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华中科技大学硕士学位论文步进式薄壁圆管成形工艺及模具的研究与开发姓名：刘玉堂申请学位级别：硕士专业：材料加工工程指导教师：李志刚;王耕耘20050506I(Press)(Roll)ExcelExcelmnKUGIIAbstractTheweldedtubeiswildlyappliedinmanyfields,suchasoilmillgastransportationarchitectureautomobiletransportation,etc..Withthedevelopmentoftheseindustries,thedemandforweldedtubeisgrowingrapidly,whichimpeltheevolutionofweldedtubeproductionenormously.Atpresent,PressMethodandRollMethodarethetwomainmethodstoformtheweldedtube.ThePressMethodissuitabletoproducethediversiformproductsinsmall-scaleproduction.Contrasttotheformer,Rollmethodfitsforthemassproductionoflongtubesbetter.Withthedemandsforfunctionsanddiversitiesgettinghigherandhigher,productsbeyondthespecificationofRollmethodaredemandedmoreandmore.Inordertomeetthesedemands,ProgressiveEdgeBendingMethodforweldedtubewasdeveloped,whichfitstoproducethediversiformlongcirculartubesinasmall-scaleproduction.HowtominimizethelongitudinalwarpageandedgewavesisthekeystepofProgressiveEdgeBendingMethod.Inthispaper,thereasonswhylongitudinalwarpageandedgewavesoccurwasanalyzedandthentheassumptionthatthesedefectscanbesuppressedwhenthelengthoftheedgeequalstothelengthofstripcenterwasproposed.Dependingonthisassumption,fourkindsoftubeformingmethodswereanalyzedandtheedgebendingmethodwaschosen.Bythedeeperresearches,authorsnotonlyconstructedtheauxiliarymodel,butalsoeducedthemathematicequationsofthekeycurvesandthevaluerangeofparameters.InExcel,accordingtotheminimumprinciple,auxiliarytablewassetupandthecurvegraphofelongationcoefficientofedgewasdrawntocalculatetheoptimumvalueofm,nandK.Onthebasisofanalysis,authorsutilizedUGtodevelopanewmouldthatintegratedshearingandsizingunitstoimprovethemould’sperformance,reducethefloorspaceandthecosts.Byanalyzingshortagesresultedfrommouldtesting,authorsproposedseriesofmethodstoimprovethedesign,whichcouldproducetheeligibleweldedtube.Theauthors’assumptionandtheconclusionwereprovedbytheactualproduction,andthemouldfitstoproducethediversiformlongcirculartubesinasmall-scaleproduction.Keywordsweldedtubeprogressivebendingedgebendinglongitudinalwarpageedgewave111.1AMINOAMINOcorporation,Japan70%1.2[1-6][9]——2182518431896450kHz1960——1%31.3203050[43]1.3.1[12]5032mm63.5mm102mm1979224199416001986200219mm18820mm201.119901999902001[8]2003699401069604199119921993199419951996199719981999261.60318.40295.20432.33495.77429.77573.80450.61450.81231.40265.20283.60303.95327.01333.98360.50346.66345.75199960F.F[47]901.3.2[12]60701938550194960801.119631997[18]1963NbVNbMoH2S30019924501958196910.6197928.319925785.522.491.21.4[15]162CATCATVAICostsavingTimereducingAvailabilityincreasingFlexibleforming3CAD/CAM/45TQCSTimeQualityCostServiceCAD/CAM71.5,,1234CADUG5822.1RollformingPress,UOUUOOUO30UO[30]2.19[23][7]2.22.12.1lllt/Dnn2lllt/Dnn3102.22.3112.32.3.1l180LLLLLe′-=10012[53][10][11]Eskg/cm2Ekg/cm2sEssll2.3.2[53]2hllΔ∝11323456.T.xcDr5014[23]20[23][21]2.41512345UO[21][53][58]CenterBendingR1802.4PInvolute[]X=Rsin+()cosqpqq-[]Y=R1-cos+()sinqpqq-04.94()RLRdppqq==-∫Ymax=(1+)2.572RRp=XY——PRLPYmax()16R(Y)(L)EdgebendingR2.5PLCycloid[]X=R()+sinpqq-Y=R(1-cos)q0==2(1cos)4.0LRdRpqq-∫Ymax=2R17CircularBendingR2.6PHelixX=*sinRpqqY=*(1-cos)RpqqL22022sincos1)1(dRpqqqqqqpq+--∫4.44RYmax=2.28R18CombineBendingR2.7X=R(1)sinsin()pjqqjq-⎡⎤-++⎢⎥⎣⎦Y=R(1cos)coscos()pjqqqjq-⎡⎤-+-+⎢⎥⎣⎦19YmaxPL2.52.820[52][52]2.2r/t0.50.20.51.50.31.53.00.333.05.00.45.00.5tt/40.50.250.30.51.50.331.55.00.4V5.00.5tt/3212.62.102.11PunchDie222.6.1[21]123abcd[21]2.14OCOCOBOBOCmYBZ=OBXZnXAZ=OCOBProfileProfileAB/nARLp=/mBKL=LZKXZRmnKab242.6.2Profile()mn1,K0Profile()Profile()en1P25n1nn32.14»»ABOCitseftsfeifetse100ts×ii1steftufgutfgi+1fgute100ut×i+1ieeeΔe0Δe0Δne2.152.16n1neΔn1.6eeΔn1.62.0m1.0,K0,PL/10n=1.0n=1.6n=2.0n=3.0n=0.81.02.0Z/LPe262.6.3nemKKn1.8m2K/LeK/LeeK/L0.050.08m1.0,K0,L/P=10n=1.0n=1.6n=1.8n=3.0Z/L27K/L0.06n1.8mmProfile2.18mmm2.5m=2,n1.8,L/P=10n1.8,K/L=0.06,L/P=10m=1.0m=2.0m=2.5m=5.00.20.4-0.20.6-0.4-0.6m=3.0Z/L282.6.42.19A-A117()nzxRLp=1()mzyKL=zy2ab29LrRxp=-3180**LrRqp=4|90|aq=-5*'*cos()180xRap=x6{*90(1sin())180'*90(1sin())180RyRapqapq-=+oo=(1cos())180Rqp-71180180arctan()*arctan()mmdyzmKdzLbpp-==z8*'sin()180eybp=gz9*'cos()180fybp=gy10Zze=-zz11'Xxx=+x121(){1cos[()]}cos[arctan()]mnmmnmzzmKYyfKRzLLKp-=+=++y13221()()dldydz=+dz142222()()()dldXdYdZ=++15122221001LmSdlLKmtdt-==+∫∫1620LLdl=∫1730L2(,,)mnKSLΦ=-(,,)(,,)(,,)FmnKLmnKmnKl=+Φ/0Fm∂∂=/0Fn∂∂=/0FK∂∂=mnK17Excel2.3D25.4mmt0.8mmr(D-2t)/211.9mmr/t14.8755.02.20.5R(D-t)/212.3mmBB2R77.28mmExcel0.20.231D(mm)25.40t(mm)0.80K/L10.059m2.384n1.837L1(mm)700K(mm)41.30R(mm)D-t/212.30B(mm)77.28B/2(mm)38.64P(mm)70N103233342.712343533.1ProfileProfileUGUnigraphicsUGUGlawcurveUGExpressionsExpressions[49]tUG01radrad(x)xabExpressionslawcurveProfileProfile36t=1L=700mmxt=t*LTT=0.8R=(D-TT)/2K=0.05818*lm=3.11n=1.865yt=pi()*R*(xt/L)^nzt=K*(xt/L)^mProfile(M)Profile(N)lawcurve373.2PPFFFFF1F1F2F2F2F2F2F2[58]38393.3[9][21]11433.1076300ab40413.4C3.14[28][36]:O-AA-BB-C42O-AAOA,,A-BBABB-CCOB,BC,1IIIXIIIVIVV3.15[54]IIIIIIIV3.163.17IV1I433.530701CAD90210443CAD3.6453.7UGLawcurve4644.1[21]123456AMINO1001850m