目的 为解决特高压输电用混合玻璃绝缘子在模内嵌件包覆成型中因玻璃绝缘子型坯脆性大、尺寸偏差大及固态硅橡胶变形抗力高、门尼黏度高,易出现碎裂、包胶不均匀等缺陷,导致一次注射成品率低的问题,通过实验验证与数值模拟相结合的方式,优化流道方案以提升成型稳定性与成品率。方法 先以160 kN混合玻璃绝缘子为对象,在填充率10%、30%、90%及100%下进行分阶段实验,验证混合玻璃绝缘子成型数值模拟结果的可靠性;再以420 kN混合玻璃绝缘子为对象,设计三伞同轴对称、两伞同轴一伞垂直对称、两伞同轴一伞45°垂直对称的3种流道方案,通过Moldflow模拟固态硅橡胶填充行为,结合Ansys流固耦合分析型坯力学响应。结果 160 kN绝缘子各填充率下的模拟结果与实验填充行为一致;420 kN绝缘子虽在3种方案下均能完全填充,但方案一因轴向受力失衡而导致型坯破裂,方案二因填充速度差异而存在压碎风险,方案三能满足填充平衡要求,剪切应力低于方案二、困气最少,且应变为1.415 4×10-5、等效应力为3.462 MPa,均为3组最小。结论 模拟模型可准确反映成型过程,420 kN绝缘子的两伞同轴一伞45°垂直对称流道方案能有效降低缺陷风险、提升成品率,为特高压混合玻璃绝缘子成型工艺优化提供支撑。
Abstract
To address the issue of low yield in one-shot injection molding of hybrid glass insulators for ultra-high voltage (UHV) power transmission due to defects such as cracking and uneven encapsulation caused by the high brittleness and dimensional deviation of the glass insulator parison, as well as the high deformation resistance and high Mooney viscosity of solid silicone rubber, the work aims to conduct experimental verification and numerical simulation to optimize the mold flow structure design to enhance molding stability and yield. Initially, a series of mold-filling experiments were conducted on a 160 kN hybrid glass insulator, with filling rates set at 10%, 30%, 90%, and 100%, to verify the accuracy and reliability of the numerical simulation model. Then, three mold flow structures were designed for a larger 420 kN hybrid glass insulator and evaluated, including a three-umbrella coaxial symmetrical runner, a two-umbrella coaxial runner with one vertically symmetrical branch and a two-umbrella coaxial runner with one 45° inclined vertical branch. Moldflow simulations were employed to analyze the flow characteristics during mold filling, while the mechanical response of the glass insulator parison was further evaluated through fluid-structure interaction (FSI) simulations in ANSYS. The results confirmed a high degree of agreement between the simulation predictions and the experimental filling behaviors for the 160 kN insulator across all filling stages. For the 420 kN insulator, all three mold flow structures achieved complete cavity filling. However, Scheme 1 led to fracture due to axial stress imbalance, Scheme 2 exhibited a risk of mechanical damage arising from significant differences in local filling speeds. In contrast, Scheme 3 demonstrated the most favorable performance, achieving uniform filling, reduced shear stress compared to Scheme 2, and minimal air entrapment. It also exhibited the lowest maximum strain (1.415 4×10-5) and equivalent stress (3.462 MPa) among the three schemes. In conclusion, the numerical simulation model accurately captures the key features of the molding process. The optimized runner design featuring a two-umbrella coaxial configuration combined with a 45° inclined vertical branch effectively minimizes defect risks and improves the first-injection yield rate for 420 kN hybrid glass insulators. These findings offer valuable guidance for refining the molding process of UHV hybrid glass insulators.
关键词
混合玻璃绝缘子 /
填充平衡 /
流道方案 /
模流分析 /
流固耦合
Key words
hybrid glass insulators /
fill balance /
flow channel configuration /
mold flow analysis /
fluid-structure interaction
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