(燕山大学 机械工程学院，秦皇岛 066004)
摘 要: 本文建立了波导管弯曲分析有限元分析模型，针对6063波导管计算了不同弯曲半径下过渡区域壁厚分布，利用稳定变形区壁厚简化计算公式，得到稳定变形壁厚与弯曲半径关系曲线。对给定波导管(内腔15.8 mm×7.9 mm，壁厚1.0 mm)计算了不同弯曲角度下(ρ=40 mm)弯曲外侧壁厚分布，指出小半径弯曲过渡区域可以延伸到30°范围甚至更大。取90°弯曲件进行了壁厚计算值与实验值比较，除去两端10°内急剧变化段，壁厚减薄率误差小于2%。通过对比变形过渡区弧长，确定弯曲过渡区中性层弧长稳定在管材宽度B的1.2倍左右，并依此给出简化的壁厚计算公式。通过计算得出芯棒支撑范围应与过渡变形区范围一致，小半径弯曲时可达到30°角度范围。文中分析了顶推力、摩擦因数、芯棒支撑角度等对壁厚变化的影响规律，并给出了合理计算结果。这些分析计算对指导波导管弯曲研究和生产技术改进提供了重要依据。
关键字: 波导管弯曲；弯曲工艺；壁厚减薄；变形区
（School of Mechanical Engineering, Yanshan University, Qinhuangdao 066004, China）
Abstract:This investigation established a finite element analysis model to determine the distribution of wall thickness in taper zones of 6063 waveguide bends with various radii, and demonstrated the relationship between wall thicknesses in the stable deformation zones and the bending radii. For the given waveguide with the chamber size of 15.8 mm in width, 7.9 mm in height and 1.0 mm in wall thickness, the distribution of outer wall thickness was calculated for a range of angles of bend at ρ=40 mm, and it was observed that the taper zone can extend to an angular range of 30° and greater. The calculated and empirical measured wall thickness values of 90° bends were compared, and apart from the 10° of abrupt tapering at either ends of the bend, the calculated rates of thickness reduction had errors of less than 2%. In addition, the arc-lengths of the neutral axes of the taper zones were also determined to be approximately 1.2 times the width B of the tube, and a formula to calculate wall thickness with angular correction was derived. Calculations also revealed that the mandrel support regions should coincide with the range of the taper zones, and that in the bends with small radii, the angular ranges could reach 30° or more. This report also analyzed other factors and their theoretical contributions to wall thickness variation, including the force exerted by the booster on the tube, coefficient of friction and mandrel support angle. These analytical calculations can provide a theoretical basis for the improvement of waveguide bends manufacturing process and research.
Key words: waveguide bending; bending process; wall thickness reduction; taper zone
