圆角结构对新型金属桥塞密封件液压成形性能的影响

Influence of fillet structure on the hydroformability of new metal bridge plug seal

针对新型金属桥塞密封件的成形工艺开展研究,探究圆角结构对密封件液压成形性的影响。采用有限元模拟(MSC.Marc软件)和实验相结合的方法,选取零件的形状和中间薄壁弧形段壁厚作为调控对象。通过比较不同圆角半径对零件等效塑性应变分布和大小以及对液压成形力的影响作用,得出合理的圆角结构尺寸。结果表明,随着圆角半径增大,零件中间弧形薄壁段等效塑性应变更加均匀,数值也逐渐减小,液压成形力逐渐增大。模拟和实验结果基本一致,圆角半径为2.5 mm时,对密封件的成形效果最佳,圆角部位不仅未开裂,且外形尺寸满足要求,因此,利用液压成形工艺加工该类金属桥塞密封件可行且高效。

The hydroforming process of a new type metal bridge plug seal was studied, and the influences of fillet radius on the hydroform- ability of metal seal were researched. Then, for the part shape and thickness of middle arc segment, by combining FEM （ software MSC. Marc） with actual hydroforming experiments, a reasonable fillet radius was obtained after analyzing the influences of different fillet radii on equivalent plastic strain and hydraulic forming force. FEM results show that its equivalent plastic strain distributes more uniform- ly, its numerical value is gradually reduced and hydraulic forming force increases gradually with the increase of fillet radius. The simula- tion and experiment results are consistent, and the seal effect is the best for metal seal when the fillet radius is 2. 5 mm, and the dimen- sions of part at the fillet positions meet the requirements without crack. Therefore, it is a feasible and efficient process to form the metal bridge plug seal parts.