基于扭矩控制的导管内径滚压连接成形特征分析

钛合金导管内径滚压连接技术主要用于飞机液压管路系统中,具有耐高压和高密封性,能够提升飞机液压管路系统的高可靠性能,满足飞机轻量化和长寿命的需求,成为航空管件连接技术的首选方案.本文以理论分析、有限元模拟和试验相结合的方法,从导管滚压连接胀形器各组件的运动状态、接触状况、受力分析以及管材节点位移变化等方面,探讨了基于扭矩控制的导管内径滚压连接成形机理及特征.研究表明,成形过程中芯轴主动转动,滚柱带动保持架周向随动转动;芯轴与滚柱之间有较大的径向挤压力和切向摩擦力,在这两个力的合力作用下,产生轴向进给力,使芯轴自动进给,导管、滚柱和芯轴之间接触面和接触力逐渐增大,成形扭矩随之增加,导管材料逐渐嵌入管套凹槽,完成连接成形,这是扭矩控制的导管内径滚压连接机理所在.理论分析与有限元模拟及试验结论吻合较好,研究结果对工程应用中的质量控制和工艺优化具有一定的指导作用.

Analysis of forming characteristics of the inner tube rolling connection based on torque control

The titanium alloy tube internal rolling connection technology is usually used for the aeronautic hydraulic system. It has the advantages of high pressure resistance and high sealing property, which can lift the reliability of aeronautic hydraulic system to meet the lightweight and long-life needs. Using the method of theory analysis and finite element simulation and experiment, the forming mechanics and characteristics of tube internal rolling based on torque control technology were revealed through the area of the movement state and the contact state and the force between the expander parts, even the displacement of the tube nodes. The result indicated that the mandrel rotated actively, then the roller holder rotated in the rolling process, large radial extrusion pressure and tangential frictional force were generated between the mandrel and the roller. The composite force of the upper two forces made the mandrel feeding automatically. The force between tube and roller and mandrel became larger and larger, and the forming torque became larger following. Last the tube embedded into the sleeve, and the connect process ended. All these conclusion disclosed the mechanics of the internal rolling connection. The results of this article present important guidelines for the quality control and process optimization in the engineering application.