CN114871326B - Pipe bulging method and device adopting metal coating magnetic collector - Google Patents
Pipe bulging method and device adopting metal coating magnetic collector Download PDFInfo
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- CN114871326B CN114871326B CN202210346078.3A CN202210346078A CN114871326B CN 114871326 B CN114871326 B CN 114871326B CN 202210346078 A CN202210346078 A CN 202210346078A CN 114871326 B CN114871326 B CN 114871326B
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- 239000002184 metal Substances 0.000 title claims abstract description 80
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 80
- 238000000576 coating method Methods 0.000 title claims abstract description 76
- 239000011248 coating agent Substances 0.000 title claims abstract description 58
- 238000000034 method Methods 0.000 title claims abstract description 28
- 230000000694 effects Effects 0.000 claims abstract description 15
- 238000004519 manufacturing process Methods 0.000 claims abstract description 5
- 238000012545 processing Methods 0.000 claims abstract description 5
- 230000008569 process Effects 0.000 claims description 14
- 239000004020 conductor Substances 0.000 claims description 7
- 230000002500 effect on skin Effects 0.000 claims description 7
- 238000010586 diagram Methods 0.000 claims description 6
- 230000004907 flux Effects 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- 230000035699 permeability Effects 0.000 claims description 4
- 238000004088 simulation Methods 0.000 abstract description 3
- 239000000463 material Substances 0.000 description 4
- 230000009471 action Effects 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 238000011160 research Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012858 packaging process Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
Classifications
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- 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
- B21D26/14—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces applying magnetic forces
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]
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- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Theoretical Computer Science (AREA)
- Computer Hardware Design (AREA)
- Evolutionary Computation (AREA)
- Geometry (AREA)
- General Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Mechanical Engineering (AREA)
- Investigating Or Analyzing Materials By The Use Of Magnetic Means (AREA)
Abstract
The invention relates to a pipe bulging method adopting a metal coating magnetic collector, which comprises the following steps: calculating to obtain a reference value of the skin depth of the magnetic collector; preliminarily determining the overall thickness of the metal coating of the magnetic collector; simulating pipe bulging, adjusting the conductivity of the magnetic collector to ensure that the uniformity of the pipe after bulging is the best, and recording the optimal conductivity of the magnetic collector; the influence of the magnetic field distribution of the magnetic collector on the end effect is simulated and analyzed, the thickness of the upper end metal coating and the lower end metal coating of the magnetic collector is adjusted, and the end effect is minimized; the thickness of the metal coating at different parts of the magnetic collector is adjusted in a simulation way, so that the pipe fitting after bulging is uniform as a whole; and manufacturing the metal coating magnetic collector according to the thicknesses of the metal coatings of different parts of the magnetic collector obtained through simulation, wherein the metal coating magnetic collector is used for bulging processing of the pipe fitting. The invention reduces the end effect and ensures that the overall uniformity of the pipe fitting is better; the magnetic field distribution of the pipe fitting area is more reasonable by utilizing the metal coatings with different thicknesses at different parts of the magnetic collector, and the forming quality and the forming efficiency of the pipe fitting are improved.
Description
Technical Field
The invention belongs to the field of metal workpiece forming control, and particularly relates to a pipe bulging method and device adopting a metal coating magnetic collector.
Background
The magnetic collector is also called as a magnetic flux collector, is one of main accessories in electromagnetic forming, has the function of moving magnetic flux into a gap between the magnetic collector and a workpiece, and has wide application in electromagnetic forming of pipe fittings and plate members. The magnetic collector can change the track distribution by changing the shape of the inner wall of the magnetic collector, so that the magnetic field of part of the space is enhanced, the magnetic field of the rest of the space is weakened, and the purpose of forming different workpieces is achieved.
The literature Inductor for forming metals by the pressure of a pulsed MAGNETIC FIELD introduces the magnetic collector tool into electromagnetic forming, when the induction current on the outer surface of the magnetic collector flows through the inner surface, the magnetic flux of the induction magnetic field is gathered in the gap between the magnetic collector and the outer surface of the workpiece, and the control of the Lorentz force and the distribution condition of the pipe fitting can be realized by adjusting the geometric dimension of the inner surface of the magnetic collector.
The literature 'research on the magnetic collectors for reducing' researches the influence of the relative diameters of the magnetic collectors, the matching relation between materials and coils of the magnetic collectors on the reducing forming performance of the pipe, and experiments confirm that the optimal relative diameter ratio of the magnetic collectors is 0.5, the materials are nonferromagnetic materials with small resistivity, such as red copper, and the height of the coils is indicated not to exceed the height of the magnetic collectors.
The literature "Impact of metal thickness and field converter on the time-varying processes during impulse electromagnetic forming in tubular geometries" analyzes the influence of the pipe thickness and the structural parameters of the magnetic collector on the tooling system, and proposes that the geometric dimensions in pipe forming are continuously changed under the action of magnetic pressure, so that the relation between stress and strain is considered from the time-varying perspective when analyzing the pipe deformation process.
The literature Effect of various FIELD SHAPERS on magnetic pressure in electromagnetic inward tube forming is used for researching a plurality of magnetic collectors with different structures, and analyzing the efficiency of the magnetic collectors with different geometric shapes by taking the magnetic induction intensity and the magnetic field force received by a pipe forming area as evaluation indexes.
The existing research of the magnetic collector does not effectively solve the problems of complex structure and packaging process of the magnetic collector, difficult manufacture and large skin depth of the magnetic collector.
[1]Khimenko L T,Mezhuev A T,Legeza A V,et al.Inductor for forming metals by the pressure of a pulsed magnetic field.USA：4143532,1965-03-13.
[2] Zhao Zhiheng, li Chunfeng, wang Yongzhi, et al. Magnetic concentrator for reducing. Electron technology, 1998, 19 (6): 215-217.
[3]Peyman D B,Pedram G,Kaveh N.Impact of metal thickness and field shaper on the time-varying processes during impulse electro-magnetic forming in tubular geometries.Journal of Korean Physical Society,2011,59(61)：3560.
[4]Garzan E,Ebrahimi H,Arezoodar A R F.Effect of various field shapers on magnetic pressure in electromagnetic inward tube forming.Journal of Iron&Steel Research,2012,(S1)：86-89.
Disclosure of Invention
The invention aims at solving the problems and provides a pipe bulging method and a pipe bulging device adopting a metal coating magnetic collector, wherein the magnetic collector comprises an insulating ring and a metal coating, the distribution of induced current on the outer side surface of the magnetic collector is controlled by utilizing the metal coatings with different thicknesses at different parts of the magnetic collector in the pipe bulging process, and the thickness of the metal coating is smaller than the skin depth so as to reduce skin effect and end effect and improve the forming quality and forming efficiency of a workpiece.
The technical scheme of the invention is that the pipe fitting bulging method of the metal coating magnetic collector is adopted, the magnetic collector comprises an insulating ring and a metal coating on the outer side surface of the insulating ring, and a slit is arranged on the insulating ring.
The pipe bulging method comprises the following steps:
Step 1: calculating to obtain a reference value of the skin depth of the magnetic collector according to the peak value, duration and equivalent frequency relation of the pulse width current of the driving coil required by pipe bulging;
Step 2: according to the principle of reducing skin effect, primarily determining the overall thickness of the metal coating of the magnetic collector;
step 3: establishing a finite element model comprising a magnetic collector, a driving coil and a pipe fitting, setting the thickness of a metal coating of the magnetic collector to be the thickness of the metal coating obtained in the step 2, simulating bulging of the pipe fitting, adjusting the conductivity of the magnetic collector, enabling the uniformity of the pipe fitting after bulging to be the best, and recording the optimal conductivity of the magnetic collector;
Step 4: setting the magnetic collector of the finite element model to the optimal conductivity obtained in the step 3, applying current to the driving coil to obtain magnetic field distribution of a pipe fitting area, namely a magnetic flux density diagram, analyzing the influence of the magnetic field distribution on the end effect of pipe fitting bulging, and adjusting the thickness of metal coatings at the upper end and the lower end of the magnetic collector according to the principle of reducing the end effect to minimize the end effect;
step 5: applying pulse width current required by pipe bulging to a driving coil of the finite element model, judging the overall uniformity of the pipe after bulging, changing the thickness of metal coatings at different parts of the magnetic collector, enabling the pipe after bulging to be overall uniform, and recording the thickness of the metal coatings at different parts of the magnetic collector, which enables the pipe after bulging to be the best in uniformity;
step 6: manufacturing the metal coating magnetic collector according to the thicknesses of the metal coatings of the different parts of the magnetic collector obtained in the step 5 and the optimal conductivity of the magnetic collector obtained in the step 3;
Step 7: and (3) using the magnetic collector obtained in the step (6) for bulging processing of the pipe fitting to be bulged.
Further, the section of the magnetic collector is trapezoid.
In step 1, the skin depth is calculated as follows:
where δ is the skin depth, σ is the conductivity of the conductor, μ is the permeability of the conductor, and f is the equivalent frequency of the current.
In the step 2, the thickness value of the metal coating of the magnetic collector is smaller than 1/2 of the skin depth value and larger than 1/5 of the skin depth value.
Preferably, the metal coating of the magnetic collector is a copper coating.
Preferably, the slit of the concentrator forms an angle of 0.5-1.5 degrees with the centerline of the concentrator.
The pipe bulging device comprises the metal coating magnetic collector, the driving coil and the pulse power supply, wherein the metal coating magnetic collector is arranged in the pipe to be bulged, the driving coil is arranged in an insulating ring of the metal coating magnetic collector, the central lines of the driving coil and the metal coating magnetic collector are respectively aligned with the central line of the pipe to be bulged, the driving coil is connected with the pulse power supply through the discharge switch, and the thickness of the metal coating magnetic collector is smaller than the skin depth.
Compared with the prior art, the invention has the beneficial effects that:
1) The end effect of pipe bulging is reduced, so that the pipe after bulging is more uniform, and the overall uniformity of the pipe is better;
2) The skin effect is reduced, and the magnetic field distribution of the pipe fitting area is more reasonable by utilizing the metal coatings with different thicknesses at different parts of the magnetic collector, so that the forming quality and the forming efficiency of the pipe fitting are improved;
3) The energy consumption of the magnetic collector is reduced;
4) The optimal thickness values of the metal coatings at different parts of the magnetic collector are obtained by utilizing the finite element model simulation, so that product defects in the pipe fitting processing technology are avoided, and the accurate control of the forming quality of the pipe fitting is realized;
5) The magnetic collector disclosed by the invention bears the electromagnetic force action of the pipe fitting and the driving coil in the pipe fitting bulging process, and compared with a pipe fitting bulging process without the magnetic collector, the magnetic collector greatly reduces the electromagnetic force action borne by the driving coil, so that the service life of the driving coil is prolonged;
6) The metal coating magnetic collector is easy to process and produce, saves conductor materials and has low cost.
Drawings
The invention is further described below with reference to the drawings and examples.
Fig. 1 is a schematic diagram of a metal-coated concentrator and drive coil according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of a metal-coated concentrator according to an embodiment of the present invention.
Fig. 3 is a schematic diagram of the magnetic field distribution around the metal coating of the concentrator.
Fig. 4 is a schematic view of a metal coated concentrator for pipe bulging according to an embodiment of the present invention.
Detailed Description
Example 1
According to the pipe bulging method, distribution of induced currents on the outer side surface of the magnetic collector is controlled by utilizing metal coatings with different thicknesses in the pipe bulging process, and the thickness of the metal coating is smaller than the skin depth, so that skin effect is reduced, and forming quality and forming efficiency of a workpiece are improved.
As shown in fig. 1 and 2, the magnetic collector 1 comprises an insulating ring 101 and a metal coating 102 on the outer side surface of the insulating ring, wherein a slit 103 is arranged on the insulating ring 101; the cross section of the magnetic collector 1 is isosceles trapezoid. The metal coating 102 is a copper coating. The angle formed by the slit of the magnetic collector and the central line of the magnetic collector is 1.2 degrees.
The pipe bulging method comprises the following steps:
Step 1: calculating to obtain a reference value of the skin depth of the magnetic collector according to the peak value, duration and equivalent frequency relation of the pulse width current of the driving coil required by pipe bulging;
The skin depth is calculated as follows:
where δ is the skin depth, σ is the conductivity of the conductor, μ is the permeability of the conductor, and f is the equivalent frequency of the current.
Step 2: according to the principle of reducing skin effect, primarily determining the overall thickness of the metal coating of the magnetic collector;
The thickness value of the metal coating of the magnetic collector is smaller than 1/2 of the skin depth value and larger than 1/5 of the skin depth value.
Step 3: establishing a finite element model comprising a magnetic collector, a driving coil and a pipe fitting, setting the thickness of a metal coating of the magnetic collector to be the thickness of the metal coating obtained in the step 2, simulating bulging of the pipe fitting, adjusting the conductivity of the magnetic collector, enabling the uniformity of the pipe fitting after bulging to be the best, and recording the optimal conductivity of the magnetic collector;
The pipe fitting to be expanded in the embodiment has the height of 120mm, the radius of 37.5mm and the expansion depth of 7mm. The magnetic permeability mu=1 of the magnetic collector is set in the finite element model, the equivalent frequency f=50 Hz of the current, the conductivity sigma i of the magnetic collector is the variable i=1, 2,3, …, and the conductivity initial value sigma 0＝1.0*e7.
The uniformity of the simulated expanded pipe is best when the conductivity sigma i＝3.1*e7 of the concentrator is high.
The skin depth δ=1.38 mm was calculated according to formula (1). Further, the thickness of the metal coating layer was 0.28 to 0.69mm.
Step 4: setting a magnetic collector of a finite element model to the optimal conductivity obtained in the step 3, applying current to a driving coil to obtain magnetic field distribution of a pipe fitting area, namely a magnetic flux density diagram, and analyzing the influence of the magnetic field distribution on the end effect of pipe fitting bulging, as shown in fig. 3; according to the principle of reducing the end effect, the thickness of the metal coating at the upper end and the lower end of the magnetic collector is adjusted, so that the end effect is minimized;
step 5: applying pulse width current required by pipe bulging to a driving coil of the finite element model, judging the overall uniformity of the pipe after bulging, changing the thickness of metal coatings at different parts of the magnetic collector, enabling the pipe after bulging to be overall uniform, and recording the thickness of the metal coatings at different parts of the magnetic collector, which enables the pipe after bulging to be the best in uniformity;
step 6: manufacturing the metal coating magnetic collector according to the thicknesses of the metal coatings of the different parts of the magnetic collector obtained in the step 5 and the optimal conductivity of the magnetic collector obtained in the step 3;
step 7: the magnetic collector obtained in the step 6 is used for bulging processing of the pipe fitting to be bulged, and is shown in fig. 4.
The pipe fitting bulging device of the pipe fitting bulging method comprises a metal coating magnetic collector 1, a driving coil 2 and a pulse power supply, wherein the metal coating magnetic collector 1 is arranged in a pipe fitting 4 to be bulged, the driving coil 2 is arranged in an insulating ring 101 of the metal coating magnetic collector 1, the central lines of the driving coil 2 and the metal coating magnetic collector 1 are respectively aligned with the central line of the pipe fitting to be bulged, and the driving coil 2 is connected with the pulse power supply through a discharge switch.
Example two
As shown in fig. 2, the metal coating magnetic collector comprises an insulating ring 101 and a metal coating 102 on the outer side surface of the insulating ring, wherein a slit 103 is arranged on the insulating ring 101; the section of the metal coating magnetic collector is trapezoid. The slit 103 of the metal coating concentrator forms an angle of 0.5 deg. -1.5 deg. with the centerline of the concentrator.
The metal coating magnetic collector of the embodiment is used for the pipe bulging process.
Claims (6)
1. The pipe bulging method adopting the metal coating magnetic collector is characterized in that the magnetic collector comprises an insulating ring and a metal coating on the outer side surface of the insulating ring, and the insulating ring is provided with a slit; according to the pipe bulging method, the distribution of induced currents on the outer side surface of the magnetic collector is controlled by utilizing metal coatings with different thicknesses in the pipe bulging process, and the thickness of the metal coating is smaller than the skin depth, so that the skin effect is reduced, and the forming quality and the forming efficiency of a workpiece are improved;
the pipe bulging method comprises the following steps:
Step 1: calculating to obtain a reference value of the skin depth of the magnetic collector according to the peak value, duration and equivalent frequency relation of the pulse width current of the driving coil required by pipe bulging;
Step 2: according to the principle of reducing skin effect, primarily determining the overall thickness of the metal coating of the magnetic collector;
step 3: establishing a finite element model comprising a magnetic collector, a driving coil and a pipe fitting, setting the thickness of a metal coating of the magnetic collector to be the thickness of the metal coating obtained in the step 2, simulating bulging of the pipe fitting, adjusting the conductivity of the magnetic collector, enabling the uniformity of the pipe fitting after bulging to be the best, and recording the optimal conductivity of the magnetic collector;
Step 4: setting the magnetic collector of the finite element model to the optimal conductivity obtained in the step 3, applying current to the driving coil to obtain magnetic field distribution of a pipe fitting area, namely a magnetic flux density diagram, analyzing the influence of the magnetic field distribution on the end effect of pipe fitting bulging, and adjusting the thickness of metal coatings at the upper end and the lower end of the magnetic collector according to the principle of reducing the end effect to minimize the end effect;
step 5: applying pulse width current required by pipe bulging to a driving coil of the finite element model, judging the overall uniformity of the pipe after bulging, changing the thickness of metal coatings at different parts of the magnetic collector, enabling the pipe after bulging to be overall uniform, and recording the thickness of the metal coatings at different parts of the magnetic collector, which enables the pipe after bulging to be the best in uniformity;
step 6: manufacturing the metal coating magnetic collector according to the thicknesses of the metal coatings of the different parts of the magnetic collector obtained in the step 5 and the optimal conductivity of the magnetic collector obtained in the step 3;
Step 7: the magnetic collector obtained in the step6 is used for bulging processing of the pipe fitting to be bulged;
in step 1, the skin depth is calculated as follows:
Wherein the method comprises the steps of Is skin depth,/>For the conductivity of the conductor,/>Is the magnetic permeability of the conductor,/>Is the equivalent frequency of the current.
2. A pipe bulging process according to claim 1, wherein the cross section of the collector is isosceles trapezoid.
3. A pipe bulging process according to claim 2, wherein in step 2 the thickness of the metal coating of the collectors has a value less than 1/2 of the skin depth value and greater than 1/5 of the skin depth value.
4. A tubular bulging process according to claim 3, wherein the optimal conductivity of the collectors is 3.1 xe 7.
5. A pipe bulging process according to claim 1, wherein the metal coating of the concentrator is a copper coating.
6. A tubular bulging process according to claim 1, wherein the slots of the concentrator are angled to the centre line of the concentrator by 0.5 ° -1.5 °.
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