CN114542947B - 一种相交球壳压力容器胀形制造方法 - Google Patents
一种相交球壳压力容器胀形制造方法 Download PDFInfo
- Publication number
- CN114542947B CN114542947B CN202210251667.3A CN202210251667A CN114542947B CN 114542947 B CN114542947 B CN 114542947B CN 202210251667 A CN202210251667 A CN 202210251667A CN 114542947 B CN114542947 B CN 114542947B
- Authority
- CN
- China
- Prior art keywords
- bulging
- container
- spherical shell
- partition plate
- intersecting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 33
- 238000003466 welding Methods 0.000 claims abstract description 25
- 239000000835 fiber Substances 0.000 claims abstract description 18
- 238000000034 method Methods 0.000 claims abstract description 18
- 229910052751 metal Inorganic materials 0.000 claims abstract description 11
- 239000002184 metal Substances 0.000 claims abstract description 11
- 239000007769 metal material Substances 0.000 claims abstract description 4
- 238000005192 partition Methods 0.000 claims description 53
- 239000000463 material Substances 0.000 claims description 25
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- 229910000963 austenitic stainless steel Inorganic materials 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 5
- 230000003014 reinforcing effect Effects 0.000 claims description 5
- 238000000137 annealing Methods 0.000 claims description 4
- 238000002347 injection Methods 0.000 claims description 4
- 239000007924 injection Substances 0.000 claims description 4
- 239000007788 liquid Substances 0.000 claims description 4
- 229910001220 stainless steel Inorganic materials 0.000 claims description 4
- 239000010935 stainless steel Substances 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 2
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 238000010276 construction Methods 0.000 claims description 2
- 230000005484 gravity Effects 0.000 claims description 2
- 238000003801 milling Methods 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 238000009423 ventilation Methods 0.000 claims 3
- 229910045601 alloy Inorganic materials 0.000 claims 1
- 239000000956 alloy Substances 0.000 claims 1
- 238000005452 bending Methods 0.000 claims 1
- 230000000452 restraining effect Effects 0.000 claims 1
- 238000004804 winding Methods 0.000 abstract description 5
- 238000003860 storage Methods 0.000 description 8
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 230000008719 thickening Effects 0.000 description 3
- 239000002131 composite material Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000010963 304 stainless steel Substances 0.000 description 1
- 238000010146 3D printing Methods 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 229910000589 SAE 304 stainless steel Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009730 filament winding Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/24—Making hollow objects characterised by the use of the objects high-pressure containers, e.g. boilers, bottles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16J—PISTONS; CYLINDERS; SEALINGS
- F16J12/00—Pressure vessels in general
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
- F17C1/02—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge involving reinforcing arrangements
- F17C1/04—Protecting sheathings
- F17C1/06—Protecting sheathings built-up from wound-on bands or filamentary material, e.g. wires
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C13/00—Details of vessels or of the filling or discharging of vessels
- F17C13/002—Details of vessels or of the filling or discharging of vessels for vessels under pressure
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2201/00—Vessel construction, in particular geometry, arrangement or size
- F17C2201/01—Shape
- F17C2201/0104—Shape cylindrical
- F17C2201/0109—Shape cylindrical with exteriorly curved end-piece
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2201/00—Vessel construction, in particular geometry, arrangement or size
- F17C2201/01—Shape
- F17C2201/0138—Shape tubular
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2201/00—Vessel construction, in particular geometry, arrangement or size
- F17C2201/05—Size
- F17C2201/054—Size medium (>1 m3)
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2203/00—Vessel construction, in particular walls or details thereof
- F17C2203/01—Reinforcing or suspension means
- F17C2203/011—Reinforcing means
- F17C2203/012—Reinforcing means on or in the wall, e.g. ribs
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2203/00—Vessel construction, in particular walls or details thereof
- F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
- F17C2203/0634—Materials for walls or layers thereof
- F17C2203/0636—Metals
- F17C2203/0639—Steels
- F17C2203/0643—Stainless steels
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2205/00—Vessel construction, in particular mounting arrangements, attachments or identifications means
- F17C2205/01—Mounting arrangements
- F17C2205/0123—Mounting arrangements characterised by number of vessels
- F17C2205/0126—One vessel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2209/00—Vessel construction, in particular methods of manufacturing
- F17C2209/21—Shaping processes
- F17C2209/2181—Metal working processes, e.g. deep drawing, stamping or cutting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2209/00—Vessel construction, in particular methods of manufacturing
- F17C2209/22—Assembling processes
- F17C2209/221—Welding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2209/00—Vessel construction, in particular methods of manufacturing
- F17C2209/23—Manufacturing of particular parts or at special locations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2209/00—Vessel construction, in particular methods of manufacturing
- F17C2209/23—Manufacturing of particular parts or at special locations
- F17C2209/234—Manufacturing of particular parts or at special locations of closing end pieces, e.g. caps
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E30/00—Energy generation of nuclear origin
- Y02E30/30—Nuclear fission reactors
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Pressure Vessels And Lids Thereof (AREA)
- Filling Or Discharging Of Gas Storage Vessels (AREA)
Abstract
本发明公开了一种相交球壳压力容器胀形制造方法,针对带隔板的相交球壳压力容器,选用塑性较好的金属材料板材,首先焊接出一个圆柱形带隔板的容器,两端采用分段锥形做成剖面为正多边形的近球底,隔板开若干个通气孔,并适当补强。焊接完毕得到一个圆柱形筒段带近球形底的容器,最后采用充内压胀形工艺,充压至金属进入塑性并膨胀为相交球壳压力容器。针对纤维缠绕相交球壳压力容器,相比带隔板容器无需焊接内部隔板,焊接得到圆柱形筒段带近球形底的容器后,套上纤维缠绕环圈再胀形至预期尺寸,即制成纤维缠绕相交球壳压力容器。本发明具有工艺成本低、结构安全性高的优点,同时在成形过程中对金属板材进行了硬化,提升了压力容器的屈服强度。
Description
技术领域
本发明涉及压力容器制造领域,是一种基于胀形技术制造金属压力容器的新技术,实现了低成本制造相交球壳压力容器、贮箱的工艺创新。
背景技术
发明申请号:202110242791.9、202210049625.1公开了两种类型的相交球壳压力容器,其结构均由若干个相交球壳组成,在相同的材料、容积和压力要求下,具有理论上与球壳压力容器相等的结构效率,两个专利的不同点在于采用圆形隔板板还是纤维缠绕环圈对球壳连接处进行径向约束。上述两项发明仅公开了压力容器的结构形式,未考虑其生产、制造方法。对采用金属材料制造该类型压力容器一般可考虑如下两种技术路线:
1)首先加工出各段的球壳和隔板,然后焊接到一起,存在球壳制造工艺复杂,成本高,焊缝数量多、可靠性低等缺点。
2)采用3D打印形式制造,存在制造成本高、薄壁结构难以实现等缺点。
传统的奥氏体不锈钢制圆柱形压力容器为了提高强度往往采用胀形工艺实现一定程度的冷作硬化,从而提高材料强度,降低材料用量。但由于普通的圆柱形压力容器在内压下应力不均匀,因此只能有限程度的胀形,胀形应变率一般小于10%。
哈尔滨工业大学王仲仁教授在1985年发明了球形压力容器的无模胀形工艺,并推广应用于椭球、圆环形压力容器的制造。由于结构内压趋球效应的影响,除了球形压力容器外,其他形式的容器普遍存在变形褶皱、最终趋近圆球等问题,限制了该技术更广泛地推广应用。
发明申请号:202110242791.9和202210049625.1公开的相交球壳压力容器是一种理想的等应力结构,在内压下作用下仍然为各方向等比例变形,不会出现整体趋球胀形问题,而且,结构趋近于该结构的压力容器,内压下也会向相交球壳形式变形,从而为该类型结构的制造启发了一个可行方向。
本发明提出首先制造一个趋近相交球壳压力容器的简单筒段结构,然后采用内压胀形工艺制造相交球壳压力容器,实现了一种简单、低成本、高可靠制造相交球壳压力容器的技术方法。
发明内容
本发明主要解决在使用简单、低成本工艺,可靠生产制造相交球壳压力容器的工艺难题。
本发明的有益效果是:使用低成本的材料和工艺实现了高强度相交球壳压力容器的制造。
基于本发明制造金属相交球壳的压力容器的步骤如下:
本发明公开了一种相交球壳压力容器胀形制造方法,①使用塑性好的金属材料,包括但不限于不锈钢、铝合金、高温合金等,优选断裂延伸率超过20%的材料;②首先焊接制造一个圆柱形封闭容器,内部焊接好隔板或在外部套上纤维环圈;③有隔板时需开通气孔,并对通气孔周边补强;④容器两端采用分段锥形焊接,形成横截面为正多边形的近似半球壳作为前后底;⑤在圆柱形封闭容器内充高压至金属进入塑性并膨胀变形,筒段受隔板或者纤维环圈约束,得到相交球壳形状压力容器。
作为优选的,①柱段半径与成形后的相交球壳半径和材料设计胀形应变,满足如下关系:
对于带隔板的相交球壳压力容器:
对于纤维缠绕相交球壳压力容器:
其中:r为圆柱半径,R为成形后相交球壳的半径,s为材料的设计胀形应变,考虑安全裕度,s需明显小于材料的断裂延伸率γ。
②圆筒的壁厚满足如下关系:
T≥H(1+s)
其中:T为筒段和前后底厚度,H为胀形后球壳段最小允许厚度。
③采用隔板时,隔板的厚度满足如下关系:
其中:t为隔板厚度,T为筒段厚度,r为筒段半径,d为隔板与其前后相邻隔板之间的间距,两端的隔板则取其与前后底外接球心的间距。
④采用纤维缠绕时,按照发明申请号202210049625.1所公开的方法设计纤维缠绕环圈。
⑤为了保证均匀胀形,要求球壳球心距尽量小,但同时可能导致隔板厚度过小或者环圈槽深度不足,综合考虑球心距一般取圆筒半径的50%左右,此时采用隔板时其厚度为圆筒壁厚度的50%。
⑥筒段前后底采用分段锥形环板焊接,锥段的横截面为近球壳内接多边形,多边形的边数越多变形越均匀,同时焊接工作量越大,推荐取正16~32边形。正多边形内切圆半径等于圆筒段内半径。
⑦锥柱对接焊缝与相邻圆柱段隔板或纤维圈中面的距离为:
其中:l为锥柱对接焊缝与相邻圆柱段隔板的距离,n为正多边形边数。
⑧可以根据需要参照直筒型压力容器的方法类推环形、变直径、异形堆积等各种形式的相交球壳压力容器的胀形前结构设计,满足发明申请号202110242791.9、202210049625.1所公开的各种形状压力容器制造需要。
优选的,①采用平面钢板下料;②将各个筒段和前后底板材弯曲后焊接为圆管形或圆锥管形;③采用隔板方案时,如果圆柱筒段直径较大,便于内部焊接施工,优选制作一个整体圆柱,并将隔板分别焊接到圆柱管内部;④采用隔板方案时,如果圆柱段直径较小,则分段制作圆柱筒段,并使隔板直径略大于筒段外径,两个圆柱段夹持一个环板以“T形”焊接为一体;⑤各个圆管、圆锥管和隔板焊接在一起制成圆柱形封闭容器。
采用隔板方案时,隔板上需开若干个透气孔,开孔后需将其边缘适当加厚补强,其特征在于:①对于气体容器,仅需开一个通气孔,液体容器需要开若干个通气孔;②开孔后需将其边缘适当加厚补强,可以通过焊接金属丝、点焊补强片、整体机铣等方式补强,补强程度以胀形后圆孔边缘的最大塑性应变满足强度设计要求为宜;③隔板上所有开孔均需补强,包括大直径容器隔板设置的人孔。
①理论上不需要设计模具,可以实施无模胀形,但为了保证胀形后的同轴度,也可以采用外模约束;②对于大尺寸、薄壁压力容器的低压胀形,如果采用注水胀形,需要考虑重力水压梯度对胀形结果的影响,优选浸没在注水槽中胀形;③针对奥氏体不锈钢压力容器,特别的301不锈钢材质容器,可以采用深冷(一般液氮介质环境)胀形制造,从而充分发挥材料深冷硬化后的高强度性能;④为了提高胀形的均匀程度,减小焊缝处的硬化不均匀性,对于可退火的高塑性材料,比如奥氏体不锈钢材料,采用首先预胀形,然后退火消除焊缝残余应力,然后二次甚至多次胀形到最终状态。
1)根据相交球壳压力容器的半径、隔板间距、球壳厚度,考虑材料许用塑性应变值,计算胀形前圆柱形容器的直径、隔板间距和板材厚度或者纤维环圈横截面积;
2)使用金属板材下料焊接制造圆柱形容器,对于有含隔板的结构,如果容器直径较大可以采用整体圆管制作筒段,在其内部焊接隔板,如果直径较小则分段焊接,并且两个筒段夹持一个隔板,以外部“T”形双面焊缝焊接到一起;
3)对于纤维缠绕的压力容器结构,预制出经固化的若干个纤维环圈;
4)使用充内压胀形方式完成容器制作。对于奥氏体不锈钢材料,可以选用液氮温度深冷胀形,提高压力容器的低温强度。对于存在焊接退火现象的材料,应避免在胀形后焊接作业。
5)为减小焊缝区域的不均匀内应力,可以采用“预胀形-退火-二次胀形”分三步甚至更多步进行胀形。
附图说明
图1含隔板的相交球壳压力容器胀形前焊接件及其内部图;
图2含隔板的相交球壳压力容器胀形后成品;
图3含隔板的相交球壳压力容器胀形前焊接件剖面示意图;
图4纤维缠绕相交球壳压力容器胀形前焊接件;
图5胀形前纤维缠绕相交球壳压力容器焊接件与纤维环圈;
图6胀形后纤维缠绕相交球壳压力容器成品。
附图中各部件的标记如下:
①圆柱壳段②分段锥形底③隔板④短壳
⑤工艺人孔
⑥防晃板
⑦胀形前金属壳体
⑧纤维缠绕环圈
具体实施方式
下面结合附图对本发明的较佳实施例进行详细阐述,以使本发明的优点和特征能更易于被本领域技术人员理解,从而对本发明的保护范围做出更为清楚明确的界定。
本发明实施例包括:
实施例1:一种用于运载火箭的薄壁大直径贮箱结构制造方法,制造工艺如下:
1)本实施例贮箱直径3.35m,容积40m3,设计内压0.5MPa,使用材料为奥氏体304不锈钢,要求最高承载压力不低于设计内压的1.5倍;
2)本实施例胀形后结构由4个直径约3.35m的球壳相交组成,球壳之间以及球壳与隔板之间采用焊接连接,球心间距为半径的50%,容积为40.2m3;
3)最大胀形应变率s取21%,则胀形前参数为:圆柱直径D=3.35/sqrt(1+21%)=3.024m,球心距为半径的50%,即0.756m,锥段与圆柱焊缝到相邻隔板距离取0.85m,近球底截面为正16边形;
4)贮箱包含3个隔板,胀形前筒段总长度为2.748m;
5)胀形前隔板、前底和后底中心设置直径500mm工艺人孔,隔板上另外设两圈直径50mm的小孔;
6)各个隔板采用焊接形式与筒段壁板连接;
7)为了与其他结构连接方便,本实施例中设计了前后短壳结构;
8)胀形前圆柱壳体厚度约为1.2mm,隔板厚度0.6mm,隔板中心直径500mm圆孔周围设置宽度70mm、厚度2mm加厚区,隔板上直径50mm小孔周围设置宽度8mm、厚度2mm加厚区;
9)近球形底中部到圆柱与近球形底焊缝的轴向距离约500mm位置设置防晃环板,宽度200mm、厚度0.6mm,胀形前结构如附图1所示;
10)首先胀形内压充至0.5MPa,前后底已经涨圆,然后进行退火处理,消除焊缝内应力,然后二次胀形至0.80MPa;
11)在内压0.80MPa左右结构胀形到直径3.35m,长度为5.45m,胀形后结构如附图2所示;
12)胀形后得到的薄壁大直径相交球壳贮箱容积为40.2m3,贮箱重量约800kg;
从本实施例可以看出,采用本发明技术制造的贮箱重量轻,强度高,材料成本低,工艺简单,大大降低了制造成本。
实施例2:一种纤维缠绕相交球壳压力容器,制造工艺如下:
1)本实施例贮箱直径0.6m,总长2.5m,设计压力13.5MPa。
2)首先焊接一个等壁厚,总长略小于2.5米的不锈钢筒段,如附图4所示。
3)加工若干个碳纤维复合材料环圈,等间距套在筒段上,如附图5所示。
4)高压胀形至设计压力,金属进入塑性,得到复合材料缠绕相交球壳压力容器,如图6所示。
以上所述仅为本发明的实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本发明的专利保护范围内。
Claims (4)
1.一种相交球壳压力容器胀形制造方法,其特征在于:①使用塑性好的金属材料,包括但不限于不锈钢、铝合金、高温合金,选用断裂延伸率超过20%的材料;②首先焊接制造一个圆柱形封闭容器,内部焊接好隔板或在外部套上纤维环圈;③有隔板时开通气孔,并对通气孔周边补强;④容器两端采用分段锥形焊接,形成横截面为正多边形的近似半球壳作为前后底;⑤在圆柱形封闭容器内充高压至金属进入塑性并膨胀变形,圆柱段受隔板或者纤维环圈约束,得到相交球壳形状压力容器;
圆柱段半径与成形后的相交球壳半径和材料设计胀形应变,满足如下关系:
对于带隔板的相交球壳压力容器:
对于纤维缠绕相交球壳压力容器:
其中:r为圆柱半径,R为成形后相交球壳的半径,s为材料的设计胀形应变,考虑安全裕度,s需明显小于材料的断裂延伸率γ;
圆柱的壁厚满足如下关系:
T≥H(1+s)
其中:T为圆柱段和前后底厚度,H为胀形后球壳段最小允许厚度;
采用隔板时,隔板的厚度满足如下关系:
其中:t为隔板厚度,d为隔板与其前后相邻隔板之间的间距,两端的隔板则取其与前后底外接球心的间距;
采用隔板方案时,隔板上需开若干个透气孔,开孔后需将其边缘适当加厚补强,①对于气体容器,仅需开一个通气孔,液体容器需要开若干个通气孔;②开孔后需将其边缘适当加厚补强,可以通过焊接金属丝、点焊补强片、整体机铣的方式补强,补强程度以胀形后圆孔边缘的最大塑性应变满足强度设计要求为宜;③隔板上所有开孔均需补强,包括大直径容器隔板设置的人孔。
2.根据权利要求1所述的相交球壳压力容器胀形制造方法,其特征在于:
为了保证均匀胀形,要求球壳球心距尽量小,但同时可能导致隔板厚度过小或者环圈槽深度不足,综合考虑球心距一般取圆柱半径的50%左右,此时采用隔板时其厚度为圆柱壁厚度的50%;
圆柱段前后底采用分段锥形环板焊接,锥段的横截面为近球壳内接多边形,多边形的边数越多变形越均匀,同时焊接工作量越大,推荐取正16~32边形,正多边形内切圆半径等于圆柱段内半径;
锥柱对接焊缝与相邻圆柱段隔板或纤维圈中面的距离为:
其中:l为锥柱对接焊缝与相邻圆柱段隔板的距离,n为正多边形边数;
可以根据需要参照直筒型压力容器的方法类推环形、变直径、异形堆积各种形式的相交球壳压力容器的胀形前结构设计。
3.根据权利要求1所述的相交球壳压力容器胀形制造方法,其特征在于:焊接制造圆柱形封闭容器,①采用平面钢板下料;②将各个圆柱段和前后底板材弯曲后焊接为圆管形或圆锥管形;③采用隔板方案时,如果圆柱段直径较大,便于内部焊接施工,制作一个整体圆柱,并将隔板分别焊接到圆柱管内部;④采用隔板方案时,如果圆柱段直径较小,则分段制作圆柱段,并使隔板直径略大于圆柱段外径,两个圆柱段夹持一个环板以“T形”焊接为一体;⑤各个圆管、圆锥管和隔板焊接在一起制成圆柱形封闭容器。
4.根据权利要求1所述的相交球壳压力容器胀形制造方法,其特征在于:①理论上不需要设计模具,实施无模胀形,但为了保证胀形后的同轴度,也可以采用外模约束;②对于大尺寸、薄壁压力容器的低压胀形,如果采用注水胀形,需要考虑重力水压梯度对胀形结果的影响,浸没在注水槽中胀形;③针对奥氏体不锈钢压力容器,可以采用深冷胀形制造,从而充分发挥材料深冷硬化后的高强度性能;④为了提高胀形的均匀程度,减小焊缝处的硬化不均匀性,对于可退火的高塑性材料,采用首先预胀形,然后退火消除焊缝残余应力,然后二次甚至多次胀形到最终状态。
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202210251667.3A CN114542947B (zh) | 2022-03-15 | 2022-03-15 | 一种相交球壳压力容器胀形制造方法 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202210251667.3A CN114542947B (zh) | 2022-03-15 | 2022-03-15 | 一种相交球壳压力容器胀形制造方法 |
Publications (2)
Publication Number | Publication Date |
---|---|
CN114542947A CN114542947A (zh) | 2022-05-27 |
CN114542947B true CN114542947B (zh) | 2024-03-29 |
Family
ID=81664513
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202210251667.3A Active CN114542947B (zh) | 2022-03-15 | 2022-03-15 | 一种相交球壳压力容器胀形制造方法 |
Country Status (1)
Country | Link |
---|---|
CN (1) | CN114542947B (zh) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN115076591B (zh) * | 2022-06-06 | 2024-01-26 | 光年探索(江苏)空间技术有限公司 | 一种不锈钢ii型气瓶及其制造方法 |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2019939A (en) * | 1978-04-27 | 1979-11-07 | Bosch Gmbh Robert | A pressure vessel |
CN1061551A (zh) * | 1990-11-19 | 1992-06-03 | 王仲仁 | 瓜瓣式结构无模胀形制造球形容器工艺 |
CN105443973A (zh) * | 2015-11-09 | 2016-03-30 | 大连理工大学 | 薄壁金属内衬纤维复合材料缠绕压力容器及其制造工艺 |
CN111207287A (zh) * | 2020-04-08 | 2020-05-29 | 王广武 | 内衬塑料瓶或树脂瓶的合金储气瓶及其制作方法 |
CN111252186A (zh) * | 2020-02-28 | 2020-06-09 | 江苏科技大学 | 一种深海环形耐压壳及其制造方法 |
CN111649224A (zh) * | 2020-05-26 | 2020-09-11 | 武汉理工大学 | 一种纤维全缠绕气瓶塑料内胆超声波注射-胀形一体化成型方法 |
CN112963534A (zh) * | 2021-03-30 | 2021-06-15 | 北京格锐德科技有限公司 | 一种带球壳隔板的相交球壳压力容器 |
CN112974614A (zh) * | 2021-02-08 | 2021-06-18 | 航天材料及工艺研究所 | 一种钛合金薄壁无缝内衬直筒段超塑成形壁厚均匀性控制方法 |
CN113028052A (zh) * | 2021-03-05 | 2021-06-25 | 北京格锐德科技有限公司 | 一种带隔板的相交球壳压力容器 |
-
2022
- 2022-03-15 CN CN202210251667.3A patent/CN114542947B/zh active Active
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2019939A (en) * | 1978-04-27 | 1979-11-07 | Bosch Gmbh Robert | A pressure vessel |
CN1061551A (zh) * | 1990-11-19 | 1992-06-03 | 王仲仁 | 瓜瓣式结构无模胀形制造球形容器工艺 |
CN105443973A (zh) * | 2015-11-09 | 2016-03-30 | 大连理工大学 | 薄壁金属内衬纤维复合材料缠绕压力容器及其制造工艺 |
CN111252186A (zh) * | 2020-02-28 | 2020-06-09 | 江苏科技大学 | 一种深海环形耐压壳及其制造方法 |
CN111207287A (zh) * | 2020-04-08 | 2020-05-29 | 王广武 | 内衬塑料瓶或树脂瓶的合金储气瓶及其制作方法 |
CN111649224A (zh) * | 2020-05-26 | 2020-09-11 | 武汉理工大学 | 一种纤维全缠绕气瓶塑料内胆超声波注射-胀形一体化成型方法 |
CN112974614A (zh) * | 2021-02-08 | 2021-06-18 | 航天材料及工艺研究所 | 一种钛合金薄壁无缝内衬直筒段超塑成形壁厚均匀性控制方法 |
CN113028052A (zh) * | 2021-03-05 | 2021-06-25 | 北京格锐德科技有限公司 | 一种带隔板的相交球壳压力容器 |
CN112963534A (zh) * | 2021-03-30 | 2021-06-15 | 北京格锐德科技有限公司 | 一种带球壳隔板的相交球壳压力容器 |
Also Published As
Publication number | Publication date |
---|---|
CN114542947A (zh) | 2022-05-27 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN114542947B (zh) | 一种相交球壳压力容器胀形制造方法 | |
EP3056792B1 (en) | Pressure vessel with spheroidal shape | |
EP2265396B1 (en) | Plastic deformation technological process for production of thin wall revolution shells from tubular billets | |
AU2015231540A2 (en) | Pressure vessels, design and method of manufacturing using additive printing | |
US2503191A (en) | Method of forming tanks of spherical configuration | |
EP3099970B1 (en) | Improved method to produce high-resistance composite vessels with inner metal liner and vessels made by said method | |
US10449633B1 (en) | Gas pressure forming method of ellipsoidal shells based on current self-resistance heating | |
CN202368981U (zh) | 大型回收油气储罐 | |
EP1034063B1 (en) | A method for producing rotational-symmetrical articles of sheet metal with double curved surface and varying thickness of material | |
CN107740862A (zh) | 一种用于耐爆型压力容器大开孔的补强结构 | |
CN108633161A (zh) | 超导加速器、超导腔及其制造方法 | |
CN113414556A (zh) | 一种用于卫星压力容器的金属复合气口及其制造方法 | |
CN209328526U (zh) | 一种海上平台反应堆压力容器支撑裙 | |
RU2289062C1 (ru) | Металлопластиковый баллон высокого давления и способ его изготовления | |
US20240159204A1 (en) | Reinforced bulging tank of launch vehicle and manufacturing method therefor | |
RU2175088C1 (ru) | Сосуд давления и способ его изготовления (варианты) | |
CN201554848U (zh) | 球形压力容器 | |
US3342209A (en) | Unsymmetrical connection-piece nozzle | |
CN115076591B (zh) | 一种不锈钢ii型气瓶及其制造方法 | |
Nazir et al. | Optimizing the Effect of Stiffening Ring on a Vessel Under External Pressure by Numerical Analysis | |
RU193002U1 (ru) | Баллон для хранения сжатого натурального газа | |
CN114777008A (zh) | 一种环管气瓶结构及其制造方法 | |
NO20230764A1 (en) | Bending machine for manufacturing a reinforced pipe | |
CN114899449B (zh) | 一种多层嵌套耐压储氢装置 | |
CN111319714B (zh) | 一种深海叠层螺旋耐压壳装置及其制造工艺 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination | ||
GR01 | Patent grant | ||
GR01 | Patent grant |