破裂管快速修复接头结构设计及有限元分析

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摘要

管道输送现已成为国民经济运输体系的重要组成部分之一。由于管道输送方

式具有运量大、建设投资相对较小、占地面积少等优点，从而广泛应用于现代工

业、农业、公用和民用建设中，特别是在给水、排水、供热、供煤气、长距离石

油和天然气输送、农业灌溉、固体物料的长距离输送等领域发挥着重要作用。然

而，突发性的管道破裂或渗漏一直是困扰着这一行业发展的瓶颈。管道破裂具有

随机性，不仅会造成资源浪费，还会给环境保护和生命安全带来危害。因此，各

国政府和管道行业都特别重视管道修复问题。但目前比较先进的管道修复技术大

多要借助专业的修复设备和修复材料，价格昂贵，难以全面推广应用。而比较常

用的管道修复技术，如焊接连接、法兰连接等，存在作业过程受环境限制、修复

时间长、难以实现在线修复的严重不足。正是基于这样的现状，本课题设计了一

种破裂管快速修复接头，并对该接头的密封性进行了有限元分析，为在 3-5 分钟

之内实现管道的在线快速修复提供了技术支持。本文的研究结果为新型接头产品

的开发和研究提供了依据。

首先，借助三维软件 Pro/E 对破裂管快速修复接头进行了结构设计，建立了

3D 模型，并给出了结构设计的关键技术以及管接头的使用方法。

其次，给出了密封的基本知识，分析了管接头密封结构中 O形橡胶圈的密封

机理、设计原则、主要失效形式以及 O形圈密封结构的特点和有限元理论，包括

橡胶材料的本构模型理论、几何非线性和接触非线性理论，为 O形圈密封结构的

有限元分析提供理论依据。

随后，运用有限元软件 ABAQUS 模拟了 O形橡胶圈的变形，得出了最大 Von

-Mises 应力和密封面上最大接触压应力的分布规律；确定了密封圈达到密封效果

的判据；分析了不同参数对管接头密封性能的影响，进一步简化了 O形圈密封的

条件；利用正交设计法找出了相关参数对密封性能影响的显著性，从而最终确定

了金属密封槽的最优结构参数。

最后，对管接头的三层金属密封管进行了有限元分析，得出了金属管的变形

规律，并验证了管接头设计思想的正确性和合理性。

关键词：破裂管快速修复接头 O形密封圈密封性结构设计非线性

有限元分析正交设计

ABSTRACT

Pipeline transportation system has become an important component of transport

system of the national economy. Because of the advantages of large volume

transportation capacity, relatively smaller construction investment and less floor area,

pipeline transportation is widely used in modern industry, agriculture, utility and civil

construction. It especially plays an important role in fields of water supply, water

drainage, heat supply, gas supply, long distance oil and gas transmission, agricultural

irrigation, long-distance conveying of solid materials. But the frequent rupture or leak-

off of pipelines has become bottlenecks to plague the development of pipeline

transportation. The broken of pipeline is random. This not only causes a waste of

resources, but also does harm to environmental protection and life safety. Therefore,

both governments and the pipeline industry pay attention to pipeline repairing

problems. However, the relatively more advanced pipeline repair technologies need the

help of a professional repair equipments and materials, leading to high cost and the

difficulty of wide application. The commonly used pipe repair technologies, such as

welded connections, flange connections, etal. , exist serious weak points as follows: the

operation process is limited by the environment, the repair time is long and it is

difficult to achieve on-line repairing. Based on the above disadvantages, the structure

design of a leak-off pipe quick repairing joint was carried out in this paper, and the

sealability analysis of the pipe joint was completed by finite element analysis (FEA)

method, which provides the technical support for on-line fast repair in 3-5 minutes.

The results of this paper offer references for development and research of new joints.

Firstly, structure design of a leak-off pipe quick repairing joint was completed

with the help of Pro /E and the 3D mode of the joint was built up. Key technologies of

structure design and usage methods of the leak-off pipe quick repairing joint were

presented.

Secondly, the basic knowledge of sealing was proposed. Sealing mechanism,

design principles and the main failure modes of rubber O sealing ring were analyzed.

Characteristics and finite element theory of O-ring sealing structure were studied. The

finite element theory includes rubber material constitutive model, geometric

nonlinearity and contact nonlinear theories, which provides a theoretical basis for the

finite element analysis of O-ring sealing structure.

After that, the deformation of rubber O sealing ring was simulated. Variation laws

of maximum Von-Mises stress and maximum contact pressure within the sealing

interface were obtained. The sealing criterion of rubber O sealing ring was determined.

Effects of different parameters on sealing capability of O sealing ring were analyzed,

further simplifying the sealing conditions of O-ring. The influence significance of

parameters on sealing was found out by using orthogonal design method. So the

optimal structure parameters of sealing groove of the metal inner pipe were obtained.

Finally, FEA of three metal sealed pipes of the leak-off pipe quick repairing joint

was carried out. The deformation law of three metal sealed pipes was presented. The

design of the pipe joint was proved to be correct and rational by FEA.

Key words: Leak-off pipe quick repairing joints, O sealing ring,

Sealability, Structure design, Nonlinearity, FEA,

Orthogonal design

中文摘要

ABSTRACT

第一章绪论.....................................................................................................................1

§1.1 引言...................................................................................................................1

§1.2 管道修复技术...................................................................................................1

§1.2.1 国外管道修复先进技术及其应用状况................................................1

§1.2.2 国内管道修复先进技术及其应用状况................................................4

§1.2.3 金属破裂管道的常用修复方法............................................................5

§1.3 本文研究课题的提出.......................................................................................5

§1.4 本文研究的主要内容.......................................................................................6

第二章破裂管快速修复接头结构设计.........................................................................7

§2.1 管接头的建模...................................................................................................7

§2.2 管接头的结构特征...........................................................................................8

§2.3 管接头的使用方法...........................................................................................9

§2.4 管接头设计的主要关键技术...........................................................................9

§2.4.1 密封性....................................................................................................9

§2.4.2 内、中、外三层金属管变形的均匀性..............................................10

§2.5 本章小结.........................................................................................................10

第三章 O形橡胶圈的密封性及其变形的有限元理论...............................................11

§3.1 O 形橡胶圈的密封性 .....................................................................................11

§3.1.1 密封的基本知识..................................................................................11

§3.1.2 O 形圈的结构和应用 ..........................................................................12

§3.1.3 O 形圈的密封机理 ..............................................................................13

§3.1.4 O 形圈的设计原则 ..............................................................................15

§3.1.5 O 形圈的主要失效形式 ......................................................................17

§3.2 O 形橡胶圈变形的有限元理论 .....................................................................19

§3.2.1 橡胶材料变形的特点..........................................................................19

§3.2.2 O 形橡胶圈密封结构的非线性特点 ..................................................20

§3.2.3 橡胶材料本构模型..............................................................................20

§3.2.4 几何非线性的有限元法......................................................................22

§3.2.5 接触非线性的描述方法......................................................................22

§3.2.6 橡胶超弹性本构模型系数的获得......................................................23

§3.3 本章小结.........................................................................................................24

第四章破裂管快速修复接头密封结构分析及优化...................................................25

§4.1 有限元法及 ABAQUS 的简介...................................................................... 25

§4.2 管接头密度结构有限元模型的建立.............................................................26

§4.2.1 几何模型..............................................................................................26

§4.2.2 物理模型..............................................................................................27

§4.2.3 O 形圈与沟槽接触问题的描述 ..........................................................28

§4.2.4 有限元分析建模..................................................................................28

§4.3 模拟结果分析................................................................................................31

§4.3.1 最大 Von- Mises 应力 .........................................................................32

§4.3.2 输送管与 O形圈接触面压应力.........................................................34

§4.3.3 密封槽与 O形圈接触面压应力.........................................................36

§4.4 O 形圈实现密封的判据 .................................................................................37

§4.5 不同参数对 O形圈密封性的影响...............................................................38

§4.5.1 间隙δ的影响........................................................................................39

§4.5.2 槽口倒角半径 r的影响...................................................................... 40

§4.5.3 压缩率ε的影响.................................................................................... 41

§4.5.4 工作压力 P的影响 ............................................................................. 42

§4.5.5 摩擦系数μ的影响................................................................................42

§4.5.6 参数分析的小结..................................................................................43

§4.6 密封槽最优结构参数的确定........................................................................44

§4.6.1 正交设计指标的确定..........................................................................44

§4.6.2 正交试验设计......................................................................................44

§4.6.3 结果分析..............................................................................................45

§4.7 本章小结.........................................................................................................48

第五章三层金属密封管的有限元分析.......................................................................49

§5.1 金属管有限元分析前处理.............................................................................49

§5.1.1 有限元模型的建立..............................................................................49

§5.1.2 载荷步的设定......................................................................................51

§5.1.3 约束和载荷的设定..............................................................................51

§5.2 金属管有限元模拟结果分析.........................................................................53

§5.2.1 弹性变形的验证..................................................................................53

§5.2.2 三层金属管变形的特点......................................................................54

§5.2.3 变形均匀性的验证..............................................................................55

§5.3 本章小结.........................................................................................................58

第六章结论与展望.......................................................................................................59

§6.1 结论.................................................................................................................59

§6.2 展望.................................................................................................................59

参考文献.........................................................................................................................61

在读期间公开发表的论文和承担科研项目及取得成果.............................................64

致谢...............................................................................................................................65

第一章绪论

§1.1 引言

管道输送现已成为国民经济运输体系的重要组成部分之一[1]。由于管道输送

方式具有运量大、建设投资相对较小，占地面积少等优点，从而广泛应用于现代

工业、农业、公用和民用建设中，用来实现给水、排水、供热、供煤气、长距离

石油和天然气输送、农业灌溉、固体物料的长距离输送等功能。但管道在长期使

用过程中，由于老化、腐蚀、维护不当等因素的影响，不可避免地会出现破裂或

渗漏的现象。据 1979～1989 年我国 28 个省市化肥、化工、炼油行业的不完全统

计，发生管道破裂重大事故 33 起[2]，不仅造成大量资源浪费，带来巨额经济损失，

而且严重威胁到人的生命安全。更重要的是，随着工业生产装置的大型化，生产

工艺向高温、高压、高速的方向发展[3]，出现泄漏的机会日趋增多，发生事故的

危险更大，造成的经济损失和危害将更严重。若对破裂或渗漏的管道进行全线更

换，必然存在工程量大、耗资大和工期长的缺点，因此，快捷而经济的恢复管道

的安全运行和选择合适的管道修复技术就成了一种有效的解决手段，而且具有重

要的意义。

§1.2 管道修复技术

管道通常埋于地下，故管道修复技术分为开挖技术和非开挖技术。由于开挖

会对交通畅通、环境保护、农作物及植被保护等方面带来不利影响，人们更为关

注管道修复的非开挖技术。该技术是对传统地下管线修复的一次革命[4]，在西方

发达国家已发展成为一项新的技术产业。

§1.2.1 国外管道修复先进技术及其应用状况

（1）局部及井口修复技术[5,6]

丹麦的BJKTrading公司推出的Beaver局部维修设备在1997年下半年已进入市

场[3]。该设备所用原料为环氧树脂的玻璃纤维层，把一段衬层放入管道后，由蒸汽

压力使其膨胀与管壁紧贴，维修过程大约需要l小时。这种技术适用于维修管道破

断、裂隙、错位、接头开缝以及损坏的支管。在市场上可买到各种不同规格长度、

直径和壁厚的衬层。

澳大利亚开发了一种PanelLok设备，用于更新检修井、雨水井等等。该设备采

用一种成型的PVC带，带子为螺旋缠绕，能与现有管道紧密贴合。该PVC带能通过

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摘要：

摘要管道输送现已成为国民经济运输体系的重要组成部分之一。由于管道输送方式具有运量大、建设投资相对较小、占地面积少等优点，从而广泛应用于现代工业、农业、公用和民用建设中，特别是在给水、排水、供热、供煤气、长距离石油和天然气输送、农业灌溉、固体物料的长距离输送等领域发挥着重要作用。然而，突发性的管道破裂或渗漏一直是困扰着这一行业发展的瓶颈。管道破裂具有随机性，不仅会造成资源浪费，还会给环境保护和生命安全带来危害。因此，各国政府和管道行业都特别重视管道修复问题。但目前比较先进的管道修复技术大多要借助专业的修复设备和修复材料，价格昂贵，难以全面推广应用。而比较常用的管道修复技术，如焊接连接、法兰连接等...

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