面向壁厚均匀的液压成形三通管的坯料设计方法与参数优化  

Design Method and Parameters Optimization of Tube Blank for Hydroforming of T-shaped Tube with Uniform Thickness

作　　者：张渝[1] 周豪[1] 王祥鉴 蓝丽招 刘奇峰 ZHANG Yu;ZHOU Hao;WANG Xiangjian;LAN Lizhao;LIU Qifeng(School of Mechanical and Electrical and Vehicle Engineering,Chongqing Jiaotong University,Chongqing 400074,China)

机构地区：[1]重庆交通大学机电与车辆工程学院,重庆400074

出　　处：《精密成形工程》2024年第5期225-234,共10页Journal of Netshape Forming Engineering

基　　金：重庆市自然科学基金面上项目(CSTB2022NSCQ-MSX1444)。

摘　　要：目的研究连续变厚度管液压成形过程中三通管的壁厚均匀性问题。方法首先,利用有限元软件分析得到了等厚管液压成形三通管过程中的成形规律,根据其成形规律,反向设计了用于液压成形三通管的连续变厚度管坯;其次,采用正交试验方法,研究了连续变厚度管厚区壁厚、过渡区长度对液压成形三通管成形质量的影响;最后,采用多岛遗传算法,对连续变厚度管的结构参数进行了优化验证,提高了液压成形三通管的成形质量。结果在等厚管液压成形三通管成形过程中,支管顶部壁厚值持续减小、轴向过渡圆角及直管底部中间位置处壁厚值持续增大;环向过渡圆角处等效应力最大,其他位置连续变化;轴向压应力使得三通管壁厚增大,拉应力使得壁厚减小;正交试验结果表明,当连续变厚度管厚区厚度、环向过渡区长度达到某一值时将出现较好的壁厚均匀性;在4种过渡区曲线线型中,直线型的壁厚均匀性最好;通过多目标优化得到最佳连续变厚度管结构参数,并通过有限元仿真进行验证,相对误差均在2%以内,使用优化后的连续变厚度管液压成形三通管相对于等厚管,壁厚均匀值减小了0.423 mm。结论可以采用厚度补偿或减薄的方式来提高成形三通管的壁厚均匀性;连续变厚度管坯相比于等厚管,显著提高了液压成形三通管的壁厚均匀性。The work aims to research the thickness uniformity of T-shaped tubes in the hydroforming process of continu-ously variable thickness tubes.Firstly,the forming rule of the equal thickness tube in the process of forming T-shaped tubes was obtained by finite element software analysis,and the continuous variable thickness tube blank was designed in the reverse direction according to the forming rule. Secondly, the effects of the thickness of continuous variable thickness tube and the length of transition zone on the forming quality of T-shaped tubes were studied by orthogonal experiment. Finally, the structural parame-ters of the continuous variable thickness tube were optimized and verified by multi-island genetic algorithm, and the forming quality of the hydroformed T-shaped tube was improved. During the forming process of the equal thickness hydroformed T-shaped tube, the thickness at the top of the branch tube decreased continuously, and the thickness at the axial transition corner and the middle position at the bottom of the straight tube increased continuously. The equivalent stress at the annular transition corner was the largest, and that at other positions changed continuously. The axial compressive stress made the thickness of the T-shaped tube increase and the tensile stress made the thickness decrease. The results of orthogonal test showed that the best uniformity of thickness would appear when the thickness of the continuous variable thickness tube and the length of the circum-ferential transition zone reached a certain value. Among the four types of transition zone curves, the linear type had the best uniformity of thickness. The optimum structural parameters of continuous variable thickness tube were obtained by mul-ti-objective optimization. The finite element simulation results showed that the relative error was less than 2%. Compared with the equal thickness tube, the thickness uniformity of the continuously variable thickness tube was reduced by 0.423 mm. In conclusion, the thickness uniformity of

关 键 词：连续变厚度管 液压成形 壁厚均匀性 结构设计 多岛遗传算法 

分 类 号：TG386[金属学及工艺—金属压力加工]