液压式耐张线夹压接过程金属流动仿真研究

周潞潞; 刘梓涵; 李成睿; 柴敬轩; 郭军礼; 赵伯阳

doi:10.3969/j.issn.1674-6457.2026.06.025

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精密成形工程 ›› 2026, Vol. 18 ›› Issue (6) : 291-303. DOI: 10.3969/j.issn.1674-6457.2026.06.025

先进制造技术与装备

液压式耐张线夹压接过程金属流动仿真研究

周潞潞¹, 刘梓涵¹, 李成睿¹, 柴敬轩^1,2,*, 郭军礼^1,2, 赵伯阳³

作者信息 +

Simulation of Metal Flow During the Hydraulic Crimping Process of Strain Clamps

ZHOU Lulu¹, LIU Zihan¹, LI Chengrui¹, CHAI Jingxuan^1,2,*, GUO Junli^1,2, ZHAO Boyang³

Author information +

文章历史 +

摘要

目的从根本上揭示液压式耐张线夹压接过程中金属流动行为与缺陷形成机理,优化压接工艺参数,预防因散股、防滑槽填充不足等而导致的断线事故,提升输电线路接头的力学可靠性与服役安全性。方法基于冷压焊理论,建立了耐张线夹与JL1X/LHA1-800/550型导线的三维有限元模型,采用DEFORM开展压接过程仿真。通过分析耐张管与钢锚防滑槽、耐张管与导线外层的变形行为,系统研究金属流动竞争机制。设置模具运动速度分别为1 mm/s和5 mm/s,保压压力为20、30、40 kN,对比不同工艺参数下金属轴向流动速率、防滑槽填充状态、导线应力与损伤演变规律。结果 1）导线松股现象与压接后导线螺旋角α增大及钢芯、铝股异种金属轴向流动速度不一致有关,该现象在现有工艺条件下难以完全避免;2）耐张管嵌入防滑槽的充分程度与金属轴向流动速度密切相关,在合模阶段,金属轴向流动速度可达模具运动速度的5倍,高速流动导致防滑槽填充质量下降,尤其是中间槽区域填充不足;3）随着保压压力从20 kN增至40 kN,应力集中区域显著扩展,表明保压压力过大会加剧材料内部损伤。结论现有研究对金属流动竞争与异质材料变形失配内在机理的揭示尚不充分。本研究基于冷压焊界面结合理论,分析了防滑槽填充不足与导线散股2类典型缺陷的金属流动竞争机制,并探讨了协同调控模具运动速度与保压压力的工艺优化思路。研究结果为耐张线夹压接工艺的机理分析与参数优化提供了理论依据。

Abstract

The work aims to fundamentally reveal the metal flow behavior and defect formation mechanism during the hydraulic crimping process of strain clamps, optimize crimping process parameters, prevent wire breakage accidents caused by strand loosening and insufficient filling of anti-slip grooves, and enhance the mechanical reliability and service safety of transmission line joints. Based on cold pressure welding theory, a three-dimensional finite element model of the strain clamp and JL1X/LHA1-800/550 conductor was established, and the crimping process was simulated with DEFORM software. By analyzing the deformation behavior of the strain sleeve against the anti-slip grooves of the steel anchor and the outer layer of the conductor, the competitive metal flow mechanism was systematically investigated. Die movement speed was set at 1 mm/s and 5 mm/s, and holding pressure at 20, 30, and 40 kN to compare the axial flow velocity of metal, filling status of anti-slip grooves, and the evolution of stress and damage in the conductor under different process parameters. The simulation results indicated that: (1) Strand loosening was related to the increase in the helical angle α of the conductor after crimping and inconsistent axial flow velocities between the steel core and aluminum strands, which was difficult to avoid completely under current process conditions; (2) The degree to which the strain sleeve embedded into the anti-slip grooves was closely related to the axial flow velocity of the metal. During the die-closing stage, the axial flow velocity of the metal reached up to five times the die movement speed, and such high-speed flow led to a decline in the filling quality of the anti-slip grooves, especially insufficient filling in the middle groove region; (3) As the holding pressure increased from 20 kN to 40 kN, the stress concentration areas expanded significantly, indicating that excessive holding pressure exacerbated internal material damage. Existing research has not yet sufficiently revealed the underlying mechanisms of metal flow competition and deformation mismatch in dissimilar materials. Based on the interface bonding theory of cold pressure welding, the competitive metal flow mechanisms underlying two typical defects are analyzed, including insufficient filling of anti-slip grooves and strand loosening and the strategy of coordinately regulating die movement speed and holding pressure is explored. The findings provide a theoretical basis for mechanism analysis and parameter optimization of strain clamp crimping processes.

导出引用

周潞潞, 刘梓涵, 李成睿, 柴敬轩, 郭军礼, 赵伯阳. 液压式耐张线夹压接过程金属流动仿真研究[J]. 精密成形工程. 2026, 18(6): 291-303 https://doi.org/10.3969/j.issn.1674-6457.2026.06.025

ZHOU Lulu, LIU Zihan, LI Chengrui, CHAI Jingxuan, GUO Junli, ZHAO Boyang. Simulation of Metal Flow During the Hydraulic Crimping Process of Strain Clamps[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 291-303 https://doi.org/10.3969/j.issn.1674-6457.2026.06.025

中图分类号： TM752

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