四通管内高压成形的工艺优化和分析

刘晓晶 陈龙 陈晓晓 王雅为 冯章超

摘要：基于Dynaform软件，建立四通管内高压成形的有限元模型。选取初始进给量、初始内压力、中间内压力作为设计变量，成形后管件的最小壁厚和最大壁厚为设计目标，基于BoxBehnken Design实验设计和响应曲面法，分别建立以管件的最小壁厚和最大壁厚为目标的响应面模型。通过数值模拟的方法研究了各个参数对成形管件的影响，并通过方差和回归分析，确定了模型的最优参数。将模型预测的因素值进行有限元数值模拟后得到的结果与模型得出的结果值的误差率小于1%，验证了模型的可靠性。结果表明，通过响应面法和数值模拟可以快速获得质量较好的四通管类零件成形工艺参数。

关键词：

四通管;响应面法;数值模拟;回归分析

DOI：10.15938/j.jhust.2018.05.025

中图分类号： TG394

文献标志码： A

文章编号： 1007-2683（2018）05-0143-04

Optimization and Analysis of Hydroforming Process for Fourway Pipe

LIU Xiaojing，CHEN Long，CHEN Xiaoxiao，WANG Yawei，FENG Zhangchao

（School of Material Science and Engineering， Harbin University of Science and Technology， Harbin 150040， China）

Abstract：Based on Dynaform， a finite element model of hydroforming for fourway pipe was built Through the initial feed rate， initial internal pressure， and the intermediate pressure were selected as the design variables， taking the minimum and maximum wall thickness of the postforming for tube as design aimBased on BoxBehnken Design and response surface method， the response surface model was established for the goals of minimum and maximum wall thickness of tube ，the effects of various parameters on the forming tube by numerical simulation was studied， and the optimal parameters of the model was determined through variance and regression analysis The result of models predicted factor through finite element simulation， compared with the result of the model， the error rate was less than 1 percent， therefore the reliability of the model was verified The results showed that highquality forming process parameters fourtube part could be quickly got through response surface method and numerical simulation

Keywords：Fourway pipe; response surface method;numerical simulation; regression analysis

0引言

近年來，为了满足轻量化的要求，管件内高压成形技术[1]开始发展起来，尤其在汽车领域与航天领域[2]，伴随着汽车行业的迅速发展[3]，内高压成形技术的优点[4]为其发展提供了广阔前景。在当代，越来越多的研究人员将有限元法[5]与内高压成形技术工艺相结合[6]。已有部分汽车零部件被成功的应用在工厂生产中[7-8]。主要在生产底盘、排气系统异型管件[9]、转向杆和发动机托架等[10-11]方面。在日常生活中，冰箱、空调等已被人们广泛使用，作为配件的管接头被大量需求[12]，这些多通管的形状复杂[13]，采用传统的焊接方法[14]经常会出现焊缝、裂纹等不良现象[15]，难以保证其质量，而采用内高压成形就能克服上述缺陷[16]。……