超高压电缆铝护套四通道连续包覆数值模拟和实验研究

Numerical simulation and experiment research on aluminum sheath of extra high voltage cables by four channel continuous sheathing

基于SSLB500双轮四通道连续包覆机,采用有限元法,对Φ120 mm×2.8 mm的超高压电缆铝护套连续包覆成形过程进行了数值模拟,分析了挤压轮转速在7.5 r·min-1时金属成形过程中的速度场、温度场和应力场的分布规律,结果表明:温度场、速度场呈对称分布,模具出口处的速度、温度分布均匀。进行了Φ120 mm×2.8 mm电缆铝护套连续包覆实验和产品性能检测,结果表明:四通道工艺不仅可以成功实现大管径铝护套的连续包覆,而且铝护套成形良好,圆度达到98.69%,同心度达到92.58%,挤压焊缝结合强度与母材强度接近;数值模拟结果与实验结果一致,证明了四通道连续包覆工艺的可行性和模拟结果的正确性。

Based on SSLB500 Konform machine with double wheels and four channel,the continuous sheathing process of Φ120 mm ×2. 8 mm extra high voltage cable aluminum sheath was numerically simulated by using the finite element method. The velocity,temperature and stress fields were observed under extrusion wheel velocity of 7. 5 r·min-1. Result shows that the distributions of velocity and temperature field are axial symmetry,and the velocity and temperature on the profile at the outlet of the die are uniform. The experiment of four channel continuous sheathing of Φ120 mm × 2. 8 mm extra high voltage cable aluminum sheath and the product properties test were conducted,and the result shows that the continuous sheathing of large diameter cable aluminum sheath with good formation can be realized by four channel process,and the roundness reaches 98. 69%,the concentricity reaches 92. 58%,the bonding strength of the welding zone approaches to that of base metal. The simulation and experiment result fit well,which proves that the four channel continuous sheathing process is reasonable and the FE model and result are correct.