直缝焊管排辊成形机理与工艺设计方法研究
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摘要
直缝焊管由于具有生产效率高、能源消耗低、成形质量好以及产品精度高等优点，在国民经济中的用途越来越广泛，不仅在煤气输送管、建筑结构管等低强度的应用领域完全取代了无缝管，而且在高压锅炉管、油气管线管等高强度的应用领域正越来越多地替代无缝管。随着焊管质量的提高以及人们对环境、能源的重视，直缝焊管将具有更加广阔的应用前景，直缝焊管成形工艺技术的开发正受到越来越多的关注。
直缝焊管排辊成形工艺是由传统辊弯成形技术逐渐演变改进而来的，在排辊成形过程中，为了减少板带回弹、改善成形质量以及增强轧辊共用性，在精成形(封闭孔型)前采用多组形状相同的小轧辊来代替传统辊弯成形时使用的水平辊和立辊。从以往的研究来看，虽然国内外学者针对直缝焊管传统辊弯成形工艺进行了大量研究，但是由于直缝焊管排辊成形工艺更加复杂，当前对于直缝焊管排辊成形工艺的理论研究还很少。直缝焊管排辊成形工艺的理论设计已经成为辊弯成形技术中极具挑战性的课题之一。
本文以上海宝钢股份有限公司钢管厂2005年引进的ERW610焊管排辊成形机组为研究对象，以直缝焊管排辊成形工艺设计为研究主线，采用现场试验、数值模拟和理论研究相结合的方法，分别从直缝焊管排辊成形中板带变形规律、花型设计、成形工艺参数设计以及轧辊设计四个方面进行系统研究。本文首先通过单向拉伸试验获得数值模拟所需要的材料性能参数，基于ADPL语言实现了排辊成形全机组CAD/CAE参数化建模，采用动力显式弹塑性有限元算法对焊管排辊成形过程进行了全流程数值模拟，从塑性应变(横向和纵向)、相对曲率、成形形状等角度详细地分析了不同成形段下板带的变形规律，发现了排辊成形工艺中所存在的变形盲区现象，并结合开口度、板宽以及截面轮廓的测量验证了数值模拟的准确性；为了克服现有各种传统花型设计方法的局限性，基于变形盲区现象提出了适合于直缝焊管排辊成形工艺的新花型设计方法，并采用新花型设计方法对Φ325mm焊管排辊成形工艺机组进行了板材花型图的参数设计；根据直缝焊管排辊成形机组中排辊机架的机构运动特点，提出了排辊成形机组中成形工艺参数设计方法，构造了与成形工艺参数相关联的动态排辊曲面方程，结合新花型设计方法确定了求解初始成形工艺参数的几何约束条件，并且给出了求解最终成形工艺参数的通用算法，在此基础上采用该成形工艺参数设计方法对Φ244.5mm焊管排辊成形机组进行了全新的成形工艺参数设计，通过新旧成形工艺参数下动态数值模拟的结果对比验证了新成形工艺设计方法的正确性和实用性；根据轧辊拓扑结构的不同，建立了轧辊设计知识库，在此基础上基于BP神经网络算法实现了任意规格焊管排辊成形机组的轧辊设计，同时采用该方法对Φ377mm新规格焊管排辊成形机组进行了轧辊设计，并且验证了新规格焊管排辊成形机组轧辊设计方法的可靠性；最后结合之前的研究成果，开发了直缝焊管排辊成形机组CAD/CAE参数化建模、花型设计、成形工艺参数设计以及轧辊设计模块，通过这些模块与参数管理模块、用户管理模块的集成，进而完成了直缝焊管排辊成形工艺设计系统的开发。
通过本文的研究，有助于打破国外的行业封锁和技术垄断，发展直缝焊管排辊成形工艺设计的基础理论，实现排辊成形工艺设计由“经验”到“理论”的转变，加快我国直缝焊管排辊成形工艺技术的推广和应用。
ERW (electric resistance welded) pipes have been increasingly applied in variousindustries, due to their advantages of high efficiency, low energy consumption, goodforming quality and high dimensional accuracy. The seamless pipes have been completelyreplaced with ERW pipes not only in the low-strength application fields such as coal gaspipeline, building structure pipe, but also in the high-strength application fields such ashigh pressure boiler tube, gas and oil line pipe. With quality improvement of ERW pipesand concern for the environment and energy, ERW pipes will be found in more extensiveapplications in future. Therefore, cold roll-forming technologies of ERW pipes have beenpaid much attention in recent years.
At present, there are two major cold roll-forming processes for ERW pipes. One isconventional contour roll-forming process, and the other is the cage roll-forming process.The cage roll-forming is developed from the conventional contour roll-forming. In the cageroll-forming process, for reducing springback, improving forming quality and enhancingroll common use, many small rolls with same shape are used before fin pass stands toreplace horizontal and vertical rolls in conventional roll forming mills. Although manyresearchers have done a lot of work on the conventional roll-forming process of ERWpipes, there are few theoretical studies on the cage roll-forming process. Design of cageroll-forming process is a formidable process, so it is impossible to get satisfactory designresult just by the traditional “trial and error method”. Theoretical design of cageroll-forming process of ERW pipes is an challenge in the cold roll-forming field.
In this thesis, the research on the process design of the cage roll-forming is conductedbased on the ERW610cage roll forming mill introduced by Baosteel in2005. Experiment,numerical simulation and theoretical analysis are combined to systematically study thedeformation behavior of strip, pattern design, forming parameters design and roll design.Through uniaxial tension tests, the required material property data are obtained. Based onADPL language, CAD/CAE parametric modeling of cage roll-forming mill is realized. Thewhole cage roll-forming process of ERW pipes is simulated by dynamic explicitelastic-plastic finite element method. The deformation behavior of strip in different forming sections has been analyzed from different aspects such as plastic strain (transverseand longitudinal), relative curvature and forming shape. The non-bending phenomenon isdiscovered. The numerical simulation is also verified through measurement of openingvalue, strip width and section profile. In order to overcome the limit of traditional patterndesign methods, a new method of pattern design, which is suitable for cage roll-formingprocess, has been put forward based on the non-bending phenomenon and is applied todesign parameters of forming flower diagram in the ERW Φ325mm cage roll-forming mill.According to frame mechanism in cage roll stands of the cage roll-forming mill, a designmethod of forming parameters for cage roll-forming process is presented. The cage rollssurface equation related to forming parameters is constructed, and geometry constraintconditions for solving initial forming parameters are determined. In combination with theproposed new pattern design method, a general algorithm for solving the formingparameters is proposed. As an illustrative case, the new forming parameters of a Φ244.5mm ERW pipe cage roll-forming mill are designed, and the practicality and validity of thedesign method of forming parameters are also proved by comparison of simulation resultsunder new and old forming parameters. According to different geometric shape of rolls, aknowledge base of roll design is built up. Based on BP neutral network algorithm, ageneral roll design method of cage roll-forming mills is implemented. Roll profiles designof the Φ377mm cage roll-forming mill is performed with the proposed roll design method,and reliability of general roll design method of cage roll-forming mills is verified. At last,in combination of above research results, modules of CAD/CAE parametric modeling,pattern design, forming parameters and roll design for cage roll-forming are developedrespectively. Through integrating these modules with parameters management and usermanagement modules, a design system of cage roll-forming process of ERW pipes isdeveloped.
The research of this thesis is helpful to break through foreign trade blockade andtechnology monopoly. By developing the basic theory of cage roll-forming process forERW pipes, the design of cage roll-forming process can be realized by “theoretical design”instead of traditional “empirical design”. This research also contributes to the applicationof cage roll-forming technology in domestic ERW pipe manufacturing industry.
直缝焊管排辊成形工艺是由传统辊弯成形技术逐渐演变改进而来的，在排辊成形过程中，为了减少板带回弹、改善成形质量以及增强轧辊共用性，在精成形(封闭孔型)前采用多组形状相同的小轧辊来代替传统辊弯成形时使用的水平辊和立辊。从以往的研究来看，虽然国内外学者针对直缝焊管传统辊弯成形工艺进行了大量研究，但是由于直缝焊管排辊成形工艺更加复杂，当前对于直缝焊管排辊成形工艺的理论研究还很少。直缝焊管排辊成形工艺的理论设计已经成为辊弯成形技术中极具挑战性的课题之一。
本文以上海宝钢股份有限公司钢管厂2005年引进的ERW610焊管排辊成形机组为研究对象，以直缝焊管排辊成形工艺设计为研究主线，采用现场试验、数值模拟和理论研究相结合的方法，分别从直缝焊管排辊成形中板带变形规律、花型设计、成形工艺参数设计以及轧辊设计四个方面进行系统研究。本文首先通过单向拉伸试验获得数值模拟所需要的材料性能参数，基于ADPL语言实现了排辊成形全机组CAD/CAE参数化建模，采用动力显式弹塑性有限元算法对焊管排辊成形过程进行了全流程数值模拟，从塑性应变(横向和纵向)、相对曲率、成形形状等角度详细地分析了不同成形段下板带的变形规律，发现了排辊成形工艺中所存在的变形盲区现象，并结合开口度、板宽以及截面轮廓的测量验证了数值模拟的准确性；为了克服现有各种传统花型设计方法的局限性，基于变形盲区现象提出了适合于直缝焊管排辊成形工艺的新花型设计方法，并采用新花型设计方法对Φ325mm焊管排辊成形工艺机组进行了板材花型图的参数设计；根据直缝焊管排辊成形机组中排辊机架的机构运动特点，提出了排辊成形机组中成形工艺参数设计方法，构造了与成形工艺参数相关联的动态排辊曲面方程，结合新花型设计方法确定了求解初始成形工艺参数的几何约束条件，并且给出了求解最终成形工艺参数的通用算法，在此基础上采用该成形工艺参数设计方法对Φ244.5mm焊管排辊成形机组进行了全新的成形工艺参数设计，通过新旧成形工艺参数下动态数值模拟的结果对比验证了新成形工艺设计方法的正确性和实用性；根据轧辊拓扑结构的不同，建立了轧辊设计知识库，在此基础上基于BP神经网络算法实现了任意规格焊管排辊成形机组的轧辊设计，同时采用该方法对Φ377mm新规格焊管排辊成形机组进行了轧辊设计，并且验证了新规格焊管排辊成形机组轧辊设计方法的可靠性；最后结合之前的研究成果，开发了直缝焊管排辊成形机组CAD/CAE参数化建模、花型设计、成形工艺参数设计以及轧辊设计模块，通过这些模块与参数管理模块、用户管理模块的集成，进而完成了直缝焊管排辊成形工艺设计系统的开发。
通过本文的研究，有助于打破国外的行业封锁和技术垄断，发展直缝焊管排辊成形工艺设计的基础理论，实现排辊成形工艺设计由“经验”到“理论”的转变，加快我国直缝焊管排辊成形工艺技术的推广和应用。
ERW (electric resistance welded) pipes have been increasingly applied in variousindustries, due to their advantages of high efficiency, low energy consumption, goodforming quality and high dimensional accuracy. The seamless pipes have been completelyreplaced with ERW pipes not only in the low-strength application fields such as coal gaspipeline, building structure pipe, but also in the high-strength application fields such ashigh pressure boiler tube, gas and oil line pipe. With quality improvement of ERW pipesand concern for the environment and energy, ERW pipes will be found in more extensiveapplications in future. Therefore, cold roll-forming technologies of ERW pipes have beenpaid much attention in recent years.
At present, there are two major cold roll-forming processes for ERW pipes. One isconventional contour roll-forming process, and the other is the cage roll-forming process.The cage roll-forming is developed from the conventional contour roll-forming. In the cageroll-forming process, for reducing springback, improving forming quality and enhancingroll common use, many small rolls with same shape are used before fin pass stands toreplace horizontal and vertical rolls in conventional roll forming mills. Although manyresearchers have done a lot of work on the conventional roll-forming process of ERWpipes, there are few theoretical studies on the cage roll-forming process. Design of cageroll-forming process is a formidable process, so it is impossible to get satisfactory designresult just by the traditional “trial and error method”. Theoretical design of cageroll-forming process of ERW pipes is an challenge in the cold roll-forming field.
In this thesis, the research on the process design of the cage roll-forming is conductedbased on the ERW610cage roll forming mill introduced by Baosteel in2005. Experiment,numerical simulation and theoretical analysis are combined to systematically study thedeformation behavior of strip, pattern design, forming parameters design and roll design.Through uniaxial tension tests, the required material property data are obtained. Based onADPL language, CAD/CAE parametric modeling of cage roll-forming mill is realized. Thewhole cage roll-forming process of ERW pipes is simulated by dynamic explicitelastic-plastic finite element method. The deformation behavior of strip in different forming sections has been analyzed from different aspects such as plastic strain (transverseand longitudinal), relative curvature and forming shape. The non-bending phenomenon isdiscovered. The numerical simulation is also verified through measurement of openingvalue, strip width and section profile. In order to overcome the limit of traditional patterndesign methods, a new method of pattern design, which is suitable for cage roll-formingprocess, has been put forward based on the non-bending phenomenon and is applied todesign parameters of forming flower diagram in the ERW Φ325mm cage roll-forming mill.According to frame mechanism in cage roll stands of the cage roll-forming mill, a designmethod of forming parameters for cage roll-forming process is presented. The cage rollssurface equation related to forming parameters is constructed, and geometry constraintconditions for solving initial forming parameters are determined. In combination with theproposed new pattern design method, a general algorithm for solving the formingparameters is proposed. As an illustrative case, the new forming parameters of a Φ244.5mm ERW pipe cage roll-forming mill are designed, and the practicality and validity of thedesign method of forming parameters are also proved by comparison of simulation resultsunder new and old forming parameters. According to different geometric shape of rolls, aknowledge base of roll design is built up. Based on BP neutral network algorithm, ageneral roll design method of cage roll-forming mills is implemented. Roll profiles designof the Φ377mm cage roll-forming mill is performed with the proposed roll design method,and reliability of general roll design method of cage roll-forming mills is verified. At last,in combination of above research results, modules of CAD/CAE parametric modeling,pattern design, forming parameters and roll design for cage roll-forming are developedrespectively. Through integrating these modules with parameters management and usermanagement modules, a design system of cage roll-forming process of ERW pipes isdeveloped.
The research of this thesis is helpful to break through foreign trade blockade andtechnology monopoly. By developing the basic theory of cage roll-forming process forERW pipes, the design of cage roll-forming process can be realized by “theoretical design”instead of traditional “empirical design”. This research also contributes to the applicationof cage roll-forming technology in domestic ERW pipe manufacturing industry.
引文
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