CN109772970B - A high-pressure one-step forming method for large deformation bellows - Google Patents
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Abstract
本发明公开了一种大变形波纹管内高压一次成形方法，包括以下步骤：（1）判断所需成形的波纹管属于大变形还是小变形；（2）波纹管毛坯尺寸计算；（3）根据波纹管的结构尺寸和管材毛坯尺寸，设计大变形波纹管内高压一次成形模具，包括左半凹模、右半凹模、左推块、右推块和内高压介质；（4）多模联动内高压一次成形；（5）卸压、开模、取件；所述的多模联动内高压一次成形过程分成三个阶段连续执行：1）第一阶段初波成形；2）第二阶段波纹成形；3）第三阶段整形。本发明提出的大变形波纹管内高压一次成形方法，能够一次成形大变形、大构件、薄壁波纹管；简化了成形工艺，提高了生产效率，降低了生产成本。
The invention discloses a high-pressure one-time forming method for a large deformation corrugated pipe, comprising the following steps: (1) judging whether the corrugated pipe to be formed belongs to a large deformation or a small deformation; (2) calculating the size of the corrugated pipe blank; (3) according to the corrugated pipe The structural size of the pipe and the size of the pipe blank, the high-pressure one-time forming die in the large-deformation bellows is designed, including the left half concave die, the right half concave die, the left push block, the right push block and the inner high pressure medium; (4) Multi-mode linkage internal high pressure One-time forming; (5) pressure relief, mold opening, and taking parts; the multi-mode linkage internal high-pressure one-time forming process is divided into three stages and continuously executed: 1) the first stage of primary wave forming; 2) the second stage of corrugated forming; 3) The third stage shaping. The high-pressure one-time forming method for a large-deformation bellows provided by the invention can form large-deformation, large components, and thin-walled bellows at one time; the forming process is simplified, the production efficiency is improved, and the production cost is reduced.
Description
Technical Field
The invention relates to an internal high-pressure forming method, in particular to a multi-mode linkage internal high-pressure one-step forming method for a large-deformation, large-component and thin-wall corrugated pipe.
Background
The corrugated pipe is a cylindrical thin-wall elastic shell with transverse corrugations, has special functions in the aspects of conversion, compensation, connection, energy storage and the like, and is widely applied to the fields of petroleum, chemical engineering, metallurgy, instruments and the like. Bellows are important pipe components in pressure vessels. The pressure vessel is subjected to a certain pressure inside or outside, and has a high requirement on safety. Maintaining the tightness of the equipment is very important because the pressure variation of the container due to air leakage or liquid leakage cannot occur in the process of bearing the pipeline system. The corrugated pipe of high temperature gas cooled reactor in nuclear pressure container is used to compensate the size change between the inner metal reactor member and the reactor pressure container caused by expansion with heat and contraction with cold, has high deformation resistance, can prevent helium in the space over the support plate and below the top cover of the reactor pressure container from participating in convective heat exchange, and has the advantages of high temperature resistance, high pressure resistance, large aperture, long service life, etc.
The internal high-pressure forming method has the advantages of simple forming die structure, simple and direct process, high product forming limit, good forming quality and the like, and has the characteristics of near-net forming, green manufacturing and the like, so the internal high-pressure forming method is widely applied to the field of light weight. The small deformation and the high pressure forming in the small component corrugated pipe are easy to form, and the forming quality is easy to control. When the corrugated pipe with large deformation, large components and thin walls is subjected to high-pressure forming, the deformation coefficient of the corrugated pipe to be formed is larger than the allowable elongation of the material due to the large size of the pipe, the deformation is large, and the internal stress of the pipe is large during plastic forming, so that the forming difficulty is very large. Meanwhile, the wall pipe is thin, the plastic flow of the material is not easy to control, the problems of wrinkling or cracking and the like are easy to occur, and the forming quality is not easy to control.
Disclosure of Invention
The invention aims to solve the problems that the pipe has large size and large deformation and the internal stress of the pipe is large during plastic forming and the forming difficulty is very large during high-pressure forming in a large-deformation, large-component and thin-wall corrugated pipe; and the forming quality of the thin-wall pipe is not easy to control, and the problems of wrinkling or cracking and the like are easy to occur, and the multi-mode linkage internal high-pressure one-step forming method capable of forming large deformation, large components and thin-wall corrugated pipes is provided.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a high-pressure one-step forming method in a large-deformation corrugated pipe comprises the following steps:
(1) shaped as desiredJudging whether the corrugated pipe to be formed belongs to large deformation or small deformation according to the structural size of the corrugated pipe, wherein the structural size comprises the maximum outer diameter D of the corrugated pipemaxAnd original outer diameter d of pipe0Calculating the deformation coefficient k and the actual elongation delta of the corrugated pipeA. Then the actual elongation delta is measuredAAllowable elongation delta to pipeTComparing the actual elongation deltaAGreater than the allowable elongation delta of the materialTIt belongs to large deformation; otherwise, the deformation is small; the small deformation can be formed at one time by adopting a conventional internal high-pressure forming method;
(2) calculating the size of a pipe blank of the corrugated pipe by means of three-dimensional modeling software according to the principle that the volume of the corrugated pipe is not changed before and after forming or the principle that the volume of a neutral layer of the corrugated pipe is not changed before and after forming;
(3) designing a high-pressure one-step forming die in the large-deformation corrugated pipe with a proper size according to the structural size of the corrugated pipe in the step 1) and the size of the pipe blank in the step 2), wherein the die comprises a left half female die (2), a right half female die (3), a left push block (4), a right push block (5) and an inner high-pressure medium (6);
(4) carrying out multi-mode linkage internal high-pressure one-step forming; the multi-mode linkage internal high-pressure one-step forming process is continuously executed in three stages;
(5) releasing pressure, opening the die and taking out the part; after the large-deformation corrugated pipe is formed by the internal high pressure, the internal pressure of an internal high-pressure medium (6) is unloaded, the left push block (4) and the right push block (5) are withdrawn, the left half female die (2) and the right half female die (3) are opened, and the large-deformation corrugated pipe is taken out;
the three stages are specifically:
1) first-stage primary wave forming; setting the forming time T as T1(ii) a The left push block (4) and the right push block (5) respectively move towards the center and displace by SpS (x); the inner high-pressure medium (6) exerts radial internal pressure P on the pipe1P (x); the left half female die (2) and the right half female die (3) are kept static; under the combined action of the axial pressure of the left push block (4) and the right push block (5) and the radial internal pressure of the internal high-pressure medium (6), the pipe is fed to the center in the axial direction and is plastically deformed to form a primary wave；
2) The second stage of corrugation forming; setting the forming time T as T2(ii) a The left half female die (2) and the right half female die (3) move towards the center respectively and displace Sd(ii) a The inner high-pressure medium (6) exerts radial inner pressure P on the pipe2P (x); the left push block (4) and the right push block (5) are kept static; the left half female die (2) and the right half female die (3) are matched to extrude the pipe, and the ripple is basically formed under the combined action of the radial internal pressure of the internal high-pressure medium (6);
3) shaping in a third stage; setting the forming time T as T3(ii) a The left half female die (2), the right half female die (3), the left push block (4) and the right push block (5) are kept static; the inner high-pressure medium exerts radial internal pressure P on the pipe3Shaping the corrugation to make the pipe completely cling to the concave mould, and forming the large-deformation corrugated pipe at one time under the internal high pressure.
The calculation formulas of the deformation coefficient of the corrugated pipe and the actual elongation of the corrugated pipe in the step (1) are respectively as follows:
k＝Dmax/d0 (5)
δA＝(Dmax-d0)/d0×100％ (6)
in the formula: k is the bellows deformation coefficient, deltaAActual elongation of the bellows, DmaxIs the maximum outer diameter of the bellows, d0Is the original outer diameter of the pipe.
The displacement S of the left push block (4) and the right push block (5) in the first stage in the step (4)pAdopting a broken line loading path:
in the formula: k is a radical ofs1And ks2Slopes of a first fold line and a second fold line, respectively, for a first stage displacement loading; x is time; bsIs the intercept of the second polyline of the first stage displacement loading.
The radial internal pressure P exerted on the pipe by the internal high-pressure medium (6) in the first stage in the step (4)1Adopting a broken line loading path:
in the formula: k is a radical ofp11And kp12Slopes of a first broken line and a second broken line respectively for first-stage pressure loading;
bpis the intercept of the first stage pressure loading second polyline.
The inner high-pressure medium (6) of the second stage in the step (4) exerts radial internal pressure P on the pipe2Adopting a broken line loading path:
in the formula: k is a radical ofp2Loading the slope of the first broken line for the second stage pressure; cp2Is a constant.
The internal high-pressure medium (6) of the third stage in the step (4) continues to apply radial internal pressure P to the pipe3Adopting a broken line loading path:
in the formula: k is a radical ofp3Loading the slope of the first broken line for the third stage pressure; cp3Is a constant.
And (4) respectively moving the left half female die (2) and the right half female die (3) in the second stage towards the center at a constant speed.
The internal high-pressure medium (6) is made of hydraulic oil or elastic rubber materials.
The invention has the beneficial effects that:
1) when large deformation, large components and thin-wall corrugated pipes are formed at internal high pressure, if the actual elongation is larger than the allowable elongation of the material, multi-pass internal high-pressure forming is needed, the problems of design, matching, processing and the like of each pass are involved, and the forming cost and time are increased. In addition, certain special applications of corrugated tubing do not allow for multiple pass formation. The high-pressure one-step forming method in the large-deformation corrugated pipe can be used for forming large-deformation, large-component and thin-wall corrugated pipes at one step at high pressure, simplifies the forming process, improves the production efficiency and reduces the production cost.
2) Because the thin-wall corrugated pipe is relatively small in thickness and the large-component corrugated pipe is high in corrugation height, materials are difficult to flow into a wave-shaped area during internal high-pressure forming, and therefore the problem of forming difficulty is caused. The invention adopts a staged material supplementing method: the first stage mainly pushes the pipe into the corrugated area through the left push block and the right push block for material supplement, and the second stage mainly pushes the primary wave into the corrugated area through the left half female die and the right half female die, so that the whole material supplement is completed.
3) The multi-mode linkage internal high-pressure one-step forming process is divided into three stages, and different radial internal pressures are set in each stage to apply pressure to the pipe. In the first stage, the left and right push blocks are mainly matched to feed the pipe to the corrugated area and form initial waves, so that a smaller pressure value is adopted. In the second stage, the left half concave die and the right half concave die are mainly matched to push the primary waves into the ripple area, and basic ripples are formed. In the third stage, the pipe is basically formed, and a large internal pressure is needed to shape the corrugated pipe so that the pipe is completely attached to the die.
Drawings
FIG. 1 is a flow chart of a high-pressure one-step forming method in a large-deformation corrugated pipe according to the invention;
FIG. 2 is a schematic structural diagram of a large deformation bellows according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a first stage of high-pressure one-shot forming in a multi-mode linkage of a large deformation bellows according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a second stage of high-pressure primary forming in the multi-mold linkage of a large deformation corrugated pipe in the embodiment of the present invention;
fig. 5 is a third stage schematic diagram of high-pressure one-step forming in the multi-mold linkage of the large-deformation corrugated pipe in the embodiment of the invention.
Detailed Description
The invention further discloses a high-pressure one-step forming method in a large-deformation corrugated pipe, which comprises the following specific operation steps:
and (1) judging whether the corrugated pipe 1 required to be formed is large deformation or small deformation. According to the structural size of the large-deformation corrugated pipe to be formed, as shown in figure 2, the maximum outer diameter D of the corrugated pipemax1293mm, original external diameter d of pipe0945mm thick, 16.2mm thick and a corrugation pitch Sb320 mm. According to equation (6), the actual elongation of the bellows is calculated as:
δA＝(Dmax-d0)/d0×100％＝(1293-945)/945×100％＝37％ (7)
the allowable elongation of the known pipe is 27%, and the actual elongation deltaAGreater than the allowable elongation delta of the materialTThe method belongs to large deformation and can adopt a high-pressure one-step forming method in a large-deformation corrugated pipe.
And (3) calculating the size of the corrugated pipe blank in the step (2). Taking a single ripple as an example, according to the principle that the volume of the corrugated pipe is not changed before and after forming, or the principle that the volume of the neutral layer of the corrugated pipe is not changed before and after forming, the size of the pipe blank of the corrugated pipe is 843mm by UG three-dimensional modeling software.
And (3) designing a high-pressure one-step forming die in the large-deformation corrugated pipe according to the structural size of the corrugated pipe and the size of the pipe blank, wherein the high-pressure one-step forming die comprises a left half female die 2, a right half female die 3, a left push block 4, a right push block 5 and an inner high-pressure medium 6. In this embodiment, the internal high-pressure medium is hydraulic oil.
And (4) carrying out multi-mode linkage internal high-pressure one-step forming. The multi-mode linkage internal high-pressure one-step forming process is continuously executed in three stages, as shown in fig. 3-5:
1) and the first stage is primary wave forming. Forming time T1＝[0，0.9]Unit of seconds(s). The left push block 4 and the right push block 5 move towards the center respectively and move by SpUnit millimeters (mm), using a broken line loading path:
the inner high-pressure medium 6 applies radial internal pressure (unit megapascal (MPa)) to the pipe 1, and the internal pressure P1Adopting a broken line loading path:
the left half female die 2 and the right half female die 3 are kept stationary. Under the combined action of the axial pressure of the push block and the radial internal pressure of the internal high-pressure medium, the pipe material is fed to the center in the axial direction and is plastically deformed to form a primary wave.
2) And a second stage of corrugation forming. Forming time T2＝[0.9，1.6]. The left half female die 2 and the right half female die 3 respectively move towards the center at a constant speed by a displacement Sd90 mm; the inner high-pressure medium 6 exerts radial internal pressure on the pipe 1, and the internal pressure P2Adopting a broken line loading path:
the left push block 4 and the right push block 5 remain stationary. And (3) closing the left half female die 2 and the right half female die 3, extruding the pipe 1, and basically forming the corrugation under the combined action of the radial internal pressure of the internal high-pressure medium.
3) And (5) shaping in a third stage. Forming time T3＝[1.6，1.8]. The female die and the push block are kept static. The inner high-pressure medium 6 exerts radial internal pressure on the pipe 1, and the internal pressure P3Adopt broken line loading route, carry out the plastic to the ripple, make tubular product paste tight die completely:
and (5): releasing pressure, opening the die and taking out the parts. After high-pressure forming is carried out in the large-deformation corrugated pipe, the internal pressure of the internal high-pressure medium 6 is unloaded, the left push block 4 and the right push block 5 are withdrawn, the left half female die 2 and the right half female die 3 are opened, and the large-deformation corrugated pipe is taken out.
In this embodiment: 1) when large deformation, large components and thin-wall corrugated pipes are formed at internal high pressure, if the actual elongation is larger than the allowable elongation of the material, a multi-pass internal high-pressure forming method is needed, the problems of design, matching, processing and the like of each pass are involved, and the forming cost and time are increased. In addition, certain special applications of corrugated tubing do not allow for multiple pass formation. The high-pressure one-step forming method in the large-deformation corrugated pipe can be used for forming large-deformation, large-component and thin-wall corrugated pipes at one step at high pressure, simplifies the forming process, improves the production efficiency and reduces the production cost.
2) Because the thin-wall corrugated pipe is relatively small in thickness and the large-component corrugated pipe is high in corrugation height, materials are difficult to flow into a wave-shaped area during internal high-pressure forming, and therefore the problem of forming difficulty is caused. This example employs a staged feeding method: the first stage mainly pushes the pipe into the corrugated area through the left push block and the right push block for material supplement, and the second stage mainly pushes the primary wave into the corrugated area through the left half female die and the right half female die, so that the whole material supplement is completed.
3) The multi-mode linkage internal high-pressure one-step forming process is divided into three stages, and different radial internal pressures are set in each stage to apply pressure to the pipe. In the first stage, the left and right push blocks are mainly matched to feed the pipe to the corrugated area and form initial waves, so that a smaller pressure value is adopted. In the second stage, the left half concave die and the right half concave die are mainly matched to push the primary waves into the ripple area, and basic ripples are formed. In the third stage, the pipe is basically formed, and a large internal pressure is needed to shape the corrugated pipe so that the pipe is completely attached to the die.
Claims (1)
1. A high-pressure one-step forming method in a large-deformation corrugated pipe is characterized by comprising the following steps:
(1) judging whether the corrugated pipe to be formed is large deformation or small deformation according to the structural size of the corrugated pipe to be formed, wherein the structural size comprises the maximum outer diameter D of the corrugated pipemaxAnd original outer diameter d of pipe0Calculating the deformation coefficient k and the actual elongation delta of the corrugated pipeA(ii) a Then the actual elongation delta is measuredAAllowable elongation delta to pipeTComparing the actual elongation deltaAGreater than the allowable elongation delta of the materialTIt belongs to large deformation; otherwise, the method belongs to small deformation, and the small deformation can be formed at one time by adopting a conventional internal high-pressure forming method;
(2) calculating the size of a pipe blank of the corrugated pipe by means of three-dimensional modeling software according to the principle that the volume of the corrugated pipe is not changed before and after forming or the principle that the volume of a neutral layer of the corrugated pipe is not changed before and after forming;
(3) designing a high-pressure one-step forming die in the large-deformation corrugated pipe with a proper size according to the structural size of the corrugated pipe in the step 1) and the size of the pipe blank in the step 2), wherein the die comprises a left half female die (2), a right half female die (3), a left push block (4), a right push block (5) and an inner high-pressure medium (6);
(4) carrying out multi-mode linkage internal high-pressure one-step forming; the multi-mode linkage internal high-pressure one-step forming process is continuously executed in three stages;
(5) releasing pressure, opening the die and taking out the part; after the large-deformation corrugated pipe is formed by the internal high pressure, the internal pressure of an internal high-pressure medium (6) is unloaded, the left push block (4) and the right push block (5) are withdrawn, the left half female die (2) and the right half female die (3) are opened, and the large-deformation corrugated pipe is taken out;
the three stages are specifically:
1) first-stage primary wave forming; setting the forming time T as T1(ii) a The left push block (4) and the right push block (5) respectively move towards the center and displace by SpS (x); the inner high-pressure medium (6) exerts radial internal pressure P on the pipe1P (x); the left half female die (2) and the right half female die (3) are kept static; under the combined action of the axial pressure of the left push block (4) and the right push block (5) and the radial internal pressure of the internal high-pressure medium (6), feeding materials to the center in the axial direction, and performing plastic deformation to form a primary wave;
2) the second stage of corrugation forming; setting the forming time T as T2(ii) a The left half female die (2) and the right half female die (3) move towards the center respectively and displace Sd(ii) a The inner high-pressure medium (6) exerts radial inner pressure P on the pipe2P (x); the left push block (4) and the right push block (5) are kept static; the left half female die (2) and the right half female die (3) are closed to extrude the pipe,and the corrugation is basically formed under the combined action of the radial internal pressure of the internal high-pressure medium (6);
3) shaping in a third stage; setting the forming time T as T3(ii) a The left half female die (2), the right half female die (3), the left push block (4) and the right push block (5) are kept static; the inner high-pressure medium exerts radial internal pressure P on the pipe3Shaping the corrugation to make the pipe completely cling to the female die, and forming the large-deformation corrugated pipe at one time under internal high pressure;
the calculation formulas of the deformation coefficient of the corrugated pipe and the actual elongation of the corrugated pipe in the step (1) are respectively as follows:
k＝Dmax/d0 (5)
δA＝(Dmax-d0)/d0×100％ (6)
in the formula: k is the bellows deformation coefficient, deltaAActual elongation of the bellows, DmaxIs the maximum outer diameter of the bellows, d0The original outer diameter of the pipe is adopted;
the displacement S of the left push block (4) and the right push block (5) in the first stage in the step (4)pAdopting a broken line loading path:
in the formula: k is a radical ofs1And ks2Slopes of a first fold line and a second fold line, respectively, for a first stage displacement loading; x is time; bsIs the intercept of the second polyline of the first stage displacement loading;
the radial internal pressure P exerted on the pipe by the internal high-pressure medium (6) in the first stage in the step (4)1Adopting a broken line loading path:
in the formula: k is a radical ofp11And kp12First fold line and second folded oblique line for first stage pressure loading respectivelyRate;
bpis the intercept of the second broken line loaded by the pressure in the first stage;
the inner high-pressure medium (6) of the second stage in the step (4) exerts radial internal pressure P on the pipe2Adopting a broken line loading path:
in the formula: k is a radical ofp2Loading the slope of the first broken line for the second stage pressure; cp2Is a constant;
the internal high-pressure medium (6) of the third stage in the step (4) continues to apply radial internal pressure P to the pipe3Adopting a broken line loading path:
in the formula: k is a radical ofp3Loading the slope of the first broken line for the third stage pressure; cp3Is a constant;
the left half female die (2) and the right half female die (3) in the second stage in the step (4) respectively move towards the center at a constant speed;
the internal high-pressure medium (6) is made of hydraulic oil or elastic rubber materials.
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