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大直径薄壁弯头广泛应用于油气输送管道工程,采用局部感应加热并通过液压推制成形是弯管加工的主要工艺方法,由此,装备的液压推制速度和感应加热参数的准确匹配成为影响弯管质量的重要因素。针对感应加热过程中集肤效应对加热效果影响的不确定性,在感应加热理论分析的基础上,研究了基于集肤效应的关键参数,同时借助有限元模拟计算的方法,分析各工艺参数对管材感应加热过程中焦耳热分布的影响,并通过建立正交试验实现参数组优化。结果表明:感应加热装置的设计应综合考虑电流频率、电流密度、管材与感应圈距离3个参数的变化梯度对集肤效应的影响,得到最优参数组,为与之相匹配的弯管推制速度提供准确的设计参数要求,在保障弯管质量的同时,大大提高装备现场调试及生产的效率。
Large-diameter thin-walled elbow is widely used in oil and gas pipeline project, the use of local induction heating and hydraulic push forming is the main process of elbow processing, thus, equipment, hydraulic push speed and induction heating parameters accurately match An important factor affecting the quality of elbows. Based on the theoretical analysis of induction heating, the key parameters based on the skin effect were studied. In the mean time, the influence of skin effect on the heating effect was analyzed. With the help of finite element method, The influence of Joule heat distribution during tube induction heating process was also optimized by establishing orthogonal test. The results show that the design of induction heating device should take into account the effect of the gradient of the current frequency, current density, distance between the pipe and the induction coil on the skin effect, and obtain the optimal parameter set for the corresponding elbow push System speed to provide accurate design parameters, while ensuring the quality of the bend, greatly improve the efficiency of equipment commissioning and production.