非焊接管连接扩口法兰旋压机设计
摘要
气体和液体的传输主要依靠管道,而管路之间通常采用法兰的方式连接。目前,比较流行、先进和可靠的法兰连接方式是非焊接法兰连接,它与传统焊接法兰连接方式相比,具有使用范围广、总成本低、结合强度高、严密性好、加工方便、安装快捷、便于拆卸、无焊接残渣、无焊接缝、清洁方便、能够防止局部腐蚀等优点。基于以上优势,非焊接法兰连接的方式广泛应用于城建、石油化工、环保、农业水利、水电等行业的气、液运输管路的连接中。
要实现非焊接法兰连接的管需进行预加工,其方法之一是采用旋压,即对管口进行旋压翻边,形成管端法兰。本文研究的主要目标就是设计用于圆管扩口法兰(37°和90°)加工的扩口法兰旋压机。
根据对国内外有关旋压机文献资料及相关技术研究现状的分析,本文提出了一种新型数控液压驱动旋压机,并基于技术实现的考虑,深入分析了该旋压机实际开发中存在的技术难点,设计了非焊接管连接扩口法兰数控旋压机。使用该旋压机相比焊接式法兰加工,不但节能、可靠性高,还可大大提高生产效率及材料的利用率,且被加工零件的外表光滑美观。
扩口法兰旋压机由机床主体、旋压机构、夹紧机构三部分组成,旋压机构又包括液压进给控制装置、主轴控制装置、旋压装置。本文对旋压机的结构及液压传动系统进行了设计,并对管件的塑性变形情况进行了有限元分析。
此外,本文对非焊接管连接扩口法兰旋压机的控制方案进行了初步研究。并根据旋压机的结构及运动特点,对主要硬件进行了选型,保证了该旋压机系统整体的可靠性和实用性。
The transportation of gas and liquid mainly depends upon the pipelines, but the flanges are usually used between the pipelines. At present, connection without welding is a popular way to connect pipes of good quality and great efficiency. Compared with the traditional ways of connection which are joint by welding, it is more simple and dependable, agiler and safer, adapt to all kinds of materials, quick to install, essentially clean, easy removal without welding residue, no welding joints, easy to assemble and preventing localized corrosion. Based on the above advantages, non-welding flange connecting is widely used in the construction, petroleum chemical industry, environmental protection, agriculture, water conservancy, hydropower sectors of the gas and liquid transportation pipeline connection.
To achieve non-welded pipe flange connection, pre-processing is needed. One of the used methods is spinning, that is spinning flanging for pipe, forming end-of-pipe flange. In this dissertation, the main objective is to design a new type of flange (37°and 90°) flange flaring machine.
Based on analysis literature and related information technology of the spinning machine produced at home and abroad, this dissertation presents a new type of hydraulic drive CNC spinning machine. Based on technology considerations, it analysizes the technical difficulties of the spinning machine during development. The flange flaring machines, which is used to manufacture the pipe connector, is designed. Compared with welded flange processing, the spinning machine is not only energy-saving, high reliability, but also greatly improve production efficiency and the utilization of materials. What’s more, the parts have smooth appearance.
Flange flaring machine is made up of the machine body, spinning mechanism, clamping device. Spinning mechanism includes hydraulic control, spindle control device and spinning devices. In this dissertation, the spinning machine and the structure of the hydraulic system are designed. The finite element analyses of tubes of plastic deformation are also performed.
In addition, the dissertation studied the control program of non-welded pipe flange connecting expanding spinning machine. According to the structure and motion features of the spinning machine, the major hardware is selected to ensure the reliability and practicality of spinning machine system.
要实现非焊接法兰连接的管需进行预加工,其方法之一是采用旋压,即对管口进行旋压翻边,形成管端法兰。本文研究的主要目标就是设计用于圆管扩口法兰(37°和90°)加工的扩口法兰旋压机。
根据对国内外有关旋压机文献资料及相关技术研究现状的分析,本文提出了一种新型数控液压驱动旋压机,并基于技术实现的考虑,深入分析了该旋压机实际开发中存在的技术难点,设计了非焊接管连接扩口法兰数控旋压机。使用该旋压机相比焊接式法兰加工,不但节能、可靠性高,还可大大提高生产效率及材料的利用率,且被加工零件的外表光滑美观。
扩口法兰旋压机由机床主体、旋压机构、夹紧机构三部分组成,旋压机构又包括液压进给控制装置、主轴控制装置、旋压装置。本文对旋压机的结构及液压传动系统进行了设计,并对管件的塑性变形情况进行了有限元分析。
此外,本文对非焊接管连接扩口法兰旋压机的控制方案进行了初步研究。并根据旋压机的结构及运动特点,对主要硬件进行了选型,保证了该旋压机系统整体的可靠性和实用性。
The transportation of gas and liquid mainly depends upon the pipelines, but the flanges are usually used between the pipelines. At present, connection without welding is a popular way to connect pipes of good quality and great efficiency. Compared with the traditional ways of connection which are joint by welding, it is more simple and dependable, agiler and safer, adapt to all kinds of materials, quick to install, essentially clean, easy removal without welding residue, no welding joints, easy to assemble and preventing localized corrosion. Based on the above advantages, non-welding flange connecting is widely used in the construction, petroleum chemical industry, environmental protection, agriculture, water conservancy, hydropower sectors of the gas and liquid transportation pipeline connection.
To achieve non-welded pipe flange connection, pre-processing is needed. One of the used methods is spinning, that is spinning flanging for pipe, forming end-of-pipe flange. In this dissertation, the main objective is to design a new type of flange (37°and 90°) flange flaring machine.
Based on analysis literature and related information technology of the spinning machine produced at home and abroad, this dissertation presents a new type of hydraulic drive CNC spinning machine. Based on technology considerations, it analysizes the technical difficulties of the spinning machine during development. The flange flaring machines, which is used to manufacture the pipe connector, is designed. Compared with welded flange processing, the spinning machine is not only energy-saving, high reliability, but also greatly improve production efficiency and the utilization of materials. What’s more, the parts have smooth appearance.
Flange flaring machine is made up of the machine body, spinning mechanism, clamping device. Spinning mechanism includes hydraulic control, spindle control device and spinning devices. In this dissertation, the spinning machine and the structure of the hydraulic system are designed. The finite element analyses of tubes of plastic deformation are also performed.
In addition, the dissertation studied the control program of non-welded pipe flange connecting expanding spinning machine. According to the structure and motion features of the spinning machine, the major hardware is selected to ensure the reliability and practicality of spinning machine system.
引文
[1]赵云豪,旋压技术现状,锻压技术,2005(5),95～97
[2]杨明辉等,旋压技术的分类及应用,机械工程技术,2004, 33(11),14～16
[3]倪征顺,帅词俊,CAE方法中的优化技术及应用,现代机械,2002,2,16～18
[4]王国强,实用工程数值模拟技术及其在ANSYS上的实践,西安:西北工业大学出版社,1999
[5]陈精一,蔡国忠,电脑辅助工程分析ANSYS使用指南,北京:中国铁道出版社,2001
[6]商跃进,有限元原理与ANSYS应用指南,北京:清华大学出版社,2005,54-57
[7]沈兴全,吴秀玲,液压传动与控制,北京:国防工业大学出版社2005(1), 102～167
[8]陈适先等,强力旋压工艺与设备,北京:国防工业大学出版社,1986.12 ,67～124
[9]《机床设计手册》编写组编,机床设计手册第四册液压,气动系统设计及机床现代设计方法,北京:机械工业出版社,1997,11,39～490
[10]范存德,液压设计手册,辽宁科学技术出版社, 2004.5,43～132,317～433,1164～1179,1634～1671,1916～1956
[11]欧雪琴,FXC一1500型旋压翻边机床研制,木工机床,2003,(1),22～25
[12]沈宗文,在普通车床上管口翻边旋压成型装置,南京化学工业(集团)公司化工机械厂,1997.10.15
[13]李兰英,穆军,HZK20防尘盖扩口机设计和改进,哈尔滨轴承,2004.7,(4),32～33
[14]刘克璋等,旋压技术,机械工业出版社1986.5,78～127
[15]赵宪明,吴迪,吕炎,筒形件强力旋压变形机理的有限元分析,哈尔滨工业大学,1997
[16]余正龙,王鹏,液压卡具,佳木斯电机厂
[17]王成和等,机械旋压技术,北京:机械工业出版社,1987.1,119～247
[18]张猛,胡重民等,回转塑性成形工艺及模具,武汉:武汉工业大学出版,1994,67～115
[19]翟德梅,翟振辉,段维峰,旋压工艺力、扭矩和功率的实验分析研究,文章编号:1003 (2004)05 0030 04
[20]花江,肖颖明,阎洪,管端回转扩口成形研究[S],南昌大学
[21]刘国楷,两种典型零件的旋压,武汉冶金设备制造公司重型设备厂,1999
[22]圭垒塑,李贺,吕更,筒形旋压件内径尺寸精度预测,西北工业大学,哈尔滨工业大学,2001
[23]刘思德,后减震器帽的工艺分析及模具设计[J],模具技术,2003,(2),31～32,395
[24]Robert H. Bishop,乔瑞萍,林欣等译,Learning with LabVIEW 7 express (美),北京:电子工业出版社,2005.30-50
[25]陈登,薄壁导管扩扣浅析,1989
[26]P.Crimmins eta,“Spinning of refractoryt alloys”,《Metal Progress》1982,23～47
[27]Penning Ton,Modern metals,Spinning Today,1987(7)∶70～80
[28]Johorn,Metal spinning and shearing forming,Spinning Today,1986(5)∶467～480
[29]张洪信,有限元基础理论与ANSYS应用,北京:机械工业出版社,2006,2
[30]杨延涛等,强力旋压成形工艺的研究进展,航天制造技术2004.2,1
[31]钟约先,林亨,机械系统计算机控制,北京:清华大学出版社,2001.4
[32]凌澄李寿成,PC总线工业控制系统精粹,北京:清华大学出版社,1998.5
[33]夏琴香,阮锋,任晓龙,三维非回转体薄壁空心零件的旋压成形技术,2002年中国机械工程学会年会论文集,制造业与中国未来,机械工业出版社,2002,104
[34]M.A.Greditor,Spinning Operation and Rotary Extrusion ,AD一755876
[35]陈依锦等,旋压技术初探,机电工程技术,2003,Vol32(5)23～24
[36]邓旻涯,摩托车过量平衡及震动分析,武汉汽车工业大学硕士学位论文,2001,02
[37]刘春景,曹卫彬,基于PRO/E与ADAMS的齿轮泵设计及动态仿真,机床与液压,2005,No11,187～188
[38]陈适先,我国旋压事业的发展与展望,锻造与冲压,2005,10,20～25
[39]李继贞,国产旋压设备的最新动态,机械工人(热加工),2002,No8,61～62
[40]夏琴香等,三维非轴对称薄壁管件旋压成形机床液压系统的研究,塑性工程学报,2005.6,Vo1.12, No3,88～91
[41]王金平,模拟信号和数字信号,物理教学探讨,2004,3(上半月),49～51
[42]翟中英,张兴敢,用A/D、D/A转换实现模拟信号可编程放大与延时, 2005微处理机, 2005.8,No4,88～91
[43]郭仁生,优化设计应用,北京:电子工业出版社,2004
[44]陈育仪,工程机械优化设计,北京:中国铁道出版社,1987
[45]王文博,机构和机械零部件优化设计.北京:机械工业出版社,1990]
[46]孙靖民,梁迎春等,机械结构优化设计,哈尔滨:哈尔滨工业大学出版社,2004
[47]叶元烈,机械优化理论与设计,北京:中国计量出版社,2001
[48]田福祥,机械优化设计理论与应用,北京:冶金工业出版社,1998
[49]James N. Siddall,Optimal engineering design,principles and applications,New York,M.Dekker,1982
[50]方世杰,綦耀光,机械优化设计,北京:清华大学出版社,1994
[51]张继春,徐斌,林波, Pro/engineer Wildfire结构分析,机械工业出版社,180
[52]N.V. Banichuk,translated by Vadim Komov,Problems and methods of optimal structural design (translation edited by Edward J. Haug),Plenum Press,1983
[53]James A,An optimization capability for automotive structures [R],SAE 790972
[54]Duane Detwiler,Computer Aided Structural Optimization of Automotive Body Structure[R],SAE 960523
[55]H.Akbulut,On optimization of a car rim using finite element method[J],Finite Elements in Analysis and Design,2003,39:433～443
[56]姜荣,一种基于运动控制卡的伺服电机控制系统,机电产品开发与创新,2006,19(3),113～114
[2]杨明辉等,旋压技术的分类及应用,机械工程技术,2004, 33(11),14～16
[3]倪征顺,帅词俊,CAE方法中的优化技术及应用,现代机械,2002,2,16～18
[4]王国强,实用工程数值模拟技术及其在ANSYS上的实践,西安:西北工业大学出版社,1999
[5]陈精一,蔡国忠,电脑辅助工程分析ANSYS使用指南,北京:中国铁道出版社,2001
[6]商跃进,有限元原理与ANSYS应用指南,北京:清华大学出版社,2005,54-57
[7]沈兴全,吴秀玲,液压传动与控制,北京:国防工业大学出版社2005(1), 102～167
[8]陈适先等,强力旋压工艺与设备,北京:国防工业大学出版社,1986.12 ,67～124
[9]《机床设计手册》编写组编,机床设计手册第四册液压,气动系统设计及机床现代设计方法,北京:机械工业出版社,1997,11,39～490
[10]范存德,液压设计手册,辽宁科学技术出版社, 2004.5,43～132,317～433,1164～1179,1634～1671,1916～1956
[11]欧雪琴,FXC一1500型旋压翻边机床研制,木工机床,2003,(1),22～25
[12]沈宗文,在普通车床上管口翻边旋压成型装置,南京化学工业(集团)公司化工机械厂,1997.10.15
[13]李兰英,穆军,HZK20防尘盖扩口机设计和改进,哈尔滨轴承,2004.7,(4),32～33
[14]刘克璋等,旋压技术,机械工业出版社1986.5,78～127
[15]赵宪明,吴迪,吕炎,筒形件强力旋压变形机理的有限元分析,哈尔滨工业大学,1997
[16]余正龙,王鹏,液压卡具,佳木斯电机厂
[17]王成和等,机械旋压技术,北京:机械工业出版社,1987.1,119～247
[18]张猛,胡重民等,回转塑性成形工艺及模具,武汉:武汉工业大学出版,1994,67～115
[19]翟德梅,翟振辉,段维峰,旋压工艺力、扭矩和功率的实验分析研究,文章编号:1003 (2004)05 0030 04
[20]花江,肖颖明,阎洪,管端回转扩口成形研究[S],南昌大学
[21]刘国楷,两种典型零件的旋压,武汉冶金设备制造公司重型设备厂,1999
[22]圭垒塑,李贺,吕更,筒形旋压件内径尺寸精度预测,西北工业大学,哈尔滨工业大学,2001
[23]刘思德,后减震器帽的工艺分析及模具设计[J],模具技术,2003,(2),31～32,395
[24]Robert H. Bishop,乔瑞萍,林欣等译,Learning with LabVIEW 7 express (美),北京:电子工业出版社,2005.30-50
[25]陈登,薄壁导管扩扣浅析,1989
[26]P.Crimmins eta,“Spinning of refractoryt alloys”,《Metal Progress》1982,23～47
[27]Penning Ton,Modern metals,Spinning Today,1987(7)∶70～80
[28]Johorn,Metal spinning and shearing forming,Spinning Today,1986(5)∶467～480
[29]张洪信,有限元基础理论与ANSYS应用,北京:机械工业出版社,2006,2
[30]杨延涛等,强力旋压成形工艺的研究进展,航天制造技术2004.2,1
[31]钟约先,林亨,机械系统计算机控制,北京:清华大学出版社,2001.4
[32]凌澄李寿成,PC总线工业控制系统精粹,北京:清华大学出版社,1998.5
[33]夏琴香,阮锋,任晓龙,三维非回转体薄壁空心零件的旋压成形技术,2002年中国机械工程学会年会论文集,制造业与中国未来,机械工业出版社,2002,104
[34]M.A.Greditor,Spinning Operation and Rotary Extrusion ,AD一755876
[35]陈依锦等,旋压技术初探,机电工程技术,2003,Vol32(5)23～24
[36]邓旻涯,摩托车过量平衡及震动分析,武汉汽车工业大学硕士学位论文,2001,02
[37]刘春景,曹卫彬,基于PRO/E与ADAMS的齿轮泵设计及动态仿真,机床与液压,2005,No11,187～188
[38]陈适先,我国旋压事业的发展与展望,锻造与冲压,2005,10,20～25
[39]李继贞,国产旋压设备的最新动态,机械工人(热加工),2002,No8,61～62
[40]夏琴香等,三维非轴对称薄壁管件旋压成形机床液压系统的研究,塑性工程学报,2005.6,Vo1.12, No3,88～91
[41]王金平,模拟信号和数字信号,物理教学探讨,2004,3(上半月),49～51
[42]翟中英,张兴敢,用A/D、D/A转换实现模拟信号可编程放大与延时, 2005微处理机, 2005.8,No4,88～91
[43]郭仁生,优化设计应用,北京:电子工业出版社,2004
[44]陈育仪,工程机械优化设计,北京:中国铁道出版社,1987
[45]王文博,机构和机械零部件优化设计.北京:机械工业出版社,1990]
[46]孙靖民,梁迎春等,机械结构优化设计,哈尔滨:哈尔滨工业大学出版社,2004
[47]叶元烈,机械优化理论与设计,北京:中国计量出版社,2001
[48]田福祥,机械优化设计理论与应用,北京:冶金工业出版社,1998
[49]James N. Siddall,Optimal engineering design,principles and applications,New York,M.Dekker,1982
[50]方世杰,綦耀光,机械优化设计,北京:清华大学出版社,1994
[51]张继春,徐斌,林波, Pro/engineer Wildfire结构分析,机械工业出版社,180
[52]N.V. Banichuk,translated by Vadim Komov,Problems and methods of optimal structural design (translation edited by Edward J. Haug),Plenum Press,1983
[53]James A,An optimization capability for automotive structures [R],SAE 790972
[54]Duane Detwiler,Computer Aided Structural Optimization of Automotive Body Structure[R],SAE 960523
[55]H.Akbulut,On optimization of a car rim using finite element method[J],Finite Elements in Analysis and Design,2003,39:433～443
[56]姜荣,一种基于运动控制卡的伺服电机控制系统,机电产品开发与创新,2006,19(3),113～114