多通管论文：基于弹性体的三通管复合胀形技术研究.docVIP

多通管论文：基于弹性体的三通管复合胀形技术研究 【中文摘要】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。 【英文摘要】As one kind of basis components in many medium and high pressure pipelines, multi-branch tubes are widely used in many fields. And the production of multi-branch tubes has been one of the most difficult processes. Method of welding, machining and casting once being the traditional and main methods, the production of multi-branch tubes has developed into the forming method. The bulging of multi-branch tubes is a non-chip finish process during which the radial expansion happens under pressure. It抯 a semi-fine/precision forming technology, and belongs to advanced manufacturing technology. In this paper, elastomer of rubber was chosen as bulging medium, and the forming of T-branch tube (which抯 a typical part of multi-branch tubes) was researched. The bulging process of multi-branch tubes has the characteristics of material nonlinearity, geometric nonlinearity and boundary nonlinearity. Whereas, non-linear explicit finite element analysis program ANSYS/LS-DYNA was selected as the numerical simulation platform, on which the forming processing parameters and loading path were optimized.Processing parameters optimization. Optimiz