Article(id=1189584026563244416, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1189584023958577387, articleNumber=null, orderNo=null, doi=10.7654/j.issn.2097-1974.20250306, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1726416000000, receivedDateStr=2024-09-16, revisedDate=1733760000000, revisedDateStr=2024-12-10, acceptedDate=null, acceptedDateStr=null, onlineDate=1761548533334, onlineDateStr=2025-10-27, pubDate=1750780800000, pubDateStr=2025-06-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1761548533334, onlineIssueDateStr=2025-10-27, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1761548533334, creator=13701087609, updateTime=1761548533334, updator=13701087609, issue=Issue{id=1189584023958577387, tenantId=1146029695717560320, journalId=1146119989267898375, year='2025', volume='48', issue='3', pageStart='1', pageEnd='106', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1761548532712, creator=13701087609, updateTime=1761549224040, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1189586923627738079, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1189584023958577387, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1189586923627738080, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1189584023958577387, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=38, endPage=44, ext={EN=ArticleExt(id=1189584028857528721, articleId=1189584026563244416, tenantId=1146029695717560320, journalId=1146119989267898375, language=EN, title=Research on the Application of Metal Bellows in Sealing Compensation of Cryogenic Coupling, columnId=1154067058611446771, journalTitle=Missiles and Space Vehicles, columnName=Launch Support, runingTitle=null, highlight=null, articleAbstract=

The cryogenic coupling is the key equipment between the rocket and the ground filling system. It is mainly used for the filling, draining,venting of cryogenic propellant, such as liquid hydrogen, liquid oxygen, liquid methane, etc. The sealing reliability of the cryogenic coupling is crucial to the launch mission. According to the application characteristics of cryogenic coupling, the performance parameters and structural parameters of the metal bellows are proposed.The stiffness, strength and fatigue life of the metal bellows are obtained by theoretical calculation. The stress distribution, contact state, stiffness and residual deformation of the metal bellows at normal temperature are obtained by simulation analysis, and the influence of low temperature on the stress and stiffness of the metal bellows is analyzed. The stiffness test, life test and performance tests of the cryogenic coupling are carried out, and the test data are in good fit with theoretical calculation and simulation analysis. The feasibility of the application of the metal bellows in cryogenic couplings for the seal compensation is verified.

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低温连接器是箭地接口的关键设备,主要用于液氢、液氧、液甲烷等超低温推进剂的加注、泄出、排气,其可靠密封直接关系发射任务的成败。通过理论计算获得了金属波纹管的刚度、强度、疲劳寿命。开展仿真分析,获得金属波纹管在常温下的应力分布、接触状态、刚度与残余变形量,并分析了低温对波纹管应力及刚度的影响。开展刚度试验、寿命试验、整机性能试验,试验数据与理论计算、仿真分析较好吻合,验证了金属波纹管在低温连接器密封补偿中应用的可行性。

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巴全坤(1992—),男,工程师,主要研究方向为气液连接器研发及应用。

戴维奇(1981—),男,高级工程师,主要研究方向为气液连接器研发及应用。

王建秋(1983—),男,高级工程师,主要研究方向为气液连接器研发及应用。

刘忠明(1978—),男,研究员,主要研究方向为加注及供配气总体技术。

许学雷(1976—),男,研究员,主要研究方向为发射支持总体技术。

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figureFileSmall=UMur+snfqAT8GZPJAc/dlw==, figureFileBig=E/tqb81G9KXf1/wAILlyaQ==, tableContent=null), ArticleFig(id=1189594616648163445, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=CN, label=图13, caption=低温试验, figureFileSmall=UMur+snfqAT8GZPJAc/dlw==, figureFileBig=E/tqb81G9KXf1/wAILlyaQ==, tableContent=null), ArticleFig(id=1189594616711078006, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=EN, label=Tab.1, caption=

Performance parameters of bellows

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序号 性能 参数
1 工作介质 液氢、液氧、液甲烷
2 工作压力/MPa 1
3 工作温度/℃ -253~50
4 工作行程/mm 10
5 内径/mm 120~126
6 外径/mm 145~152
7 轴向刚度/(N·mm-1) ≥360
8 工作寿命 不低于1 000次
9 工作寿命内残余变形/mm ≤1.5
), ArticleFig(id=1189594616773992567, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=CN, label=表1, caption=

金属波纹管性能参数

, figureFileSmall=null, figureFileBig=null, tableContent=
序号 性能 参数
1 工作介质 液氢、液氧、液甲烷
2 工作压力/MPa 1
3 工作温度/℃ -253~50
4 工作行程/mm 10
5 内径/mm 120~126
6 外径/mm 145~152
7 轴向刚度/(N·mm-1) ≥360
8 工作寿命 不低于1 000次
9 工作寿命内残余变形/mm ≤1.5
), ArticleFig(id=1189594616857878648, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=EN, label=Tab.2, caption=

Structural parameters of the bellows

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序号 名称 参数
1 内径d/mm 120
2 外径D/mm 152
3 壁厚δ 0/mm 0.4
4 层数Z 4
5 波距q/mm 16
6 波数n 6
7 总长度L/mm 112
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金属波纹管结构参数

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序号 名称 参数
1 内径d/mm 120
2 外径D/mm 152
3 壁厚δ 0/mm 0.4
4 层数Z 4
5 波距q/mm 16
6 波数n 6
7 总长度L/mm 112
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Axial stiffness of the bellows

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序号 工况 温度/℃ E t /GPa 轴向总刚度/(N·mm-1
1 常温 20 195 428
2 液甲烷 -83 202 443
3 液氧 -183 208.9 458
4 液氢 -253 213.6 469
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金属波纹管轴向刚度

, figureFileSmall=null, figureFileBig=null, tableContent=
序号 工况 温度/℃ E t /GPa 轴向总刚度/(N·mm-1
1 常温 20 195 428
2 液甲烷 -83 202 443
3 液氧 -183 208.9 458
4 液氢 -253 213.6 469
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Performance parameters of strength

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强度校核

σ 1

/MPa

σ 2

/MPa

σ 3

/MPa

σ 4

/MPa

C W C m σ s
参数 38.0 19.1 4.8 99.8 0.7 3.0 277
), ArticleFig(id=1189594617214394493, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=CN, label=表4, caption=

强度性能参数

, figureFileSmall=null, figureFileBig=null, tableContent=
强度校核

σ 1

/MPa

σ 2

/MPa

σ 3

/MPa

σ 4

/MPa

C W C m σ s
参数 38.0 19.1 4.8 99.8 0.7 3.0 277
), ArticleFig(id=1189594617285697662, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=EN, label=Tab.5, caption=

Parameters of fatigue life

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疲劳寿命校核 σ t/MPa σ 5/MPa σ 6/MPa n f N c/次
参数 568.1 6.2 488.7 10 143 769
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疲劳寿命参数

, figureFileSmall=null, figureFileBig=null, tableContent=
疲劳寿命校核 σ t/MPa σ 5/MPa σ 6/MPa n f N c/次
参数 568.1 6.2 488.7 10 143 769
), ArticleFig(id=1189594618351050880, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1189584026563244416, language=EN, label=Tab.6, caption=

Resilience at different temperatures

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温度/℃ 20 -83 -183 -253
回弹力/N 4 271.5 4 283.5 4 292.4 4 296.8
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不同温度下的回弹力

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温度/℃ 20 -83 -183 -253
回弹力/N 4 271.5 4 283.5 4 292.4 4 296.8
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金属波纹管在低温连接器密封补偿中的应用研究
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巴全坤 , 戴维奇 , 王建秋 , 刘忠明 , 许学雷
导弹与航天运载技术(中英文) | 发射技术 2025,48(3): 38-44
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导弹与航天运载技术(中英文) | 发射技术 2025, 48(3): 38-44
金属波纹管在低温连接器密封补偿中的应用研究
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巴全坤, 戴维奇, 王建秋, 刘忠明, 许学雷
作者信息
  • 北京航天发射技术研究所,北京,100076
  • 巴全坤(1992—),男,工程师,主要研究方向为气液连接器研发及应用。

    戴维奇(1981—),男,高级工程师,主要研究方向为气液连接器研发及应用。

    王建秋(1983—),男,高级工程师,主要研究方向为气液连接器研发及应用。

    刘忠明(1978—),男,研究员,主要研究方向为加注及供配气总体技术。

    许学雷(1976—),男,研究员,主要研究方向为发射支持总体技术。

Research on the Application of Metal Bellows in Sealing Compensation of Cryogenic Coupling
Quankun BA, Weiqi DAI, Jianqiu WANG, Zhongming LIU, Xuelei XU
Affiliations
  • Beijing Institute of Space Launch Technology, Beijing, 100076
出版时间: 2025-06-25 doi: 10.7654/j.issn.2097-1974.20250306
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低温连接器是箭地接口的关键设备,主要用于液氢、液氧、液甲烷等超低温推进剂的加注、泄出、排气,其可靠密封直接关系发射任务的成败。通过理论计算获得了金属波纹管的刚度、强度、疲劳寿命。开展仿真分析,获得金属波纹管在常温下的应力分布、接触状态、刚度与残余变形量,并分析了低温对波纹管应力及刚度的影响。开展刚度试验、寿命试验、整机性能试验,试验数据与理论计算、仿真分析较好吻合,验证了金属波纹管在低温连接器密封补偿中应用的可行性。

低温连接器  /  金属波纹管  /  密封  /  轴向刚度  /  残余变形

The cryogenic coupling is the key equipment between the rocket and the ground filling system. It is mainly used for the filling, draining,venting of cryogenic propellant, such as liquid hydrogen, liquid oxygen, liquid methane, etc. The sealing reliability of the cryogenic coupling is crucial to the launch mission. According to the application characteristics of cryogenic coupling, the performance parameters and structural parameters of the metal bellows are proposed.The stiffness, strength and fatigue life of the metal bellows are obtained by theoretical calculation. The stress distribution, contact state, stiffness and residual deformation of the metal bellows at normal temperature are obtained by simulation analysis, and the influence of low temperature on the stress and stiffness of the metal bellows is analyzed. The stiffness test, life test and performance tests of the cryogenic coupling are carried out, and the test data are in good fit with theoretical calculation and simulation analysis. The feasibility of the application of the metal bellows in cryogenic couplings for the seal compensation is verified.

cryogenic coupling  /  metal bellow  /  seal  /  axial stiffness  /  residual deformation
巴全坤, 戴维奇, 王建秋, 刘忠明, 许学雷. 金属波纹管在低温连接器密封补偿中的应用研究. 导弹与航天运载技术(中英文), 2025 , 48 (3) : 38 -44 . DOI: 10.7654/j.issn.2097-1974.20250306
Quankun BA, Weiqi DAI, Jianqiu WANG, Zhongming LIU, Xuelei XU. Research on the Application of Metal Bellows in Sealing Compensation of Cryogenic Coupling[J]. Missiles and Space Vehicles, 2025 , 48 (3) : 38 -44 . DOI: 10.7654/j.issn.2097-1974.20250306
低温连接器是地面加注系统和运载火箭低温贮箱之间的关键接口设备,主要用于液氢、液氧、液甲烷等超低温推进剂的加注、泄出、排气。低温推进剂温度低、渗透性强,其可靠密封一直是国内外航天工程的技术难点1。2019年,美国载人龙飞船在地面进行静态点火测试时因阀门密封泄漏导致爆炸2。2022年,美国SLS重型运载火箭在4次合练及首飞任务中,多次出现液氢泄漏故障,导致合练及首飞任务多次推迟和终止3
金属波纹管具有弹性与密封特性,而且还具有承压、耐低温、耐冲击等优良特性,广泛应用于管路补偿器、阀门、仪器弹性元件、机械密封等4。现役型号使用的低温连接器大部分通过气缸等机构提供密封压紧力,结构较为复杂。金属波纹管具有结构简单、性能稳定、被压缩后产生回弹力、在介质压力作用下能补偿低温收缩导致的密封力下降等特性,适用于低温连接器密封补偿功能。本文开展金属波纹管在低温连接器密封补偿中的应用研究,针对低温连接器使用特点,通过理论计算、仿真分析、性能试验,获得金属波纹管各项性能参数,验证了金属波纹管在低温连接器密封补偿中应用的可行性。
低温连接器主要包括连接器和箭上接口两部分。连接器与箭上接口在常温下进行对接,对接完成后金属波纹管被压缩,产生的回弹力提供连接器箭地接口密封压紧力,连接器密封结构如图1所示。加注过程中,在介质压力作用下,金属波纹管有伸长趋势,以此来补偿低温冷缩导致的密封力下降。某DN100低温连接器对金属波纹管性能要求如表1所示。
按照金属波纹管的结构形式,金属波纹管主要分为U型金属波纹管、V型金属波纹管、Ω型金属波纹管、S型金属波纹管等。其中U型应用较为广泛,成型工艺简单,承压能力和抗挠曲能力较好,常用于动密封和行程不大的部位5。考虑可靠性、经济性,连接器金属波纹管采用多层U型金属波纹管结构。根据使用温度、介质相容性、精度要求、工作寿命等条件,并考虑材料成形和焊接工艺,金属波纹管材料选择316L。
金属波纹管结构参数的选择需要依据连接器结构特点和设计要求综合确定。根据推进剂加注量、加注时间、管路承压、推进剂最大安全流速综合确定连接器公称通径,然后根据连接器公称通径确定金属波纹管内径。内径确定后,依据轴向刚度、承压要求确定金属波纹管层数、外径、波距等其他参数。为减小行程引起的金属波纹管局部应力过大,同时降低生产制造难度,金属波纹管采用小板厚、多层结构。金属波纹管设计后对刚度、强度、疲劳寿命、稳定性进行校核,根据校核结果优化参数,反复迭代以达到最优的设计方案。根据表1性能要求设计的金属波纹管结构参数如表2所示。
金属波纹管设计校核的主要性能参数为刚度、强度、疲劳寿命、稳定性等。金属波纹管刚度为回弹力与位移的比值,常用K表示。相同使用条件下,刚度值越小,位移补偿量越大,但强度和稳定性降低,因此在满足强度和稳定性要求的前提下尽量降低设计刚度值。金属波纹管刚度主要分为轴向刚度、弯曲刚度、扭转刚度,金属波纹管在连接器密封补偿应用时主要承受轴向载荷,故本文主要对金属波纹管的轴向刚度进行校核。
U型金属波纹管的轴向刚度按照经验公式进行计算,单波轴向刚度按式(1)计算6
K t = 1.7 D m E t δ m 3 Z h 3 C f
金属波纹管轴向总刚度按式(2)计算:
K X = K t n
D m为金属波纹管平均直径,其按式(3)计算:
D m = D + d 2
δ m为金属波纹管最小有效厚度,按式(4)计算:
δ m = δ 0 d / D m
h为金属波纹管的波高,其按式(5)计算:
h = D - d - 2 Z δ 0 2
其中,C f为行程引起的波纹管子午向薄膜应力系数,C f与波距q、波高h、平均直径D m、最小有效厚度δ m有关,由文献[5]查得, E tt时材料的弹性模量。
金属波纹管在低温下使用时,需考虑低温对波纹管弹性模量的影响,金属材料的弹性模量随温度变化关系如式(6)所示7
E t = E 0 1 - β E Δ t
式中 E 0为初始温度时材料的弹性模量; β E为弹性模量的温度系数,不锈钢材料温度系数为3.5×10-4 Δ t为温度变化量(Δt = t - t 0,单位℃,t 0为初始温度20 ℃);
根据计算得到波纹管在液甲烷、液氧、液氢3种工况下的轴向刚度,如表3所示。
金属波纹管承受外压力强于承受内压力,因此在金属波纹管进行强度计算时,按内压进行计算。应力评定按式(7)~(9)执行6
σ 1 C W σ
σ 2 C W σ
σ 3 + σ 4 C m σ
式中 σ 1为内压引起的波纹管直边管段周向薄膜应力; σ 2为内压引起的波纹管周向薄膜应力; σ 3为内压引起的波纹管子午向薄膜应力; σ 4为内压引起的子午向弯曲应力;C W为纵向焊缝有效系数,取0.7~0.9;C m为材料强度系数,未经过退火的波纹管C m=3.0;波纹管作为敏感元件时,[ σ]= σ s σ s为材料的屈服强度。强度校核数据如表4所示,满足要求。
金属波纹管的疲劳寿命影响低温连接器重复使用次数,且疲劳寿命也反映残余变形大小。奥氏体不锈钢成型金属波纹管的疲劳寿命按式(10)~(11)进行计算6
N c = 12   820 σ t - 370 3.4 / n f
σ t = 0.7 σ 3 + σ 4 + σ 5 + σ 6
式中 N c为疲劳寿命次数; n f为疲劳安全系数,一般取10~15; σ t为子午向总应力; σ 5为内压引起的波纹管子午向薄膜应力; σ 6为行程引起的波纹管子午向弯曲应力。疲劳寿命数据如表5所示。金属波纹管疲劳寿命高于105,属于高周疲劳,满足要求。
根据金属波纹管在连接器密封补偿中的应用状态,采用ANSYS软件对金属波纹管进行静力学仿真分析。
a)仿真模型:金属波纹管为轴对称结构,为减小网格数量,增加计算速度,采用二维轴对称模型来进行仿真;模型按照理论尺寸建立,未考虑成型过程中冷作硬化等生产过程对金属波纹管性能的影响。
b)单元类型:单元类型选择平面单元PLANE42,每个单元有4个节点,每个节点有2个自由度,该单元适用于二维轴对称模型。
c)接触设置:为模拟多层金属波纹管之间的相互影响,各层金属波纹管之间采用摩擦接触,摩擦系数为0.1。金属波纹管成型后,为防止水气等进入金属波纹管夹层,影响金属波纹管焊接质量,金属波纹管两端直边采用滚焊熔为一体,故仿真时将两端直边之间设置绑定接触。
d)边界条件:金属波纹管一端直边段采用远端位移约束,约束轴向及旋转自由度,径向方向不做约束。另一端约束分两种:计算强度与刚度时,采用位移约束,径向位移为0,轴向位移随载荷步逐步增加;计算残余变形时,采用力约束,力值随载荷步逐步增加。
e)材料:金属波纹管采用316L制造,弹性模量为1.95×105 MPa,泊松比为0.3,密度为7.85×103 kg/m3,线膨胀系数为16.5×10-6/℃。金属波纹管压缩量较大时,局部应力会超过材料的屈服强度,产生一定的塑性变形,故仿真时采用弹塑性模型来进行计算。为获得金属波纹管板材的应力-应变曲线,对板材取样进行拉伸试验,获得的应力-应变曲线如图2所示。在ANSYS材料特性中增加多线性等向强化模型,将图2中的工程应力-应变数据转化为真实的应力-应变数据,然后以表格的形式输入。
在10 mm压缩量下,金属波纹管的应力云图如图3所示,可以看出金属波纹管最大应力为439.7 MPa,超过了材料的屈服强度,金属波纹管局部出现屈服现象。金属波纹管的波峰和波谷为应力较大区域,最大应力位于波峰与波谷的圆弧段与竖直段相接区域,且位于每层金属波纹管的接触面,每层波纹管除接触面外的区域应力相对较小。最大应力为每层金属波纹管内侧、外侧弯曲变形较大以及每层波纹管之间相互挤压造成的应力集中。
10 mm压缩量下,金属波纹管每层之间的接触状态如图4所示,可以看出金属波纹管的波峰、波谷以及圆弧段与竖直段相接处为紧密贴合状态,这部分区域每层金属波纹管之间发生了挤压现象。金属波纹管其他部位为靠近状态,未发生挤压现象。
提取远端位移约束的回弹力,获得回弹力随压缩量的变化曲线,如图5所示。从曲线可以看出,在压缩量小于7 mm时,回弹力与压缩量呈线性正比关系,说明在压缩量小于7 mm时,金属波纹管处于线弹性阶段。当压缩量大于7 mm后,曲线斜率开始逐渐减小,回弹力随压缩量的增加开始减缓,说明压缩量大于7 mm后金属波纹管开始出现屈服。在10 mm压缩量下,回弹力为4 271 N,即刚度为427.1 N/mm,满足轴向刚度要求。仿真获得的刚度与理论计算值能较好吻合。
波纹管在载荷作用下产生位移,当载荷卸除后,波纹管不恢复原始状态的现象称为残余变形。将位移约束改为力约束,将图5中随压缩量变化的回弹力转化为随载荷步变化的力值。在压缩量增加至10 mm后,将随后两个载荷步力值设为0,以此来计算压缩10 mm状态下的残余变形量,重复加载4次,计算金属波纹管多次使用状态下的残余变形是否增加。
仿真得到金属波纹管变形量随载荷步变化曲线,如图6所示。从曲线可以看出,在首次压缩10 mm后,残余变形量约1.230 mm;第二次压缩10 mm后,残余变形量为1.232 mm,残余变形量的增加较小;第三、四次压缩10 mm后,残余变形量保持1.232 mm,残余变形量不再增加。可见金属波纹管保持行程的起点、终点一致的状态下,金属波纹管的残余变形主要发生在首次压缩,最大残余变形量约为1.232 mm,满足工作寿命内残余变形不大于1.5 mm的要求。
连接器在常温下与箭上接口进行对接,金属波纹管被压缩后提供初始的密封压紧力,确保箭地接口可靠密封。连接器对接完成后,进行全系统气检和贮箱置换,最后进行低温推进剂加注。连接器金属波纹管直接与低温推进剂接触,低温会导致其冷缩,长度减小,相当于压缩量减小。根据式(6),温度降低,材料的弹性模量增加,金属波纹管刚度增加。同时低温会导致金属波纹管材料的屈服强度和抗拉强度显著增加,塑性和韧性降低8。因未找到316L材料在低温下的应力-应变数据,故本文暂不考虑低温导致材料屈服强度和抗拉强度增加对金属波纹管性能的影响。在材料特性中增加不同温度下的弹性模量,同时根据连接器使用流程施加温度载荷:在压缩10 mm前的载荷步,温度载荷为20 ℃(室温),在压缩10 mm后的载荷步,温度载荷分别为-83 ℃、-183 ℃、-253 ℃。计算得到金属波纹管在低温度下的应力云图如图7图9所示。
从不同温度下的应力云图可以看出,在压缩量为10 mm状态下,不同温度下的应力分布基本相同,随着温度降低,金属波纹管的最大应力逐渐缓慢增加。
提取施加温度载荷后的回弹力,如表6所示。在10 mm压缩量下,随着温度降低,金属波纹管的回弹力逐渐增加,但增加量相对较小。可见在不考虑低温导致材料屈服强度和抗拉强度增加状态时,低温导致的弹性模量增加与低温冷缩相互抵消,回弹力基本保持不变。
金属波纹管成型完成后进行常温下的刚度试验,试验装置主要由底座、金属波纹管、压力机组成,如图10所示。试验时通过压力机控制金属波纹管压缩量,同时采集不同压缩量下的回弹力。
试验获得的回弹力随压缩量变化曲线如图11所示。可以看出,在相同压缩量下,试验回弹力比仿真回弹力要略小。同时试验获得的回弹力随压缩量变化曲线的线性度比仿真结果要好,说明实物金属波纹管材料屈服现象要轻一些,可能是波纹管成型时应变强化导致。分析试验数据,在压缩量大于7 mm后,曲线斜率开始降低,与仿真数据现象一致。在10 mm压缩量下,回弹力为4 193 N,即刚度为419.3 N/mm,满足轴向刚度要求。理论计算、仿真计算、试验结果的刚度值偏差小于3%,误差较小。
连接器金属波纹管要求工作寿命不低于1 000次,为了保留一定的安全裕度,疲劳寿命试验共开展1 500次。试验采用如图10所示的刚度试验装置进行,寿命试验500、1 000、1 500次后均进行刚度测试并记录残余变形。寿命试验期间,每次试验时的起点、终点一致,不根据金属波纹管残余变形情况调整测试行程的起点,防止造成金属波纹管持续变形。
图12可以看出,500次寿命试验后,金属波纹管压缩量小于1.2 mm时,回弹力为0,即压力机在前1.2 mm的行程内未与金属波纹管接触,说明金属波纹管在500次寿命试验后已经发生了残余变形。根据金属波纹管常温仿真结果,金属波纹管可能在首次压缩后就发生了残余变形。进行500次、1 000次、1 500次寿命试验后的回弹力随压缩量变化曲线基本重合,且线性度较好。金属波纹管残余变形1.2 mm,相当于后续金属波纹管压缩量仅有8.8 mm,即金属波纹管在压缩量小于8.8 mm状态下的性能基本稳定。寿命试验1 500次后,压缩量为10 mm的回弹力为4 034 N,即刚度为403.4 N/mm,满足轴向刚度要求。
金属波纹管在刚度试验与寿命试验合格后与其他零件进行焊接,并完成低温连接器组装。组装完成后,低温连接器与模拟箭上接口进行对接,对接过程控制金属波纹管压缩量为10 mm。
对接完成后,给连接器内腔充压至1 MPa,对箭地接口在常温下的密封性能进行检查,密封性能满足要求。
常温密封性检查合格后,开展整机液氮低温试验,低温试验状态如图13所示。液氮低温时间3 h,确保连接器冷透,然后关闭出口阀,将连接器内腔憋压至1 MPa左右,通过检漏口对箭地接口密封性能进行检查,箭地接口低温密封性能正常,金属波纹管性能满足要求。
本文开展金属波纹管在低温连接器中应用研究,提出金属波纹管各项设计参数,通过理论计算、仿真分析、试验研究,获得金属波纹管在常温及低温下的各项性能参数,主要结论如下:
a)金属波纹管作为密封补偿元件时,为保证足够的密封补偿力,工作行程下的局部应力可能会超过屈服强度,可采用本文提出的仿真分析方法对残余变形进行分析计算。通过仿真分析发现,金属波纹管在压缩时的起点、终点保持不变情况下,残余变形量主要在首次压缩时发生,而后保持稳定。
b)低温仿真结果表明,在不考虑低温导致材料屈服强度和抗拉强度增加对金属波纹管性能的影响下,压缩量相同时,波纹管在不同温度下的应力分布基本相同,回弹力基本保持不变。即波纹管在低温下使用,刚度与强度性能优于常温状态,设计时可仅对常温状态进行校核。
c)经验公式计算结果、有限元仿真分析结果、试验数据能较好吻合,在工程应用中可以采用3种方式对比验证。本文提出的有限元仿真方法能比较真实地计算多层金属波纹管在常温与低温状态下的应力分布、每层接触状态、刚度、残余变形等,满足实际工程应用。
d)金属波纹管常温压缩后能提供初始的密封压紧力,低温作用下金属材料强度和刚度增加,能补偿低温冷缩导致的密封比压下降,通过刚度试验、寿命试验、整机性能试验,验证了金属波纹管在低温连接器密封补偿中应用的可行性。
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doi: 10.7654/j.issn.2097-1974.20250306
  • 接收时间:2024-09-16
  • 首发时间:2025-10-27
  • 出版时间:2025-06-25
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  • 收稿日期:2024-09-16
  • 修回日期:2024-12-10
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    北京航天发射技术研究所,北京,100076
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2种不同金属材料的力学参数

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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
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红菇属 Russula 17 8.13
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