Quality control on crimping of large diameter welding pipe
Quality control on crimping of large diameter welding pipe
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DOI：
10.3901/cjme.2012.06.1264
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发表时间：
2012-10
影响因子：
4.2
通讯作者：
Li-feng Fan;Ying Gao;Qiang Li;Hongshen Xu
中科院分区：
文献类型：
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作者：
Li-feng Fan;Ying Gao;Qiang Li;Hongshen Xu
大口径埋弧焊管生产中采用压接工艺。针对某一焊管制造模式下的卷曲问题进行了大量的研究。由于理论分析缺乏统一性，使得研究成果的应用范围受到限制。为了提出卷曲预测方法以控制成形质量，建立了基于弹塑性力学的卷曲理论模型。通过理论分析，确定了卷边长度、凸模底面半径、凸模端面角度、凹模底面半径、凹模端面角度、凸模水平距离等主要工艺参数。此外，还提出了一种评价成形质量的方法，即考察回弹后的弯曲角、成形力、直边长度和当量曲率半径。为了研究工艺参数对成形质量的影响，利用有限元软件ABAQUS建立了二维有限元模型。通过对比实验验证了有限元模型的形状误差小于5%，表明其几何精度满足要求。通过模拟分析，得到了成形过程中的应力应变分布、成形力变化等卷曲特性，并给出了工艺参数与成形质量的关系曲线。敏感度分析表明，卷曲长度、凸模工艺参数对成形质量的影响显著。利用响应面方法(RSM)对模拟分析的数据进行回归，建立预测模型。从预测模型中得到了可行的工艺参数。该方法为卷曲成形工艺参数设计提供了一种新的思路，为提高卷曲成形质量奠定了基础。
Crimping is used in production of large diameter submerged-arc welding pipes. Many researches are focused on crimping in certain manufacturing mode of welding pipe. The application scopes of research achievements become limited due to lack of uniformity in theoretical analysis. In order to propose a crimping prediction method in order to control forming quality, the theory model of crimping based on elastic-plastic mechanics is established. The main technical parameters are determined by theoretical analysis, including length of crimping, base radius of punch, terminal angle of punch, base radius of die, terminal angle of die and horizontal distance between punch and die. In addition, a method used to evaluate the forming quality is presented, which investigates the bending angle after springback, forming force, straight edge length and equivalent radius of curvature. In order to investigate the effects of technical parameters on forming quality, a two-dimensional finite element model is established by finite element software ABAQUS. The finite element model is verified in that its shapes error is less than 5% by comparable experiments, which shows that their geometric precision meets demand. The crimping characteristics is obtained, such as the distribution of stress and strain and the changes of forming force, and the relation curves of technical parameters on forming quality are given by simulation analysis. The sensitivity analysis indicates that the effects of length of crimping, technical parameters of punch on forming quality are significant. In particular, the data from simulation analysis are regressed by response surface method (RSM) to establish prediction model. The feasible technical parameters are obtained from the prediction model. This method presented provides a new thought used to design technical parameters of crimping forming and makes a basis for improving crimping forming quality.