目的 针对IN625镍基高温合金薄壁管在小弯曲半径绕弯成形过程中容易产生壁厚减薄、截面畸变的问题,通过优化绕弯成形工艺参数,提升管材的成形质量。方法 以外径D=25.4 mm、壁厚t=0.89 mm及相对弯曲半径R/D=2（即弯曲半径R）的IN625镍基高温合金薄壁管为对象,建立有限元模型,对其小弯曲半径绕弯成形过程进行模拟。以芯模伸出量、芯模间隙、压块间隙和弯曲模间隙为优化变量,以最大壁厚减薄率和最大截面畸变率为评价指标,采用Box-Behnken响应面法设计试验方案,并借助Design-Expert软件建立二次回归模型,从而获得优化工艺参数组合。最后,采用DB2090数控弯管机开展试验,以验证有限元模拟结果及优化工艺参数的有效性。结果 优化后的工艺参数组合为：芯模伸出量4.2 mm、弯曲模间隙0.05 mm、芯模间隙0.08 mm、压块间隙0.12 mm。采用上述参数进行30°、60°、90°有限元模拟和绕弯试验,仿真模拟的最大壁厚减薄率分别为8.96%、10.21%、10.85%,最大截面畸变率分别为2.49%、2.58%、2.68%;试验件的最大壁厚减薄率分别为9.77%、10.53%、11.1%,最大截面畸变率分别为2.68%、2.72%、2.85%,仿真模拟与试验件的最大壁厚减薄率最大相对误差为8.3%,最大截面畸变率的最大相对误差为7.1%,且均未超出规定允许范围。试验件弯曲区域未发生外弧侧拉裂或截面畸变严重等失效现象,验证了优化参数组合的可行性。结论 采用有限元模拟、响应面优化与实验验证相结合的技术路线,可有效提高IN625镍基高温合金薄壁管小弯曲半径绕弯成形质量。优化得到的工艺参数组合不仅使最大壁厚减薄率满足标准限值,而且有效抑制了截面畸变,可为类似薄壁管的绕弯成形工艺优化提供参考。
Abstract
The work aims to improve the forming quality of tubes by optimizing the process parameters of bending forming, to solve the problems of wall thickness thinning and cross-sectional distortion of IN625 nickel-based superalloy thin-walled tubes in the process of small bending radius bending forming. A thin-walled tube of IN625 nickel-based superalloy with outer diameter D=25.4 mm, wall thickness t=0.89 mm and relative bending radius R/D=2 (bending radius R) was taken as the object, and a finite element model was established to simulate the winding forming process of small bending radius. Taking the mandrel extension amount, mandrel clearance, briquetting clearance and bending die clearance as the optimization variables, the maximum wall thickness reduction rate and the maximum cross-sectional distortion rate as the evaluation indexes, the Box-Behnken response surface method was used to design the test scheme, and a quadratic regression model was established by Design-Expert software, so as to obtain the optimized process parameter combination. Finally, a DB2090 CNC pipe bender was used to carry out experiments to verify the effectiveness of the finite element simulation results and the optimization of process parameters. The optimized process parameters were determined as follows: mandrel protrusion of 4.2 mm, bending die clearance of 0.05 mm, mandrel clearance of 0.08 mm, and pressure block clearance of 0.12 mm. Based on these parameters, finite element simulations and rotary bending experiments were conducted at bending angles of 30°, 60°, and 90°. The simulated maximum wall thinning rates were 8.96%, 10.21%, and 10.85%, and the maximum cross-sectional distortion rates were 2.49%, 2.58%, and 2.68%, respectively. The corresponding experimental values were 9.77%, 10.53%, and 11.10% for wall thinning, and 2.68%, 2.72%, and 2.85% for cross-sectional distortion. The maximum relative errors between simulation and experiment results were 8.3% and 7.1%, respectively, both within the allowable range. No cracking or severe cross-sectional distortion occurred in the bent specimens, confirming the feasibility of the optimized parameter combination. In conclusion, the combination of finite element simulation, response surface optimization and experimental verification can effectively improve the forming quality of IN625 nickel-based superalloy thin-walled tubes with small bending radius. The optimized combination of process parameters not only makes the maximum wall thickness reduction rate meet the standard limit, but also effectively suppresses the cross-sectional distortion, which can provide a reference for the optimization of the bending forming process of similar thin-walled tubes.
关键词
IN625镍基高温合金 /
薄壁管 /
小弯曲半径 /
绕弯成形 /
有限元分析 /
响应面
Key words
IN625 nickel-based superalloy /
thin-walled tube /
small bending radius /
rotary draw bending /
finite element analysis /
response surface
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基金
省联合基金（科技攻关类）（242103810045）
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