大型折边锥形封头的分辩冲压成型工艺及模具

1、第 50 卷第 2 期2013 年 4 月化工设备与管道PROCESS EQUIPMENT & PIPINGV ol. 50No.2Apr. 2013大型折边锥形封头的分瓣冲压成形工艺及模具陆博福(中国第一重型股份公司 重装事业技术质量部, 黑龙江 富拉尔基161042摘要:在石化压力容器制造过程中,对于大型折边锥体封头因受本企业加工设备能力限制而不能如愿,只有靠外委解决,耗资大。介绍了一种分部成形组焊方法,即对锥体部分按常规工艺进行卷制组焊成形。而对折边段则进行分瓣冲压组焊成形,最后再将两分段部分组焊成形大直径折边锥形封头工艺及模具设计技术。 关键词:大径折边锥封头;分瓣冲压工艺;压

2、模设计制做中图分类号:TQ 050.6;TH 49文献标识码:A 文章编号:1009-3281(201302-0023-004 收稿日期:2012-11-10作者简介:陆博福(1954,男,辽宁辽阳人,高级工程师。现从事压力容器、机械产品检测仪器质量管理工作。在石油化工设备压力容器设计与制造中,锥形封头使用较为普遍。当锥顶半角30°时,要求采用折边锥形封头,其大端有一过渡圆弧,用来降低筒体与锥体连接边缘应力,以改善压力容器受压状态,保证设备安全运行使用。在石化压力容器制造过程中,理想的加工成形工艺是:先卷制成形锥形体,而后用模具对过渡圆弧区进行整体热冲压成形。但由于所制造设备的折边锥

3、体之大受到本企业加工设备能力限制而不能如愿1-5。现介绍一种分部成形组焊方法,即对锥体部分可按常规制法进行卷制组焊成形。而对折边段进行分瓣冲压组焊成形最后再将两分段部分组焊成形大直径折边锥形封头工艺及模具设计技术。1折边锥形封头设计原始条件已知所承制分离器设备的折边锥形封头2 200 mm ×12 mm ,高度H =1 800 mm,下部小端的接口法兰孔直径60 mm 、大端直边H 0=40 mm 、过渡圆弧半径R =330 mm 、锥顶半角=32.75°,材质Q235-A 。为便于制造成形大径折边锥体,对工件进行分部成形,即折边部分和锥体部分,分体的直径尺寸d 取值为:d

4、 =(0.40.75D n = (0.40.75×2 200=1 600 mm 对锥体部分可按常规制法进行卷制组焊成形。对折边段部分进行分瓣冲压组焊成形而后将两分段部分再组焊成形大直径折边锥形封头。2折边锥形封头基本尺寸计算及分瓣数确定大径折边锥形封头基本计算公式推导(图1,图2图1折边锥形封头Fig. 1 Toriconical head图2折边锥形封头分部冲压计算Fig.2 C alculation of separated piece punch for toriconical head2.1折边锥体封头直锥体与过渡圆弧分界直径D iD i =D n -2r (1-cos 例D

5、 i =2 200-2×330(1-cos 32°45'=2 095 mm第 50 卷第 2 期· 24·化工设备与管道2.2压制分瓣段展开曲线长度计算 2.3锥体展开计算(1锥体展开直径(图3 展开分瓣外径弧长计算L K (取n=8试算 K小于YA71-250液压机工作台1 000尺寸,可用。图3折边锥形封头分瓣展开Fig.3 Unfolding of divided piece for toricanicle head3分瓣冲压折边锥形封头模具几何参数 (见图4、图53.1基本数据计算 m 图4折边锥封头主截面弯曲深度d m计算Fig.4 C

6、alculation of curved depth d m for main section图5分瓣冲压折边锥形封头模具计算Fig.5 C alculation of molding tool for divided piece of toriconicle3.2折边封头圆弧过渡曲面在主截面内压形深度d m见图4示出,曲线方程式图形坐标系,公式推导如下:2013 年 4 月· 25·设直线l3/l1,斜率k=tg m(m为已知数l1为圆方程x2+y2=r2的切线,r过渡圆弧半径,其切点为M1, 坐标切线方程为l1: x1x + y1y=r2 (1 l3: y + h0=k

7、 (x+r一般式kx-y + kr-h0 (2由(1 因l3/l1 则有x1=-ky1 (3 (3 解方程得 ;与一般式(2代入点到直线距离公式得出 :整理 ;式中r为过渡弧半径=330,h0直边刻度=40,k=tg =2。例 :3.3模具参数计算 f'=f ctgmf '=75ctg63°33'=37.3 4模具制造材料选择由于采用热压成型,载荷相对减小较多,对于分瓣冲压宜采用铸制压模较为理想(也可采用钢板拼焊制做模具。模具材料为铸铁HT300均可满足要求。5铸制压模的木型及造型方法模具木型及砂型造法,若按图纸做出整体木型,一是周期长,二是耗用材料多,为此采

8、用“底板卧式靠模刮板造型方法”5.1木型的制做(1拼做一块1 m2、厚度40 mm模板,中间挖空,其内腔形状按=10°、S=842、S2=613、圆弧以R f'=2 394,R f2'=1 720参数值放样做图。(2按S = 842、f = 75、R f = 1 219、f = 37.3、R f' =2394、及S2 = 613、f2 = 55、R f2 = 879.6、f ' = 27.13、R f2'=1 720值,分别做底板上面的靠模元件,其中R f、R f2的凸凹向应与模具体工件各自相反。(3按主视图截形曲面的r、D n、H、d0、m

9、=63°33、L做刮板。5.2砂型造法先将底板靠模弧曲面向上卧入地砂中打实四周,而后用刮板在靠模板上,空腔形内刮动,注意按等分角刻线内移动,即可刮出曲面砂型。当造好一个砂型后,将木型送交改制,更换相反向的靠模板,随后可造出另一个砂型。6分瓣冲压折边锥体封头组对拼焊成型对分瓣冲压成型的瓣片按样板划线切割打磨坡口见金属光泽,而后在地平台上按D n直径分布点焊拼板限位和定位立柱,而后对装点固焊接成型焊缝,陆博福.大型折边锥形封头的分瓣冲压成形工艺及模具第 50 卷第 2 期· 26 ·化工设备与管道最后进行RT 射线探伤符合图纸JB 47302005无损检测技术要求。7

10、结束语对于大型折边锥体封头制造,采用分部成形组焊方法,即对锥体部分按常规工艺进行卷制组焊成形。而对折边段则进行分瓣冲压组焊成形,最后再将两分段部分组焊成形大直径折边锥形封头工艺及模具设计技术,是利用现有加工设备成形大型折边锥体封头的最佳有效途径。参考文献 1 曹洪飚.浅谈封头制作工艺及设备J.化工设备与管道,2011,48(5:10-13. 2 刘福玲,冀峰,俞树荣,等.折边锥形封头厚度计算探讨J.石油化工设备,2006,35(2:50-52. 3 郭振杰.一种异形封头成形方法研究与实践J.化工设备与管道,2009,46(5:9-11. 4 李业勤.旋转薄壳边缘应力存在原因分析J.石油化工设备

11、,2011,40(4:31-34. 5 王洪海,闫胜昝,高炳军,等.折边锥形封头应力增强系数分析J.石油化工设备,2007,36(1:43-46.Separated Piece Punch Forming Process for Large Toriconical Headand Molding ToolLU Bofu(China First Heavy Industries, Fulaerji 161042, China Abstract: In petrochemical pressure vessel manufacture process, large toriconical head

12、 cannot be fabricated due to the limit of the owned equipment and it has to be contracted to other enterprise. In this article, one method of welding with separated pieces was introduced. In this method, the conical part is fabricated with the process of rolling and welding as usual, and the knuckle

13、 part is fab-ricated with separated pieces punched and then welded together. Finally, two parts are welded for a large toriconical head. Key word: large diameter toriconical head; separated piece punching process; punch model design and fabricationSafety Design and Finite Element Analysis for Steel

14、WireWound Composite CylinderMA Kai 1,YOU Hongxin 1,CHEN Ying 2(1. School of Chemical Machinery, Dalian University of Technology, Dalian 116024, China;2. Commissioning Operation Company of CPP , Langfang 065001, China Abstract: With respect to the stresses in steel wire wound composite cylinder and t

15、he objective of stress optimization, finite element model was established by using software ANSYS. Under the two conditions - autofrettage and non-autofrettge, the stress distribution in the cylinder was analyzed. It was shown that under autofrettage condition, the stress is obviously low. For the c

16、ylinders wound with different diameter wires, calculation was carried out and different layers of wire for the safety of cylinder were obtained. Based on the comparison of weight, it has been concluded that when being wound with 9 layers of 0.35 mm steel wire, the cylinder of 342.8 mm in diameter weighs relative light and can work in pressure of 20 MPa.Key words: wire wound composite cylinder; ANSYS; autofrettage; finite element simulation 4 薛克兴.复合材料结构的损伤与修补M.北京:航空工业出版社,1992:1-4. 5 颜永年. 预应力钢丝缠绕超高压筒体的应力及变形分析J.清华大学学报,1978(2:86-110. 6 GB 24