外方内圆铜管连续挤压数值模拟与实验研究
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摘要
外方内圆铜管是制造水冷电机线圈的关键材料,但是采用现有工艺生产这类产品,存在加工难度大、工序复杂、加工成本高、产品长度短等缺点,不能满足市场的需求。采用连续挤压技术,对14 mm×14 mm-Φ8.5 mm外方内圆铜管的连续挤压成型过程进行了数值模拟和实验研究,数值模拟结果表明:焊合面上的温度分布在600～711℃之间,大部分区域的静水压力分布在300～500 MPa之间,模具出口处的温度、速度分布均匀。实验结果表明:铜管成型良好,焊缝的结合强度达到母材的98%;焊合区域较非焊合区域晶粒尺寸小,没有明显焊缝存在,结合区域的横向断口内存在大量韧窝,断裂形式为韧性断裂。研究结果证明了外方内圆铜管续挤压工艺的可行性和有限元模型的准确性。
Copper tube with outer square and inner circle is key material in large generator and electron accelerator manufacturing, which could not meet the demand of the market, because of complex and difficult processing, short product length and high cost in traditional process. In this paper, the continuous extrusion technology was employed, the continuous extrusion process of 14 mm×14 mm-Φ8.5 mm copper tube with outer square and inner circle was studied by numerical simulation and experiment, results showed that when the temperature on weld surface was between 600～711 ℃, the pressure distributed between 300～500 MPa, the velocity and temperature on the profile at the outlet of the die were uniform. The continuous extrusion experiment of 14 mm×14 mm-Φ8.5 mm copper tube with outer square was conducted and the product properties were tested, the results showed that the copper tube formed well, the bonding strength of the welding zone reached 98% as that of the parent metal; the welded area had small grain size, and there were no obvious weld seam observed; the fracture mode of welding area was ductile fracture which was full of dimples. The feasibility of continuous extrusion process and the accuracy of the Finite element method(FEM) model were proved by the results.
Copper tube with outer square and inner circle is key material in large generator and electron accelerator manufacturing, which could not meet the demand of the market, because of complex and difficult processing, short product length and high cost in traditional process. In this paper, the continuous extrusion technology was employed, the continuous extrusion process of 14 mm×14 mm-Φ8.5 mm copper tube with outer square and inner circle was studied by numerical simulation and experiment, results showed that when the temperature on weld surface was between 600～711 ℃, the pressure distributed between 300～500 MPa, the velocity and temperature on the profile at the outlet of the die were uniform. The continuous extrusion experiment of 14 mm×14 mm-Φ8.5 mm copper tube with outer square was conducted and the product properties were tested, the results showed that the copper tube formed well, the bonding strength of the welding zone reached 98% as that of the parent metal; the welded area had small grain size, and there were no obvious weld seam observed; the fracture mode of welding area was ductile fracture which was full of dimples. The feasibility of continuous extrusion process and the accuracy of the Finite element method(FEM) model were proved by the results.
引文
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[9] Wan F, Yun X B, Bi S, Pei J Y, Yang J , Yan Z Y. Microstrure, properties and refining performance of Al-Si alloy under different forming process [J]. Chinese Journal of Rare Metals, 2018, 42(8): 799.(万帆, 运新兵, 毕胜, 裴久杨, 杨军, 闫志勇. 成形工艺对铝锶合金组织性能及细化性能的影响 [J]. 稀有金属, 2018, 42(8): 799.)
[10] Sun J, Liu P, Liu X K, Chen X H, He D H, Ma F C, Li W. Research progress on continuous extrusion technology [J]. Hot Working Technology, 2013, 42(23): 14.(孙健, 刘平, 刘新宽, 陈小红, 何代华, 马凤仓, 李伟. 连续挤压技术的研究进展 [J]. 热加工工艺, 2013, 42(23): 14.)
[11] Yun X B, Song B Y, Gao F. Application of continuous extrusion technology for the production of copper tube [J]. Metal Forming Technology, 2002, 20(3): 46.(运新兵, 宋宝韫, 高飞. 连续挤压技术在铜管生产上的应用 [J]. 金属成形工艺, 2002, 20(3): 46.)
[12] Yan M, Wu Y P, Xie S S. Study on continuous extrusion forming for copper hollow conductor [J]. Nonferrous Metals, 2010, (4): 49.(鄢明, 吴朋越, 谢水生. 空心铜导体的连续挤压研究 [J]. 有色金属, 2010, (4): 49.)
[13] Xu G L, Mao Y Z, Yao Y F, Luo Y F. Research on continuous extrusion square copper tube with circle inner [J]. Nonferrous Metals Procession, 2011, 40(6): 33.(徐高磊, 毛毅中, 姚幼甫, 骆越峰. 连续挤压内圆外方铜管的研究 [J]. 有色金属加工, 2011, 40(6): 33.)
[14] Li Y L. Definition and mechanical characteristics of true stress-strain [J]. Journal of Chongqing University, 2001, 24(3): 58.(李玉兰. 真应力-应变的定义及其力学特征 [J]. 重庆大学学报, 2001, 24(3): 58.)
[15] Liu Y W, Cao X, Song B Y. Numerical simulation of copper continuous extrusion with finite volume method [J]. Forging & Stamping Technology, 2007, 32(6): 148. (刘元文, 曹雪, 宋宝韫. 铜连续挤压的有限体积法数值模拟 [J]. 锻压技术, 2007, 32(6): 148.)
[16] Sui X, Song B Y, Li B, Yun X B. Deformation behaviour and microstructure characteristic of H62 brass alloy during continuous extrusion process [J]. Nonferrous Metals, 2011, 63(1):11.(隋贤, 宋宝韫, 李冰, 运新兵. H62黄铜合金连续挤压的变形行为和组织演变特征 [J]. 有色金属, 2011, 63(1): 11.)
[2] Xie S S, Li H Q, Li Z, Liu H T. The Production Technology and Equipment of Copper and Copper Alloy Products [M]. Changsha: Central South Press, 2014. 195.(谢水生, 李华清, 李周, 刘海涛. 铜及铜合金产品生产技术与装备 [M]. 长沙: 中南大学出版社, 2014. 195.)
[3] Lu X S, Zhao Q H, Zhang Y T, Chen Q M. Special-shaped copper optimize production process [J]. Die and Mould Technology, 2014, (1): 29.(卢祥胜, 赵庆会, 张永统, 陈全明. 异型铜材生产工艺优化 [J]. 模具技术, 2014, (1): 29.)
[4] Zhao Q H, Zhang Y T, Lu X S. Problem and countermeasures of shaped copper tubes in productive process [J]. Nonferrous Metals Procession, 2013, 42(3): 19.(赵庆辉, 张永统, 卢祥胜. 异型铜管生产过程中出现问题的解决方法 [J]. 有色金属加工, 2013, 42(3): 19.)
[5] Zhao Q H. Study on Optimization Design for Mold of Shaped Copper [D]. Luoyang: Henan University of Science and Technology, 2015. 8.(赵庆辉. 异型铜材成形模具设计与优化 [D]. 洛阳: 河南科技大学, 2015. 8.)
[6] Xing J S, Lin J, Wang Z H, Zhong J Q, Cai Y X, Wei S M. The main coil of 100 MeV cyclotron has been successfully developed [A]. Annual Report for China Institute of Atomic Energy [M]. 2009. 46.(邢建升, 林军, 王振辉, 钟俊晴, 才月新, 魏素敏. 100 MeV回旋加速器主线圈研制成功 [A]. 中国原子能科学研究院年报 [M]. 2009. 46.)
[7] Xie J X, Liu J A. The Theory and Technology of MetalExtrusion [M]. Beijing: Metallurgical Industry Press, 2012. 219.(谢建新, 刘静安. 金属挤压理论与技术 [M]. 北京: 冶金工业出版社, 2012. 219.)
[8] Fan Z X, Chen L, Sun H Y. Development and applicationof continuous extrusion technology [J]. Materials China, 2013, 32(5): 276.(樊志新, 陈莉, 孙海洋. 连续挤压技术的发展与应用 [J]. 中国材料进展, 2013, 32(5): 276.)
[9] Wan F, Yun X B, Bi S, Pei J Y, Yang J , Yan Z Y. Microstrure, properties and refining performance of Al-Si alloy under different forming process [J]. Chinese Journal of Rare Metals, 2018, 42(8): 799.(万帆, 运新兵, 毕胜, 裴久杨, 杨军, 闫志勇. 成形工艺对铝锶合金组织性能及细化性能的影响 [J]. 稀有金属, 2018, 42(8): 799.)
[10] Sun J, Liu P, Liu X K, Chen X H, He D H, Ma F C, Li W. Research progress on continuous extrusion technology [J]. Hot Working Technology, 2013, 42(23): 14.(孙健, 刘平, 刘新宽, 陈小红, 何代华, 马凤仓, 李伟. 连续挤压技术的研究进展 [J]. 热加工工艺, 2013, 42(23): 14.)
[11] Yun X B, Song B Y, Gao F. Application of continuous extrusion technology for the production of copper tube [J]. Metal Forming Technology, 2002, 20(3): 46.(运新兵, 宋宝韫, 高飞. 连续挤压技术在铜管生产上的应用 [J]. 金属成形工艺, 2002, 20(3): 46.)
[12] Yan M, Wu Y P, Xie S S. Study on continuous extrusion forming for copper hollow conductor [J]. Nonferrous Metals, 2010, (4): 49.(鄢明, 吴朋越, 谢水生. 空心铜导体的连续挤压研究 [J]. 有色金属, 2010, (4): 49.)
[13] Xu G L, Mao Y Z, Yao Y F, Luo Y F. Research on continuous extrusion square copper tube with circle inner [J]. Nonferrous Metals Procession, 2011, 40(6): 33.(徐高磊, 毛毅中, 姚幼甫, 骆越峰. 连续挤压内圆外方铜管的研究 [J]. 有色金属加工, 2011, 40(6): 33.)
[14] Li Y L. Definition and mechanical characteristics of true stress-strain [J]. Journal of Chongqing University, 2001, 24(3): 58.(李玉兰. 真应力-应变的定义及其力学特征 [J]. 重庆大学学报, 2001, 24(3): 58.)
[15] Liu Y W, Cao X, Song B Y. Numerical simulation of copper continuous extrusion with finite volume method [J]. Forging & Stamping Technology, 2007, 32(6): 148. (刘元文, 曹雪, 宋宝韫. 铜连续挤压的有限体积法数值模拟 [J]. 锻压技术, 2007, 32(6): 148.)
[16] Sui X, Song B Y, Li B, Yun X B. Deformation behaviour and microstructure characteristic of H62 brass alloy during continuous extrusion process [J]. Nonferrous Metals, 2011, 63(1):11.(隋贤, 宋宝韫, 李冰, 运新兵. H62黄铜合金连续挤压的变形行为和组织演变特征 [J]. 有色金属, 2011, 63(1): 11.)
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