銅包鋁電力扁排軋制工藝數(shù)值模擬及實(shí)驗(yàn)研究

銅包鋁電力扁排軋制工藝數(shù)值模擬及實(shí)驗(yàn)研究銅包鋁電力扁排軋制工藝數(shù)值模擬及實(shí)驗(yàn)研究

摘要：隨著電力工業(yè)的不斷發(fā)展，銅包鋁扁排作為一種新型的導(dǎo)電材料，受到了廣泛關(guān)注。然而，其制造過程中存在的問題也日益顯著。傳統(tǒng)的鋁板軋制常常會引起凸起和波狀現(xiàn)象，嚴(yán)重影響了產(chǎn)品質(zhì)量。本研究通過數(shù)值模擬和實(shí)驗(yàn)研究，探討了銅包鋁電力扁排軋制過程中的問題，并給出了優(yōu)化方案?；贏BAQUS數(shù)值模擬軟件，建立了軋機(jī)模型，并分別進(jìn)行了剛性和彈性材料模擬以驗(yàn)證模型的合理性。隨后，通過軋機(jī)實(shí)驗(yàn)驗(yàn)證了數(shù)值模擬的結(jié)果。研究發(fā)現(xiàn)，在置換率、軋制力等參數(shù)的控制下，可以有效減少軋制過程中的波紋和凸起，并提高產(chǎn)品的精度和均勻性。因此，本研究為銅包鋁電力扁排軋制過程的優(yōu)化提供了一定參考。

關(guān)鍵詞：銅包鋁電力扁排；軋制工藝；數(shù)值模擬；實(shí)驗(yàn)研究；優(yōu)化方案。

Abstract:Withtheconstantdevelopmentofthepowerindustry,copper-cladaluminumflatbarshaveattractedextensiveattentionasanewtypeofconductivematerial.However,theproblemsinitsmanufacturingprocessarealsoincreasing.Traditionalaluminumplaterollingoftencausesprotrusionsandwave-likephenomena,whichseriouslyaffectproductquality.Inthisstudy,throughnumericalsimulationandexperimentalresearch,theproblemsinthecopper-cladaluminumpowerflatrollingprocessareexplored,andoptimizationsolutionsareprovided.BasedontheABAQUSnumericalsimulationsoftware,therollingmillmodelwasestablished,andrigidandelasticmaterialsimulationswerecarriedoutrespectivelytoverifytherationalityofthemodel.Subsequently,thenumericalsimulationresultswereverifiedbyrollingmillexperiments.Thestudyfoundthatunderthecontrolofdisplacementrate,rollingforceandotherparameters,thewaveandprotrusionsintherollingprocesscanbeeffectivelyreduced,andtheaccuracyanduniformityoftheproductcanbeimproved.Therefore,thisstudyprovidescertainreferencefortheoptimizationoftherollingprocessofcopper-cladaluminumpowerflatbars.

Keywords:copper-cladaluminumpowerflatbar;rollingprocess;numericalsimulation;experimentalresearch;optimizationsolutionThenumericalsimulationandexperimentalresearchconductedinthisstudyhaveshedlightontherollingprocessofcopper-cladaluminumpowerflatbars.Withthehelpoffiniteelementanalysis,thetemperaturedistribution,deformationbehavior,andstressfieldintherollingprocesscanbeeffectivelyanalyzed,providingatheoreticalbasisfortheoptimizationoftherollingprocess.

Furthermore,theexperimentalresultshaveconfirmedthevalidityofthenumericalsimulationanddemonstratedthattherollingspeedandreductionratehaveasignificantimpactonthemicrostructureandmechanicalpropertiesofthecopper-cladaluminumpowerflatbars.Itwasfoundthattheappropriatecombinationofrollingspeedandreductionratecanimprovethestrengthandconductivityoftheproduct.

Moreover,theoptimizationsolutionproposedinthisstudyhasbeenprovedtobeeffectiveinreducingthewaveandprotrusionsintherollingprocess,whichcansignificantlyimprovetheaccuracyanduniformityoftheproduct.Itisworthmentioningthattheoptimizationsolutioncanbeappliednotonlytotherollingprocessofcopper-cladaluminumpowerflatbarsbutalsototherollingprocessofothermaterials.

Insummary,thisstudyprovidesvaluableinsightsintothenumericalsimulation,experimentalresearch,andoptimizationsolutionoftherollingprocessofcopper-cladaluminumpowerflatbars.ThefindingsofthisstudycanserveasareferencefortheoptimizationoftherollingprocessofsimilarproductsandcontributetothedevelopmentofthepowerindustryInadditiontotheinsightsgainedfromthisstudyontherollingprocessofcopper-cladaluminumpowerflatbars,thereareseveralareasthatcouldbefurtherexploredinfutureresearch.

Oneareaoffocuscouldbeonthematerialpropertiesofcopper-cladaluminumandhowtheyaffecttherollingprocess.Forexample,theeffectofdifferentcoppertoaluminumratios,andtheimpactofimpuritiesontherollingprocesscouldbeinvestigated.Thiswouldhelptofurtherrefinetheoptimizationapproachoftherollingprocessandimprovethequalityofthefinalproduct.

Anotherareaofpotentialresearchcouldbeontheeffectofdifferentparametersduringthecoolingprocessafterrolling.Thiscouldincludeinvestigatingthetemperatureandcoolingrate,aswellasanyotherfactorsthatcouldinfluencethemechanicalpropertiesofthefinalproduct.

Finally,therecouldbefurtherresearchintotheuseofalternativealloysforthecopper-cladlayerofthepowerflatbars.Forexample,exploringtheuseofsilverorgoldlayersasanalternativetocoppercouldprovidenewinsightsintotheoptimizationoftherollingprocessandultimatelyleadtothedevelopmentofmoreefficientandcost-effectivepowersystems.

Overall,thisstudyprovidesarobustframeworkfortheoptimizationoftherollingprocessofcopper-cladaluminumpowerflatbars.Bycontinuingtoexplorenewavenuesofresearch,thepowerindustrycancontinuetoevolveandimprovethequalityandefficiencyoftheseimportantcomponentsInadditiontothepotentialbenefitsofusingaluminumforpowertransmission,therearealsochallengesassociatedwiththismaterial.Forexample,aluminumhasalowerconductivitycomparedtocopper,whichmakesitnecessarytousealargercross-sectionalareaofaluminumforthesamelevelofconductivity.Thisincreasestheweightandsizeofthecomponents,whichcanbealimitationincertainapplicationswherespaceandweightarecriticalfactors.

Anotherchallengeisthesurfacequalityofaluminum.Unlikecopper,whichhasanaturallysmoothsurface,aluminumtendstodevelopalayerofoxideonitssurface,whichcanaffectitselectricalconductivity.Toovercomethischallenge,varioussurfacetreatmentssuchasetchingorcoatingwithaconductingmaterialhavebeendeveloped.However,thesetreatmentscanaddtothecostandcomplexityofthemanufacturingprocess.

Additionally,theuseofaluminuminpowertransmissioncomponentsrequiresadifferentdesignapproachthancopper.Forexample,theincreasedthermalexpansionofaluminumcomparedtocoppercancauseproblemswithjointconnectionsbetweenaluminumandcoppercomponents.Thisrequirescarefulconsiderationduringthedesignphasetoensurethatthecomponentsoperateeffectivelyovertheirintendedlifespan.

Despitethesechallenges,theincreasedinterestinaluminumforpowertransmissionapplicationsisdrivingongoingresearchtodevelopnewsolutionsandtechnologiestooptimizetheperformanceandefficiencyofaluminum-basedcomponents.Thisincludestheuseofadvancedmanufacturingtechniquessuchas3Dprintingandsimulationtoolstomodelandoptimizethebehaviorofaluminumcomponentsunderdifferentoperatingconditions.

Inconclusion,theuseofaluminuminpowertransmissioncomponentsisapromisingareaofresearchwiththepotentialtooffersignificantbenefitsintermsofcost,weight,andef