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提出一种大型对焊法兰四点弯曲JCO成形新工艺,该工艺无需预弯工序,且具有成形道次少、形状精度高和模具柔性化程度高等优点。采用相似性原理,将大型法兰环形件按照1∶15的比例缩小,利用有限元模拟软件ABAQUS对大型对焊法兰四点弯曲JCO成形过程进行数值模拟,得到了摩擦系数、凸模圆角半径和凹模圆角半径对卸载前弯曲半径的影响规律,并且通过调整凸模跨距和凹模跨距,将模拟成形法兰环形件的椭圆度控制在约0.5%。通过物理实验对成形工艺的可行性进行了验证,实验法兰环形件的最大椭圆度<3%,满足工程实际要求。
A new four-point bending JCO forming process for large flanged butt welded flange is proposed, which requires no pre-bending process and has the advantages of less forming pass, higher shape precision and higher flexibility of the mold. Using the principle of similarity, a large flange ring is reduced by a ratio of 1:15. The finite element simulation software ABAQUS is used to simulate the four-point bending JCO process of large butt flange. The friction coefficient, Radius and radius of the die on the bending radius before unloading, and by adjusting the punch span and die span, the simulated shape of the flange ring is controlled at about 0.5% ovality. The feasibility of the forming process was verified by physical experiments. The maximum ellipticity of the experimental flange ring was <3%, which meets the actual engineering requirements.