圆成方辊弯成形孔型设计及工艺参数优化  

Pass design and process parameter optimization of circular tube roll forming square tube

作　　者：邢梦龙 王海军 付玉涛 杜凤山 XING Menglong;WANG Haijun;FU Yutao;DU Fengshan(National Engineering Research Center for Equipment and Technology of Cold Strip Rolling,Yanshan University,Qinhuangdao 066004,Hebei China;Qinhuangdao Chen-Ming Special-Shaped Tube Manufacturing Co.Ltd.,Qinhuangdao 066000,Hebei China)

机构地区：[1]燕山大学国家冷轧板带装备及工艺工程技术研究中心,河北秦皇岛066004 [2]秦皇岛宸铭异型管制造有限公司,河北秦皇岛066000

出　　处：《华中科技大学学报（自然科学版）》2024年第6期135-141,163,共8页Journal of Huazhong University of Science and Technology(Natural Science Edition)

基　　金：国家自然科学基金面上项目(51975510);河北省自然科学基金重点资助项目(E2017203043)。

摘　　要：基于体积不变定律和金属连轧秒流量相等原则计算了孔型设计中的相关参数,以50 mm×50 mm×6 mm的方管为研究目标,基于拓扑映射原理对孔型参数进行设计计算;根据辊花图建立了辊弯成形有限元模型,分析不同工艺参数对增厚系数的影响,基于响应面法建立了角部增厚的回归模型;结合国标GB/T6728-2002和角部充满度考虑,采用不同优化算法对回归模型进行优化,将优化方案的仿真结果与原方案进行对比;以优化方案作为初始参数进行辊弯成形试验,将优化方案的仿真结果与试验结果进行对比.结果表明:孔型设计的仿真结果与设计结果在角部存在一定误差;角部的欠充满状态可以采用增加圆管管径的方式进行补偿,但同时会引起壁厚的增加;虚拟仿真数据能够用于回归模型的建立,优化方案的仿真结果与回归模型的预测结果误差较小,验证了回归模型的可靠性;优化方案的仿真结果使得角部充满度较原方案更高,验证了优化结果的有效性;优化结果与试验结果误差小于10%,验证了有限元模型的准确性.Based on the law of constant volume and the principle of equal flow per second in continuous metal rolling,the relevant parameters in pass design were calculated.Taking the square pipe of 50 mm×50 mm×6 mm as the research object,the parameters of the pass were designed and calculated based on the topology mapping principle.The finite element model of roll forming was established according to the roll flower,and the influence of different process parameters on the thickening coefficient was analyzed.The regression model of corner thickening was established based on the response surface method.Considering GB/T6728-2002 and corner filling degree,different optimization algorithms were used to optimize the regression model,and the simulation results of the optimization scheme were compared with the original scheme.The optimized scheme was used as the initial parameter for the roll forming test,and the simulation results of the optimized scheme were compared with the testing results.Results show that there is an error in the corner between the simulation results and the design results of the pass design.The underfilling state of the corner can be compensated by increasing the diameter of the circular tube,but this way will cause the increase of the wall thickness.The virtual simulation data can be used to establish the regression model,and the error between the simulation results of the optimization scheme and the prediction results of the regression model is small,which verifies the reliability of the regression model.The simulation results of the optimization scheme make the corner filling degree higher than the original scheme,which verifies the effectiveness of the optimization results.The error between the optimization results and the testing results is less than 10%,which verifies the accuracy of the finite element model.

关 键 词：辊弯成形 孔型设计 有限元模型 响应面法 优化算法 

分 类 号：TG335[金属学及工艺—金属压力加工]