大口径直缝焊管JCO成形有限元分析与关键工艺参数优化
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摘要
随着我国国民经济的迅速发展，社会对石油、天然气的需求量每年都在不断增加，管道运输作为能源输送的主要方式之一，其焊管成形方式以及成形质量也因此受到了社会的广泛关注。近年来，尽管国内许多专家学者对JCOE直缝焊管做了研究，并取得很多重要研究成果；但对于直缝焊管JCO成形过程中关键工艺参数与焊管成形质量关系的研究较少；因此，为提高JCOE直缝焊管生产效率，减少焊管成形所需成形道次，也为可以得到成形质量更好的JCOE直缝焊管，本文将对大口径直缝焊管JCO成形过程中关键工艺参数进行研究。
首先，本文基于大口径直缝焊管JCO成形工艺特点，建立了直缝焊管JCO几何规划模型，利用该模型推导出了板料单次折弯时的目标折弯卷角，为后续JCO工艺参数研究提供了基础。基于直缝焊管JCO成形弯曲平面应变特点建立了二维直缝焊管JCO成形有限元模型，并通过实验验证了有限元模型的可行性。
其次，本文通过有限元模拟技术与正交试验相结合的办法，对大口径直缝焊管JCO成形过程中关键工艺参数（预弯上模渐开线基圆半径、预弯上模渐开线终止角度、JCO成形上模曲率半径、JCO成形下模曲率半径、成形下模间距以及成形道次）与直缝焊管成形质量指标（椭圆度、JCO曲率半径最大偏差、预弯曲率半径最大偏差）和成形难易程度（最大成形力）的变化关系做了研究；通过对模拟结果数据的方差分析和图形分析，明确了各工艺参数对JCO成形管坯的椭圆度、JCO曲率半径最大偏差、预弯曲率半径最大偏差以及最大成形力的影响强弱次序关系以及变化规律。
最后，本文根据模拟结果利用modeFRONTIER软件建立了JCO工艺参数优化模型；优化后，对所得到的Pareto解中不同成形道次下椭圆度最好的工艺参数优化方案进行了模拟分析，结果发现：模拟结果与优化结果在直缝焊管成形质量指标和成形难易程度方面都基本吻合，证明优化结果可靠。通过对优化结果的分析，本文给出了最佳的JCO工艺参数优化方案，该方案既可以保证JCO成形管坯成形质量同时也可以满足企业利润最大化要求。
With the rapid development of China’s national economy, the demand for oil and gasin our society is in increasing every year. Pipeline transport as one of the main mode ofenergy delivery,its forming method and shaping quality have also been concerned by allover the society. In recent years, although many experts and scholars have made lots ofstudies on JCOE forming of Large diameter straight weld steel pipe(LSAW), and haveachieved many important achievements, but as far as the influence and relationshipbetween the key technological parameter in JCO forming process and the molding qualityindex of LSAW are concerned,there are still lack of necessary study.Hence, In order toimprove the production efficiency,reduce the molding number and also in order to getbetter quality’s JCOE LSAW, This paper has studied the key technological parameters inthe forming process of JCO LSAW.
First,the paper put forward JCO geometric model of LSAW based on technologycharacteristics of LSAW and derived the target roll angle using in single bending by themodel.The model provided basic conditions for study to technology parameter of JCO.According to the characteristics of bending plane strain of JCO LSAW, the paper hassetted up the2d JCO finite element model of the forming process,and proved itsrationality by the experiment.
Second, through the way of combining the finite element simulation technology andorthogonal experiment design,the paper has studied and analyzed the relationshipbetween the key technology parameters(the preflex upper die involute circle radius,thetermination angle of preflex upper die involute,the radius of curvature of upper formingdie,the radius of curvature of under forming die,the distance between the underdies,molding number) in the forming process of JCO LSAW and the molding qualityindex(ovality,the maximum curvature deviaton of JCO,the maximum curvature deviatonof preflex) and difficulty level (maximum forming force). Through the variance analysisand the graphics analysis, cleared their reponse relation and significance.
In the end, according to the simulation results,the paper makes use of themoldFRONTIER software established optimization model of technological parameters inthe forming process of JCO LSAW,and according to the principle of best ovality, in theoptimization results, the paper selects the process parameter combination under differentmolding number for simulation. The results shows that simulation results and theoptimization results are almost consistent.This point explains that the optimization resultsare reliable,and through the analysis to the optimization results,the paper provided the bestprocess parameter scheme.The schem not only could ensure quality of JCO LSAW,butalso could meet the maximun request of corporate profit.
首先，本文基于大口径直缝焊管JCO成形工艺特点，建立了直缝焊管JCO几何规划模型，利用该模型推导出了板料单次折弯时的目标折弯卷角，为后续JCO工艺参数研究提供了基础。基于直缝焊管JCO成形弯曲平面应变特点建立了二维直缝焊管JCO成形有限元模型，并通过实验验证了有限元模型的可行性。
其次，本文通过有限元模拟技术与正交试验相结合的办法，对大口径直缝焊管JCO成形过程中关键工艺参数（预弯上模渐开线基圆半径、预弯上模渐开线终止角度、JCO成形上模曲率半径、JCO成形下模曲率半径、成形下模间距以及成形道次）与直缝焊管成形质量指标（椭圆度、JCO曲率半径最大偏差、预弯曲率半径最大偏差）和成形难易程度（最大成形力）的变化关系做了研究；通过对模拟结果数据的方差分析和图形分析，明确了各工艺参数对JCO成形管坯的椭圆度、JCO曲率半径最大偏差、预弯曲率半径最大偏差以及最大成形力的影响强弱次序关系以及变化规律。
最后，本文根据模拟结果利用modeFRONTIER软件建立了JCO工艺参数优化模型；优化后，对所得到的Pareto解中不同成形道次下椭圆度最好的工艺参数优化方案进行了模拟分析，结果发现：模拟结果与优化结果在直缝焊管成形质量指标和成形难易程度方面都基本吻合，证明优化结果可靠。通过对优化结果的分析，本文给出了最佳的JCO工艺参数优化方案，该方案既可以保证JCO成形管坯成形质量同时也可以满足企业利润最大化要求。
With the rapid development of China’s national economy, the demand for oil and gasin our society is in increasing every year. Pipeline transport as one of the main mode ofenergy delivery,its forming method and shaping quality have also been concerned by allover the society. In recent years, although many experts and scholars have made lots ofstudies on JCOE forming of Large diameter straight weld steel pipe(LSAW), and haveachieved many important achievements, but as far as the influence and relationshipbetween the key technological parameter in JCO forming process and the molding qualityindex of LSAW are concerned,there are still lack of necessary study.Hence, In order toimprove the production efficiency,reduce the molding number and also in order to getbetter quality’s JCOE LSAW, This paper has studied the key technological parameters inthe forming process of JCO LSAW.
First,the paper put forward JCO geometric model of LSAW based on technologycharacteristics of LSAW and derived the target roll angle using in single bending by themodel.The model provided basic conditions for study to technology parameter of JCO.According to the characteristics of bending plane strain of JCO LSAW, the paper hassetted up the2d JCO finite element model of the forming process,and proved itsrationality by the experiment.
Second, through the way of combining the finite element simulation technology andorthogonal experiment design,the paper has studied and analyzed the relationshipbetween the key technology parameters(the preflex upper die involute circle radius,thetermination angle of preflex upper die involute,the radius of curvature of upper formingdie,the radius of curvature of under forming die,the distance between the underdies,molding number) in the forming process of JCO LSAW and the molding qualityindex(ovality,the maximum curvature deviaton of JCO,the maximum curvature deviatonof preflex) and difficulty level (maximum forming force). Through the variance analysisand the graphics analysis, cleared their reponse relation and significance.
In the end, according to the simulation results,the paper makes use of themoldFRONTIER software established optimization model of technological parameters inthe forming process of JCO LSAW,and according to the principle of best ovality, in theoptimization results, the paper selects the process parameter combination under differentmolding number for simulation. The results shows that simulation results and theoptimization results are almost consistent.This point explains that the optimization resultsare reliable,and through the analysis to the optimization results,the paper provided the bestprocess parameter scheme.The schem not only could ensure quality of JCO LSAW,butalso could meet the maximun request of corporate profit.
引文
[1]赵敏.对“十一五”中国钢管行业发展战略的思考[N].中国冶金报，2006：6-7.
[2]李茂坤.钢管行业“十二五”发展规划纲要[N].中国广告商务网，2011：3-5.
[3]唐立峰.大口径直缝焊管成形应力分析[D].天津：天津大学材料加工工程硕士学位论文，2006：24-32.
[4]王三云.国外大口径直缝埋弧焊管生产技术发展概况[J].焊管，2000（6）：50-58.
[5]潘家华.我国管道发展的发展方向[J].焊管，2008（4）：16-18.
[6]吴坚. UOE成形大直径直缝焊管生产[J].钢管，2000（5）：24-29.
[7]陈国栋.大中口径直缝焊管的排辊成形工艺[J].钢管，2008（2）：43-49.
[8]唐国明. JCOE成形大口径直缝焊管生产工艺介绍[J].钢管，2007（4）：64-66.
[9]谢志民，夏金明.直缝埋弧焊管预弯工艺参数设计[J].焊管，2007（3）：53-55.
[10]李延峰，孙奇. JCOE直缝埋弧焊钢管生产线的研发和应用[J].焊管，（6）：48-53.
[11]肖曙红，郑时雄.大口径直缝焊管机械扩径成形机理研究[J].焊管，2009（4）：48-51.
[12]贺幼良，白光润,等.焊管胀径工艺理论研究[J].焊管，2002（6）：9-11.
[13]李继刚.国外逐步折弯技术发展概况[J].板料成形塑性理论，2005（3）：46-53.
[14]杨专钊，李记科.国内直缝埋弧焊钢管生产状况[J].焊管，2006（3）：13-16.
[15]唐中川，高强. UOE和JCOE管线管的性能和成本分析[J].现代制造技术与装备，2010（2）：14-15.
[16]李霄，熊庆人，石凯，等.成形过程对焊管残余应力的影响[J].机械工程材料，2010（5）:94-97.
[17]李强,范利锋,高颖，等.模具曲率半径对X80管线钢管JCO成形影响分析.塑性工程学报，2010,17(3):113~118.
[18]郭宝锋，聂绍珉，金淼.大口径管线钢管机械扩径工艺实验研究[J].锻压技术，2001（3）：44-46.
[19]邓波，李云龙，惠非.直缝埋弧焊管机械扩径影响因素分析[J].焊管，2010（5）：42-45.
[20]赵国伟，王元勋.板料成形回弹模拟及补偿技术研究现状[J].锻压技术，2005（3）：45-48.
[21]罗云华，王磊.高强板料冲压回弹影响因素研究[J].锻压技术，2009（2）：46-49.
[22]谢晖.基于CAE仿真的冲压回弹影响因素研究[J].湖南大学学报，2003（5）：34-38.
[23]官英平，张庆，赵军.中性层内移对弯曲回弹的影响[J].锻压技术，2007（2）：56-59.
[24] Ludwik. On springback after the pure bending of beams and plates of elastic work-hardeningmaterials—III[J]. International journal of mechanical scienccs,2010(23):687-695.
[25] R.Hill．The Mathematical Theory of Plasticity[J].Oxford,London,1950:435-443.
[26] F.J. Crafoord. Springback after the biaxial elastic-plastic pure bending of a rectangular plate—I[J].International journal of mechanical scienccs,2009(23):619-630.
[27] Chnantao Wang,Gary ginzel,Taylan Altan. Mathematical modeling of plane-strain bending of sheet andplate [J]. Journal of materials proceeding tecbuolngy,1993(39):279-304.
[28] Chuantao Wang,Gafy Kinzci,Taylan Altan. Process and springback control in plane strain sheetbending[J]. SAE Technical paper,1993(24):332-342.
[29] Chuantao Wang. A new model for springback prediction in which the Bauschinger effect isconsidered[J]. International Journal of Mechanical Sciences，2001(8):1813-1832.
[30] Chin-ChanChu. The effect of restraining force on springback[J]. International Journal of SolidsStructure,2009(27):1035-1046.
[31] Farhang.pourboghra. Springback in plane strain stretch/draw sheet forming[J]. InternationalJournal of Mechanical Sciences,2010(36):327-341.
[32] Z.T.Zhang. Development of a new model for plane strain bending and springback analysis[J]. Journal ofmaterials engineering and performents,2000(4):291-299.
[33] Z.T.Zhang, SJ．Hu. Stress and residual stress distributions in plane strain bending[J].Internationnaljournal of mechanlcal science,2006(6):533-543.
[34] Daw-Kwei Leul. On the effects of geometric parameters on springback in sheets of five materialssubjected to air V bending[J]. Journal of Materials Processing Technology,2010(123):459-463.
[35] Daw-Kwei Leul,Magnusson. An empiric model for controlling springback in V-die bending ofsheet metals[J]. Journal of Materials Processing Technology,2009(34):449-455.
[36] The UNCOMMON APPROACH to metalforming[J]. jxr，译.美国Grotnrs金属成型设备公司关于钢管机械扩径机建议书，1999：3.
[37] ABAQUS/Standard有限元软件入门指南[M].朱以文，蔡元奇，译.北京：清华大学出版社，1998：44-58.
[38]非线性有限元软件ABAQUS[M].梁明刚，译.北京：新世纪出版社，2005：33-45.
[39] ABAQUS非线性有限元分析与实例[M].庄茁，张帆，岑松，译.北京：科学出版社，2003：33-43.
[40]弹塑性实例分析[M].石亦平，译.北京：清华大学出版社，2007：44-48.
[41]陈魁.试验设计与分析[M].北京：清华大学出版社，2005：89-122.
[42]多目标稳健设计优化解决方案Isight培训手册[M].李明义，译.北京：赛特达科技有限公司，2009.
[43]张文修，梁怡.遗传算法的数学基础[M].西安：西安交通大学出版社，2003：3-8.
[44] modeFRONTIER多目标优化软件[M].梁怡.北京：清华大学出版社，2009：5-14.
[45] Deb.K, Pratap.A, Agarwal.S, Meyarivan.T. A fast and elitist multiobjective genetic algorithm:NSGA-II[J]. Evolutionary Computation,2002(26):182-197.
[46] Elahe Fallah-Mehdipour,Omid Bororg Haddad,Mahmoud.M.Rezapour Tabari. Extraction ofdecision alternatives in constructions management projects:Application and adaptation ofNSGA-II and MOPSO[J]. Computationnal Optimization and Application,2011(39):2794-2803.
[47] KAWASAKI Steel Corporation.Technical Specification and Scope of Supply[J].2009(42):38-42.
[2]李茂坤.钢管行业“十二五”发展规划纲要[N].中国广告商务网，2011：3-5.
[3]唐立峰.大口径直缝焊管成形应力分析[D].天津：天津大学材料加工工程硕士学位论文，2006：24-32.
[4]王三云.国外大口径直缝埋弧焊管生产技术发展概况[J].焊管，2000（6）：50-58.
[5]潘家华.我国管道发展的发展方向[J].焊管，2008（4）：16-18.
[6]吴坚. UOE成形大直径直缝焊管生产[J].钢管，2000（5）：24-29.
[7]陈国栋.大中口径直缝焊管的排辊成形工艺[J].钢管，2008（2）：43-49.
[8]唐国明. JCOE成形大口径直缝焊管生产工艺介绍[J].钢管，2007（4）：64-66.
[9]谢志民，夏金明.直缝埋弧焊管预弯工艺参数设计[J].焊管，2007（3）：53-55.
[10]李延峰，孙奇. JCOE直缝埋弧焊钢管生产线的研发和应用[J].焊管，（6）：48-53.
[11]肖曙红，郑时雄.大口径直缝焊管机械扩径成形机理研究[J].焊管，2009（4）：48-51.
[12]贺幼良，白光润,等.焊管胀径工艺理论研究[J].焊管，2002（6）：9-11.
[13]李继刚.国外逐步折弯技术发展概况[J].板料成形塑性理论，2005（3）：46-53.
[14]杨专钊，李记科.国内直缝埋弧焊钢管生产状况[J].焊管，2006（3）：13-16.
[15]唐中川，高强. UOE和JCOE管线管的性能和成本分析[J].现代制造技术与装备，2010（2）：14-15.
[16]李霄，熊庆人，石凯，等.成形过程对焊管残余应力的影响[J].机械工程材料，2010（5）:94-97.
[17]李强,范利锋,高颖，等.模具曲率半径对X80管线钢管JCO成形影响分析.塑性工程学报，2010,17(3):113~118.
[18]郭宝锋，聂绍珉，金淼.大口径管线钢管机械扩径工艺实验研究[J].锻压技术，2001（3）：44-46.
[19]邓波，李云龙，惠非.直缝埋弧焊管机械扩径影响因素分析[J].焊管，2010（5）：42-45.
[20]赵国伟，王元勋.板料成形回弹模拟及补偿技术研究现状[J].锻压技术，2005（3）：45-48.
[21]罗云华，王磊.高强板料冲压回弹影响因素研究[J].锻压技术，2009（2）：46-49.
[22]谢晖.基于CAE仿真的冲压回弹影响因素研究[J].湖南大学学报，2003（5）：34-38.
[23]官英平，张庆，赵军.中性层内移对弯曲回弹的影响[J].锻压技术，2007（2）：56-59.
[24] Ludwik. On springback after the pure bending of beams and plates of elastic work-hardeningmaterials—III[J]. International journal of mechanical scienccs,2010(23):687-695.
[25] R.Hill．The Mathematical Theory of Plasticity[J].Oxford,London,1950:435-443.
[26] F.J. Crafoord. Springback after the biaxial elastic-plastic pure bending of a rectangular plate—I[J].International journal of mechanical scienccs,2009(23):619-630.
[27] Chnantao Wang,Gary ginzel,Taylan Altan. Mathematical modeling of plane-strain bending of sheet andplate [J]. Journal of materials proceeding tecbuolngy,1993(39):279-304.
[28] Chuantao Wang,Gafy Kinzci,Taylan Altan. Process and springback control in plane strain sheetbending[J]. SAE Technical paper,1993(24):332-342.
[29] Chuantao Wang. A new model for springback prediction in which the Bauschinger effect isconsidered[J]. International Journal of Mechanical Sciences，2001(8):1813-1832.
[30] Chin-ChanChu. The effect of restraining force on springback[J]. International Journal of SolidsStructure,2009(27):1035-1046.
[31] Farhang.pourboghra. Springback in plane strain stretch/draw sheet forming[J]. InternationalJournal of Mechanical Sciences,2010(36):327-341.
[32] Z.T.Zhang. Development of a new model for plane strain bending and springback analysis[J]. Journal ofmaterials engineering and performents,2000(4):291-299.
[33] Z.T.Zhang, SJ．Hu. Stress and residual stress distributions in plane strain bending[J].Internationnaljournal of mechanlcal science,2006(6):533-543.
[34] Daw-Kwei Leul. On the effects of geometric parameters on springback in sheets of five materialssubjected to air V bending[J]. Journal of Materials Processing Technology,2010(123):459-463.
[35] Daw-Kwei Leul,Magnusson. An empiric model for controlling springback in V-die bending ofsheet metals[J]. Journal of Materials Processing Technology,2009(34):449-455.
[36] The UNCOMMON APPROACH to metalforming[J]. jxr，译.美国Grotnrs金属成型设备公司关于钢管机械扩径机建议书，1999：3.
[37] ABAQUS/Standard有限元软件入门指南[M].朱以文，蔡元奇，译.北京：清华大学出版社，1998：44-58.
[38]非线性有限元软件ABAQUS[M].梁明刚，译.北京：新世纪出版社，2005：33-45.
[39] ABAQUS非线性有限元分析与实例[M].庄茁，张帆，岑松，译.北京：科学出版社，2003：33-43.
[40]弹塑性实例分析[M].石亦平，译.北京：清华大学出版社，2007：44-48.
[41]陈魁.试验设计与分析[M].北京：清华大学出版社，2005：89-122.
[42]多目标稳健设计优化解决方案Isight培训手册[M].李明义，译.北京：赛特达科技有限公司，2009.
[43]张文修，梁怡.遗传算法的数学基础[M].西安：西安交通大学出版社，2003：3-8.
[44] modeFRONTIER多目标优化软件[M].梁怡.北京：清华大学出版社，2009：5-14.
[45] Deb.K, Pratap.A, Agarwal.S, Meyarivan.T. A fast and elitist multiobjective genetic algorithm:NSGA-II[J]. Evolutionary Computation,2002(26):182-197.
[46] Elahe Fallah-Mehdipour,Omid Bororg Haddad,Mahmoud.M.Rezapour Tabari. Extraction ofdecision alternatives in constructions management projects:Application and adaptation ofNSGA-II and MOPSO[J]. Computationnal Optimization and Application,2011(39):2794-2803.
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