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锆合金管校直工艺机理及其成套设备研究
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摘要
金属锆具有优异的加工性能和很小的热中子捕获截面,在核能领域广泛应用,其中核反应堆中的核燃料包壳管和压力管等都要大量用到锆合金薄壁管件。锆合金薄壁管的制造精度要求很高,需要进行精密校直。由于薄壁管易于发生截面扁化,同时锆合金材料成本昂贵,手工校直不能满足制造精度和成品率高的要求,因此必须大力发展锆合金薄壁管的自动精密校直技术。
     本论文在分析管件变形特征的基础上,根据反弯校直原理,指出管件校直工艺理论中两个根本问题,即压点、支点组合问题和校直量计算问题,依据弹塑性力学理论建立了管件行程控制型单步校直计算方法。对薄壁管件校直过程中产生截面扁化的现象、特征、机理,以及截面应力应变变化进行了深入研究,分析了管件的材料特征、几何形状和弯矩等对截面扁化率的影响,建立了截面扁化率的计算公式。在此基础上,提出了薄壁管“跬积校直法”校直工艺方法,综合考虑壁厚、材料特性、几何尺寸等因素,将一次大行程压弯校直过程细分为多步小行程校直过程,实现薄壁管的充分校直,同时有效地避免校直中出现截面扁化变形。
     采用最小二乘法原理分析了杠杆检测系统的原理,依据键合图法研究了复位弹簧的优化问题,应用最小二次判别法探讨了管件圆度检测最小点数问题,结合拟合函数法分析了杠杆式接触检测系统中管件半径对误差的影响,探讨了检测杠杆的长度优化问题。
     结合液压机的工艺动作要求,研究了比例伺服液压控制系统,采用传递函数法计算了校直机液压系统的动态性能,并进行了相关仿真计算,并借助模糊控制PID理论对系统动态特性进行实时控制,从而实现了锆合金校直成套设备液压压头的精密控制。
     本论文最后在前面理论研究和工艺设计的基础上,结合企业实际需求,提出了锆合金管校直液压成套设备的总体设计方案。设计了成套设备的主机控制系统、液压系统、检测系统、校直工作台、移动工作台、以及管件自动上下料系统。现场试验表明,所设计的锆合金管件校直成套设备能很好满足锆合金薄壁管的自动精密校直需求。
Zirconium alloys pipe is used to be nuclear fuel cladding tube in nuclear reactor, and the thin-wall zirconium pipe manufacture precision is so high that manual straightening technology can not meet the requirements, and automatic precise straightening technology must be developed.
     Two basic problems about the straightening stroke calculation and the combination of press and support points in the pipe straightening technology were put forward according to the anti-bend leveling principle and analysis of pipe deformation characteristics. The pipe single step straightening calculation controlled by stroke had been built up from the elastic plastic theory. The pipe stress and strain in straightening deformation had been analyzed based on elastic-plastic theory, and the flatten rate computation formula was built from the plane displacement triangle series assumption. The simulation result expressed the flatten factor was hard effected by the load exerted on the pipe.
     The least square method was applied in level measuring system errors analysis. The reset spring rigidity optimization was performed by the bond graph. And the minimum measuring points around the pipe wall was decided in the quadratic discriminate analysis, and the level touch measuring system errors from the pipe radius was researched by the fitting function methods, and the level length optimization was performed.
     The hydraulic proportion serve system had been designed to meet the straightening press function. The system dynamic characteristics were calculated through the transfer function methods, and simulation experiments performed. Fuzzy logical PID control was presented to realize the press precise movement, and the positioning precision was less than0.02mm.
     The overall design scheme of the zirconium pipe straightening press was put forward based on the theory research and process design, some key main machine body such as main control system, hydraulic system, detecting system, straightening work bench, traverse table and the automatic feeding and unloading system were designed. And the experimental results expressed the Zirconium alloys pipe straightening whole set equipment well meet the actual requirements of the manufacture precision.
引文
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