大直径电缆铝护套四通道连续包覆数值模拟和实验研究

摘要

Using the finite element(FE)method,based on SSLB500 konform machine with doub-le wheels and four grooves,the continuous extrusion process ofϕ178 mm×4 mm cable aluminum sheath was numerically simulated.The velocity,temperature,stress and strain fields were observed respectively.The optimized die was tested,the aluminum sheath forms well,diameter uniform rea-ches 99%,concentricity reaches 90%,the transverse mechanical properties of the welding zone consist-ents with longitudinal,which indicates that the die design and parameter selections are all reasonable. The simulation and experimental results fit well.It proves that the FE model and results are correct, so they may be used as a theoretical guidance for big size cable aluminum sheath continuous sheathing.%采用有限单元法，基于SSLB500型双轮四槽立式连续包覆机，采用四根直径15 mm 的铝杆为坯料，运用四通道方式对ϕ178 mm×4 mm电缆铝护套的连续包覆成形过程进行有限元分析，分别得到了成形过程中变形金属速度场、温度场、应力场的分布规律；基于挤压速度和分流结构对模具结构进行了优化设计；进行了铝护套的连续包覆实验，铝护套外径尺寸波动小、壁厚均匀，圆度达到99％，同心度达到90％；对铝护套焊合区域进行了横向力学性能测试，抗拉强度、延伸率与母材一致，焊缝结合强度达到使用要求，表明模具结构设计和工艺参数选择合理；数值模拟结果与实验结果一致，证明有限元模型准确，可用于指导大管径电缆铝护套连续包覆生产。