Mechanism of weld-line movement within hydroforming of tailor-welded tube

To reveal the reason of weld-line movement in hydroforming of a tailor-welded tube (TWT) with dissimilar thickness,the stress ratio of axial stress to circumferential stress is derived by mechanical analysis and analyzed between the thicker and thinner tubes,as well as the property of the axial strain. During TWT hydroforming,tensile strain along axial direction happens on the thinner tube. On the contrary,compressive strain happens on the thicker tube. Experiments are conducted to varify the weld-line movement regularity and strain distribution. It indicates that the weld-line moves from the thinner part to the thicker during TWT hydroforming. The thinning ratio of the thinner tube is bigger than that of the thicker tube,especially in the zone near weldline. Stress ratio difference between the thicker tube and the thinner tube is the main reason of weld-line movement and non-uniform thinning ratio distribution.     

Influence of loading path on formability of 304 stainless steel tubes

The loading path affects the metal formability remarkably in tube hydroforming, and it is also one of the research focuses. Recently, some scholars abroad proposed a new fluctuant hydraulic loading method, which can improve the formability of tubes in hydroforming. Related studies have shown that this new loading method can improve the tube formability, the distribution of deformation is more uniform and this is useful for avoiding excessive local thinning. In this paper, tube hydroforming experiments without axial feeding were carried out; the influences of the loading methods on formability of stainless steel tubes were studied. Through the comparison of the experimental results under the condition of monotonous increase loading and fluctuation hydraulic loading, the outside diameter distribution, the thickness distribution and the crack expansion forms of deformation zone all fully prove that the uniformity of the distribution of tube deformation and formability have been increased significantly under the condition of fluctuation loading without axial feeding, the reasons should be distinguished from the fluctuation hydroforming with axial feeding. In order to study the forming mechanism, uniaxial tensile test of tubes similar to fluctuation loading deformation is designed in this paper, namely intermittent tensile test. It is found that intermittent uniaxial stretch can improve the tube elongation at fracture by about 40% and the deformation distribution is more uniform than that through uniaxial tensile test of the stainless steel tube. In the process of intermittent tensile tests, changes of metal microstructures brought by the loading and unloading processes are the main reasons that improve the formability of the tubes.     

Corner forming of AZ61A magnesium alloy tube within warm hydroforming

The corners with small radii on cross sections are crucial for forming hydroformed components with polygonal sections.In this paper,warm hydroforming experiments of AZ61A magnesium alloy tubes were carried out to study the forming regularity of round corners by using a demonstration part with square sections.Effects of temperature on radius forming,thinning ratio distribution and microstructure were revealed and a component with relative outer corner radius of 3.0 was obtained by warm hydroforming at 240℃.The minimum thickness of the formed square section was located in the transition position between the corner and the straight wall.The thinning ratio of the round corner increased with the increase of forming temperature.Formability of the magnesium tube was improved by raising temperature under the effect of dynamic recrystallization at 240℃.     

轴向进给速度对内高压成形三通管影响的有限元分析

利用有限元法证实了内高压成形三通管的可行性,给出了不同轴向进给速度下零件的壁厚及应变分布,并就轴向进给速度对成形的影响进行了分析.结果表明,轴向进给速度的选取对内高压成形三通管具有重要影响.     

Experimental and Numerical Research on Deformation Behavior of Thin-Walledand Large Expansion Ratio Guide Vane Liner in Hydroforming Process

Some tube hydroforming process tests and further research work were conducted to manufacture hollow guide vane liners (made of super alloy GH3030).The relative thickness (t₀/OD) of the tubular blank is approximately 0.01,and the maximum expansion ratio (Dmax/OD) of the needed part is more than 40％, and the length to diameter ratio of the expansion regionis more than 3.0. It is very hard to manufacture this kind of ultra-thin-wall, curved axis and large expansion ratio tubular part without fracture and wrinkles. The success of the process is highly dependent on useful wrinkles with appropriate internal pressure and axial feeding. A simplified finite element model and a theoretical model are used for detecting the deformation behavior and forming laws. Further study results demonstrate that the useful wrinkles do not appear at the same time and middle-wrinkles need bigger axial force than tube-end-wrinkles and feeding-wrinkles. The wrinkles can transfer bigger axial force after its wave peak has come into contact with the die inner surface. The thickness thinning rate of the element at the peak is bigger than that at the trough.With the increase of the axial and hoop stress ratio, the critical buckling stress also increases. Microstructure examination results show that the grain size in the maximum thinning zone has been stretched and refined after the large deformation and annealing treatment. The process is feasible and the finished part is qualified.     

Deformation and defects in hydroforming of Y-shaped tubes

Hydroforming process of a Y-shaped stainless steel tube was investigated through numerical simulation and experiments. The forming process and reasons of typical defects were analyzed with three different loading paths. Thickness distribution of formed Y-shaped tube was obtained. It is shown by numerical and experimental results that the transition regions are depressed in the forming condition of low inner pressure and wrinkles occur, while fracture occurs in the forming condition of high inner pressure. After forming, the thickness in left transition fillet region is the largest, that in fight transition fillet region is thinner, and the thinnest thickness is at the top of the protrusion. The original thickness line is below the top of the protrusion. The thinning area occurs above this line, while the thickening area is below this line. The maximum thinning rate is significantly increased as the calibration pressure increases, while the maximum thickening rate remains almost unchanged.     

双锥形管液压成形过程中破裂和起皱的力学条件

针对双锥形管液压成形过程,分析了破裂和皱纹产生的几何及力学原因,并用数值模拟和工艺实验进行了验证。研究结果表明,有益皱纹需要同时满足几何条件和力学条件。几何条件是补料结束时形成的局部皱纹表面积略小于零件相应的表面积。力学条件是皱纹形状参数G不小于中间皱峰半径R,皱峰在后续高压整形过程中壁厚无减薄。当几何条件不满足时,即坯料任一段表面积大于零件相应表面积会起皱,过小会破裂:当力学条件不满足时,整形过程中中间皱峰发生开裂。     

T型管液压成形加载路径自适应多目标优化

为解决静态代理模型非线性结构优化效率、精度低的问题,采用最小二乘支持向量回归机(LSSVR)模型进行T型管液压成形加载路径自适应多目标优化研究.用一个数值算例说明本文方法的有效性,以管与背压冲头的接触面积最大及管的最大减薄率最小为优化目标,以接触面积大于对标仿真值、最大减薄率小于实验值、高度大于实验值为约束条件进行多目标优化设计.采用拉丁超立方体设计构造初始支持向量回归模型,用自适应法将每次迭代中获得的额外取样点添加到重建的支持向量回归机模型,得到帕累托最优解集.用理想点法,选择一个最优妥协解以供工程师选用.在成形高度没有变差的情况下,自适应多目标优化结果的管与被压冲头接触面积比实验值提高了32.42%,最小厚度比实验值增加了14.97%.表明自适应迭代LSSVR模型能够在少量样本下保证优化设计精度和计算效率.     

全浮芯棒二辊孔型中轧管金属变形行为研究

为分析连轧荒管管壁收缩的原因,借助有限元模拟软件MSC.Super Form,对宝钢Φ140 mm全浮芯棒连轧管机组Φ119 mm主孔型系钢管的单机架轧制过程进行数值模拟仿真,研究轧制过程中不同工艺参数对金属变形行为的影响,分析产生壁厚收缩缺陷的倾向性。结果表明：孔型顶部的壁厚压下量一定时,孔型开口处壁厚随空减坯径壁比的增大由＂增壁＂变为＂减壁＂,并且存在一临界径壁比;径壁比一定时,孔型开口处壁厚变化随压下量的增大由＂增壁＂变为＂减壁＂,并存在临界压下量;径壁比、压下量均一定时,单机架轧制高钢级时孔型开口处壁厚值相对较大。     

Optimizing loading path and die linetype of large length-to-diameter ratio metal stator screw lining hydroforming

In order to meet the high temperature environment requirement of deep and superdeep well exploitation, a technology of large length-to-diameter ratio metal stator screw lining meshing with rotor is presented. Based on the elastic-plasticity theory, and under the consideration of the effect of tube size, material mechanical parameters, friction coefficient and loading paths, the external pressure plastic forming mechanical model of metal stator screw lining is established, to study the optimal loading path of metal stator lining tube hydroforming process. The results show that wall thickness reduction of the external pressure tube hydroforming(THF) is about 4%, and three evaluation criteria of metal stator screw lining forming quality are presented: fillet stick mold coefficient, thickness relative error and forming quality coefficient. The smaller the three criteria are, the better the forming quality is.Each indicator has a trend of increase with the loading rate reducing, and the adjustment laws of die arc transition zone equidistance profile curve are acquired for improving tube forming quality. Hence, the research results prove the feasibility of external pressure THF used for processing high-accuracy large length-to-diameter ratio metal stator screw lining, and provide theoretical basis for designing new kind of stator structure which has better performance and longer service life.     

横掠椭圆管的换热及流动特性分析

利用隐式有限差分法,对横掠不同轴径比a/b情况下的椭圆管换热及流动特性进行了研究。得到了边界层内速度分布和边界层厚度发展状况。讨论了a/b对边界层分离点的影响。得到了不同管型椭圆管的局部对流换热分布规律,并与圆管和平板绕流进行了比较。     

汽车桥壳液压胀形工艺的研究及最新进展

介绍了半滑动式液压胀形的基本思想以及小型汽车桥壳的液压胀形工艺过程,在普通液压机上试制出模拟样件。提出了钢管胀压成形工艺,先将两端缩径的管坯进行液压胀形得到轴对称的预成形管坯,再对其内部充液（水）并用模具压制成形,并试制出胀压成形桥壳样件。与液压胀形样件比较表明：胀压成形样件轮廓清楚,桥包部分过渡小圆角贴模性好,壁厚减薄量小,成形液压力低。     

Drum instability of thinning spinning ultra thin-walled tubes with large diameter-to-thickness ratio

In order to explore drum instability problems of thinning spinning ultra thin-walled tubes with large diameter-to-hickness ratio, experiments of thinning spinning ultra thin-walled tubes with different clearances between the mandrel and the tube were carried out. The phenomena of drum instability were analyzed. Drum instability mechanism was studied. The important influence of the mandrel-locked ring on stable thinning spinning was found. Besides, two important parameters, namely drum ratio and drum stiffness, were proposed to characterize the drum instability of spinning ultra thin-walled tubes with large diameter-to-thickness ratio. What's more, numerical simulations were applied to explore the influences of different clearance ratios and diameter-to-thickness ratios on the drum instability. As a result, it is found that the mandrel-locked ring is the key to the stability and precision of spinning; drum ratio can reflect the degree of the deformation of the tubes; drum stiffness is a comprehensive index to measure the influences of the tube's own parameters on the spinning instability; both the clearance ratio and diameter-thickness ratio have significant influences on the drum ratio and drum stiffness.     

铝/钢双金属管电磁缩径数值模拟

为指导实际双金属管精确成形工艺,基于LS-Dyna对铝/钢双金属管电磁缩径连接进行了结构场-电磁场耦合的有限元数值模拟,研究了内外管壁厚比值、内外管间隙、放电电压以及芯模对成形质量的影响规律.结果表明:内外管壁厚比值过小易引起内外管连接不紧密,比值过大易导致内管凹陷和外管开裂;随着放电电压增大或内外管间距的减小,外管缩...     

Behavior of galvanized steel tube subjected to web crippling

The details of a research study of galvanized steel tube under web crippling were presented. A total of 48 galvanized steel square hollow sections with different boundary conditions, loading conditions, bearing lengths and web slenderness were tested. The experimental scheme, failure modes, load-displacement curves and strain intensity distribution curves were also presented. The investigation was focused on the effects of loading condition, bearing length and slenderness on web crippling ultimate capacity, initial compressive stiffness and ductility of galvanized steel tube. The results show that web crippling ultimate capacity increases linearly with the increase of the bearing length under EOF and IOF loading condition. In the end-flange and ITF loading conditions, strain intensity of the centerline of web reaches the peak and decreases progressively from central web to flanges. Finite element models were developed to numerically simulate the tests in terms of failure modes and ultimate capacity. Web crippling strength of galvanized steel tube increases linearly with the increase of the ratio of the bearing length to web thickness and decrease of web slenderness. The effect of ratio of galvanized layer thickness to web thickness on web crippling strength is small. Based on the results of the parametric study, a number of calculation formulas proposed in this work can be successfully employed as a design rule for predicting web crippling ultimate capacity of galvanized steel tube under four loading and boundary conditions.     

转化炉管失效分析

某厂转化炉炉管仅运行一段时间就发生开裂,造成经济损失,因此,有必要对失效炉管进行全面的分析。通过化学成分分析、宏观及微观显微组织分析、Ｘ射线衍射分析以及常温、高温力学性能分析等,对转化炉炉管进行失效分析。结果表明,炉管材料失效的主要原因是蠕变开裂,而超温是导致蠕变发生的直接原因,原设计的有效厚度不足是造成炉管爆裂先天性根本原因。     

Numerical simulation and experimental investigation of incremental sheet forming process

In order to investigate the process of incremental sheet forming （ISF） through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those of experiment. The results of numerical simulations, such as the strain history and distribution, the stress state and distribution, sheet thickness distribution, etc, were discussed in details, and the influences of process parameters on these results were also analyzed. The simulated results of the radial strain and the thickness distribution are in good agreement with experimental results. The simulations reveal that the deformation is localized around the tool and constantly remains close to a plane strain state. With decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces, leading to less thinning and more homogeneous plastic strain and thickness distribution. During ISF, the plastic strain increases stepwise under the action of the tool. Each increase in plastic strain is accompanied by hydrostatic pressure, which explains why obtainable deformation using ISF exceeds the forming limits of conventional sheet forming.     

管件液压成形过程的有限元分析及实验研究

以圆管变形为管球相间零件为研究对象,对液压成形这种新工艺进行研究.采用计算机数值模拟与试验相结合的方法,分析了圆管液压成形过程.管件液压成形主要有褶皱和破裂两种失效形式,而成形控制中最主要的参数之一是压力,即管件内部压力和轴向压力.在对不同加载路径进行分析后,得出模拟结果与相同条件下的实验结果比较吻合的结论.研究表明了液压成形工艺中加载路径(内压力与轴向压力的配比关系)的重要性,同时也证实了用计算机模拟仿真液压成形过程具有一定的可靠性.     

四种FRP管约束UHPC轴压特性的试验研究

为研究纤维增强聚合物(fiber reinforced polymer,FRP)管约束超高性能混凝土(ultra-high performance concrete,UHPC)的轴压特性,分别对4个未约束和36个约束圆柱体试件进行了轴压试验,测定了应力-应变全曲线,获得了强度和极限应变值.试验结果发现:FRP约束UHPC可明显提高其强度和变形能力,纤维布层数愈多、强度越高,改善效果愈明显;轴压应力-应变曲线为双线性;在相近的约束比下,FRP管约束刚度越小,约束试件的极限应变值越大;已有的强度和极限应变的模型预测值均高于实测值,极限应变预测值偏离试验值更大.本文回归得到了FRP管UHPC的强度和极限应变预测公式预测精度较高.     

高强钢芯筒-螺栓连接钢管柱节点静力性能试验

为解决现有钢管柱节点单边螺栓锚固不足和操作复杂的问题,提出高强钢芯筒-螺栓连接副装配式节点,连接副由内置于钢管柱的高强钢芯筒和常规高强螺栓组成.为考察这种新型节点的静力性能,对6个1∶1足尺钢管柱框架边节点进行单调加载试验,研究变量为钢芯筒类型、筒壁厚度、螺栓直径、钢梁端板厚度.重点分析节点关键部位的应力变化、变形能力、破坏模式、螺栓拉力和节点类型.结果表明:试件均为半刚性节点、梁端塑性铰破坏机制,封闭型芯筒厚度与螺栓直径相当时可以满足梁柱刚接的强度条件;节点域变形很小可以忽略,芯筒转动变形对节点转动影响不超过10%;钢梁端板与柱的间隙随着芯筒厚度减小而快速增长,螺栓有拔出趋势,连接副的抗拉设计值可按钢板螺纹抗拉承载力的70%取用.