电缆车削剥皮过程理论分析与仿真模拟

Theoretical Analysis and Numerical Simulation of Cable Turning and Stripping Process

为解决人工剥离电缆外皮效率低、精度差的问题,通过材料力学分析和有限元方法对电缆车削剥皮过程进行了理论模型构建和仿真模拟分析,研究了电缆车削剥皮过程中的变形规律,为一种机械车削中间剥皮方式提供理论依据并验证可行性。对电缆结构特性进行分析,建立了电缆几何模型。采用复合材料力学理论分析与均匀化方法,进行电缆力学模型建立及参数的求解。建立了影响车削剥皮质量的中间剥皮车削加工力学模型,研究影响剥皮质量的电缆弯曲与扭转变形力学特性规律,并进行了电缆线径、长度、切削位置因素显著性分析。分析了电缆绝缘外皮交联聚乙烯(cross-linked polyethyline,XLPE)切削加工特点、刀具几何参数与材料选择,求解出了XLPE的修正J-C本构模型,运用ABAQUS进行热力耦合切削数值模拟,研究了切削速度、切削深度与刀具角度对切削力、切削温度及切屑形态影响规律。结果表明:电缆线径对电缆弯曲和扭转变形均有较大影响,线径越大,产生的变形越小。长度和切削位置对线缆弯曲变形影响较大,对扭转变形影响不明显。电缆XLPE外皮切削有限元模拟结果清晰直观,切削速度、切削深度和刀具前角对XLPE外皮切削形态和切割温度影响规律明显。

In order to solve the problems of low efficiency and poor accuracy of manual peeling of cable,the theoretical model and simulation analysis of cable turning and peeling process were carried out through material mechanics analysis and finite element method,and the deformation law in the process of cable turning and peeling was studied,which provides a theoretical basis for an intermediate peeling method of mechanical turning and verifies its feasibility.The cable structure characteristics were analyzed and the cable geometric model was established.The mechanical model of cable was established and the parameters were solved by using the theoretical analysis and homogenization method of composite mechanics.The mechanical model of intermediate peeling machining affecting the peeling quality was established,the mechanical characteristics of cable bending and torsional deformation affecting the peeling quality were studied,and the significance of cable diameter,length and cutting position were analyzed.The cutting characteristics,tool geometric parameters and material selection of cross-linked polyethyline(XLPE)for cable insulation sheath were analyzed.The modified J-C constitutive model of XLPE was solved.The thermal mechanical coupling cutting numerical simulation was carried out by ABAQUS.The effects of cutting speed,cutting depth and tool angle on cutting force,cutting temperature and chip shape were studied.The results show that the cable diameter has a great influence on the bending and torsional deformation of the cable,and the larger the cable diameter,the smaller the deformation.Length and cutting position have great influence on cable bending deformation,but have no obvious influence on torsional deformation.The finite element simulation results of cable XLPE sheath cutting is clear and intuitive,and the cutting speed,cutting depth and tool rake angle have obvious effects on XLPE sheath cutting shape and cutting temperature.