高頻感應焊接製管分析模型與製程設計之研究

金屬有縫焊管在日常生活中的使用相當常見，主要的用途包括運輸管線、機械結構件、液壓成形的下料管件等。而在有縫焊管製程中，傳統輥軋成形製程(Conventional Roll Forming Process)與高頻感應焊接製程(High-Frequency Induction Welding Process, HFIW)受到廣泛應用。完整之HFIW製管製程中包含粗成形段、閉口段、焊接站、正寸段、矯直段，其中各段的製程設計對於管件品質的影響均十分值得探討，本論文因此針對製管製程中的製程設計進行研究。本論文基於現有的有限元素分析模型進行全線製管製程分析模型的優化，包括了全線輥軋成形分析模型與高頻感應焊接分析模型，且高頻感應焊接分析模型由三維加熱分析與二維擠壓分析組成。首先調整了板材分析時的分析條件，使管件的輥軋成形分析由焊接銜接至正寸段時得以納入焊道的材料性質，進而考量焊接對於成形的影響；同時於輥軋成形分析中加入了回彈應力量測方法，配合二維焊接擠壓分析將焊接後的回彈影響納入考量。本論文在完成全線製管分析模型的優化後，進行了製程設計的探討。其中，在輥輪設計與下料帶寬的探討中，首先提出了全線輥軋成形製管製程的輥輪設計方法，以七項輥輪設計參數完整定義出目標管件尺寸下的全線輥輪設計，並歸納了不同輥輪設計參數與下料帶寬對於不同成形品質的影響，隨後探討了不同管件尺寸與成形品質之關聯性，進而歸納出成形過程中帶寬變化與管件尺寸的關係式，以及塑性應變量與管件尺寸的關係式。本論文同時評估了加熱線圈設計、碳棒(Impeder)設計與管件幾何對於高頻感應焊接加熱效率的影響，並探討了溫度場分布與焊接擠壓量對於焊接品質的影響。本研究對於製管製程分析模型技術之貢獻在於加入了回彈量測的方法與焊道材料性質延續的機制，並考量了回彈對於焊接的影響。而本研究對於製管製程之貢獻在於探討了製程參數對管件品質的影響，透過本研究的分析方法，可針對不同材料建立帶寬變化與塑性應變對於不同管件尺寸之預測模型，進而評估管件需求之品質與成本。綜上所述，本論文的研究成果可為輥輪設計、下料帶寬、線圈與碳棒設計提供參考，並針對不同的成形品質與焊接品質提供製程改善的方向。

關鍵字

輥軋成形；高頻感應焊接；有限元素分析；輥輪設計；下料帶寬

並列摘要

Metal seamed tubes are commonly used in daily life, including transportation pipelines, structural engineering, and automotive engineering. In the seamed tube manufacturing process, the conventional roll forming process and the high-frequency induction welding process (HFIW) are widely used. A complete HFIW tube manufacturing line consists of roll forming section, fin-pass section, welding station, sizing section, and straightening section. The process design of each section is worth discussing for the great influence on the quality of tube products. Therefore, an analysis of process design for the HFIW roll forming tube manufacturing process is proposed in this study. This study optimizes the simulation model of the full-line tube manufacturing process based on the existing finite element analysis model, including the comprehensive forming process simulation and the high-frequency induction welding simulation, which consists of three-dimensional heating analysis and two-dimensional extrusion analysis. First of all, the analysis conditions of the initial strip were adjusted, so that the material properties of the heat-affected zone (HAZ) could be assigned on the tube before modeling the sizing section, thus the impact of welding was considered in the forming analysis. Simultaneously, the springback stress measurement approach was introduced into the roll forming analysis model. Combined with the two-dimensional welding extrusion analysis, the springback effect after welding extrusion could be taken into consideration. In this study, the process design is discussed after the optimization of the full-line tube manufacturing analysis model is completed. In order to carry out the discussion of roll design and initial strip width design, the roll design method of the tube roll forming process was established, and the full-line roll design under the target tube factor (diameter, thickness) was completely defined with seven independent roll design parameters. The influence of different roll design parameters and initial strip width on forming characteristics is then summarized, and the correlation between tube factor and forming quality is discussed as well. The result shows that there is a clear relationship between the strip width variation and the tube factor, and so does the relationship between the plastic strain and the tube factor. This study also evaluates the influence of inductor (heating coil) design, impeder design and tube geometry on the heating efficiency of high-frequency induction welding, and analyzes the influence of temperature field distribution and welding extrusion on welding characteristics. As the numerical simulation technology of tube manufacturing process, the contribution of this study lies in the establishment of the springback measurement method, the continuity of the material properties of HAZ, and the consideration of springback effect on welding process. While the contribution of this research to the tube manufacturing process is to explore the influence of process parameters on the quality of products. Through the analysis process implemented in this research, a prediction model of strip width change and plastic strain for different tube sizes can be established for different materials, and the demand for tube quality and cost can be evaluated. In summary, the achievement of this study provides assistance for roll design, initial strip width design, inductor design, impeder design, and provide process optimization approaches for target forming quality and welding quality.

並列關鍵字

roll forming ； high-frequency induction welding ； finite element analysis ； roll design ； initial strip width

參考文獻

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