of the axial compression and compound bulging of the three-way tube, it is shown that the wall thickness of the compound bulging tube is reduced more slowly, the distribution of the wall thickness is more uniform, and finally the larger branch length is obtained. The superiority of compound bulging process is verified.
【学位授予单位】：华侨大学
【学位级别】：硕士
【学位授予年份】：2011
【分类号】：TH136
本文编号：2308980
[Abstract]:Multi-way pipe is widely used in industrial field and is one of the essential basic components in various medium-high pressure pipeline systems, but the production of multiway pipe has been one of the most difficult processes. The production of multiway pipe has gradually changed from traditional welding, machining and casting to bulging forming method. Multipass tube bulging is a kind of forming technology which makes the tube expand along the radial direction under the action of pressure. It is a kind of less cutting and semi-fine / fine forming technology, which belongs to the advanced manufacturing technology category. In this paper, the bulging process of multipass tube with rubber elastomer as bulging medium is studied. Because the bulging process of multichannel tube includes material nonlinearity, geometric nonlinearity and boundary nonlinearity, the nonlinear explicit finite element analysis program ANSYS/LS-DYNA is chosen as the numerical simulation platform. The process parameters and loading path are optimized. Optimization of process parameters. Optimization of tube billet parameters: the finite element model of tube bulging was established, and the training and test samples were obtained based on the idea of orthogonal design. The Elman artificial neural network is used to build the prediction model of pipe billet parameters. The network input parameters are the length of the billet, the wall thickness of the billet and the radius of the transition corner of the die, and the maximum length of the branch pipe when the increase or decrease of the wall thickness is not more than 30 is the output parameter. The prediction network was established, trained, tested and optimized on the platform of MATLAB software, and the billet parameters of r-7 mm, wall thickness t _ (1.5) mm, ~ (-1) mm, ~ (100) mm were obtained. The influence of friction on forming was analyzed. The scheme design of friction coefficient 渭 1 between tube and die and friction coefficient 渭 2 between rubber rod and tube blank was carried out. The optimum combination 渭 1 = 0.1, 渭 2 = 0.35 was obtained by introducing evaluation function and considering rubber life. Compound bulging loading path optimization. The application mode and loading path of compound bulging back pressure are designed. The variation of branch height with time during axial pressure bulging is linear simplified. The height h _ 0 and the moving speed V _ 3 of the back pressure punch are chosen to replace the applied of the back pressure F _ 3 when the back pressure punch and the branch pipe are in contact with the branch tube, and the H _ 0 = 6 mm, is determined. The ratio of the velocity of V3 to V1 of the axial extrusion punch is V3/V1 = 1, the length of the small end of the axial press punch is 1 = 5mm, and the tri-way pipe fitting with ideal branch length is obtained. Through the wall thickness analysis, strain stress analysis and support length analysis of the axial compression and compound bulging of the three-way tube, it is shown that the wall thickness of the compound bulging tube is reduced more slowly, the distribution of the wall thickness is more uniform, and finally the larger branch length is obtained. The superiority of compound bulging process is verified.
【学位授予单位】：华侨大学
【学位级别】：硕士
【学位授予年份】：2011
【分类号】：TH136
【引证文献】
相关期刊论文 前1条
1 王玲;付冬雪;郎利辉;王少华;杨春雷;;大比例三通接头成形工艺研究及质量控制[J];锻压技术;2013年02期
，本文编号：2308980
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