Exploring Influence of Filling Rate of Formed Aluminum Wire on Radial Force
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摘要: 碳纤维复合芯导线由碳纤维复合芯棒和铝型线构成，型线铝股结构型式填充率高，与圆线铝股传力性能不同，目前针对碳纤维复合芯导线填充率对径向传力影响的相关研究空白。本文对卡线器夹嘴夹紧时导线的受力状态进行了有限元仿真模拟，利用ABAQUS软件建立不同填充率导线结构模型，仿真得到不同填充率下导线铝型线和芯棒的应力情况，仿真结果表明导线夹持受力状态下，铝型线填充率会对导线外部受力向芯棒传递造成一定影响，随着填充率减小，导线铝型线和芯棒压应力逐渐变大。研究结果可作为1 660 mm2碳纤维复合芯导线用卡线器夹嘴长度优化设计参考依据。Abstract: Aluminum conductor composite core is made of carbon fiber composite core and formed aluminum wire, and the filling rate of the structure type of formed aluminum wire is high. It has different radial force performances compared with round wire. There is not enough research on the influence of filling rate of formed aluminum wire on radial force at present. This paper carried out the finite element simulation of stress states of the conductor clamped by grip jaw and established the structural model of the conductor that has different filling rates with the ABAQUS software. The simulation produces the stress states of the formed aluminum wire and carbon fiber composite core with different filling rates. The simulation results show that when the conductor is clamped with grip jaw in the stress state, the filling rate influences the transfer of the external force of the conductor to the carbon fiber composite core. As the filling rate decreases, the compressive stress of the formed aluminum wire and carbon fiber composite core increases gradually. The research results can be used as a reference for the optimal design of the length of the clamp of grip jaw for 1 660 mm2 aluminum conductor composite core.
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表 1 1660/95-492导线技术参数(按92%)
项目 技术参数 铝线结构 62 半硬铝型线外层 23根, 等效直径5.84 mm 半硬铝型线邻外层 18根, 等效直径5.84 mm 半硬铝型线邻内层 13根, 等效直径5.84 mm 半硬铝型线内层 8根, 等效直径5.84 mm 复合芯 11.0 mm 铝型线截面积 1 660.76 mm2 复合芯截面积 95.03 mm2 外径 49.2±0.5 mm 
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表 2 不同填充率半硬铝型线参数
填充系数 参数 内层 临内层 临外层 外层 n 8 13 18 23 θ/(°) 44 27 19.5 15.2 D/mm 20.438 30.000 39.592 49.200 92% d/mm 11.000 20.438 30.000 39.592 δ/mm 0.10~0.18 0.11~0.17 0.13~0.17 0.15~0.19 D/mm 20.599 30.285 39.995 49.715 90% d/mm 11 20.599 30.285 39.995 δ/mm 0.10~0.18 0.12~0.18 0.13~0.18 0.16~0.20 D/mm 20.766 30.583 40.414 50.250 88% d/mm 11.000 20.766 30.583 40.414 δ/mm 0.10~0.18 0.13~0.18 0.13~0.18 0.16~0.20 注:δ为同层相邻两个铝股最小间距。
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表 3 1660/95碳纤维复合芯导线模型材料参数
弹性模量/GPa 泊松比 密度/
(kg·m-3)屈服强度/MPa 抗拉强度/MPa 复合芯棒 120 0.31 1 620.00 - 2 400 半硬铝型线 70 0.33 2 703.01 100 120
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表 5 不同填充率下稳定状态铝型线、芯棒应力对比
填充率 半硬铝型线应力/MPa 复合芯棒应力/MPa 最大应力位置 92% 114.5 120.8 芯棒外层 90% 118.1 134.1 芯棒外层 88% 120.1 172.0 芯棒外层
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表 6 不同填充率下最大应力状态铝型线、芯棒应力对比
填充率 半硬铝型线 复合芯棒 最大应力/MPa 塑性区比例(>100MPa) 最大应力/MPa 截面节点平均应力/MPa 截面圆周平均应力/MPa 92% 121.0 10.5% 188.8 68.9 78.4 90% 121.0 9.0% 189.8 69.8 78.7 88% 121.0 8.9% 199.6 76.2 88.9
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表 7 不同填充率下稳定状态铝型线变形引起的间隙数据
92%填充率 90%填充率 88%填充率 初始状态同层铝股间隙/mm 稳定状态同层铝股间隙/mm 初始状态同层铝股间隙/mm 稳定状态同层铝股间隙/mm 初始状态同层铝股间隙/mm 稳定状态同层铝股间隙/mm 0.225 9 0.252 5 0.119 5 0.076 9 0.197 3 0.366 7 0.217 6 0.166 1 0.103 0 0.129 6 0.208 8 0.141 5 0.206 2 0.164 8 0.112 8 0.314 7 0.183 1 0.116 7 0.225 9 0.174 5 0.128 1 0.151 4 0.195 5 0.158 0 0.217 6 0.216 7 0.119 5 0.090 8 0.162 0 0.189 0 0.201 2 0.159 0 0.103 0 0.310 9 0.165 0 0.231 8 0.214 9 0.212 2 0.112 8 0.190 1 0.275 3 0.142 9 0.116 9 0.108 4 0.117 9 0.167 4 0.204 6 0.161 9 0.201 8 0.105 7 0.177 8 0.155 3 0.193 9 0.070 0 0.133 9 0.134 8 0.115 4 0.134 5 0.206 4 0.177 1 0.126 9 0.073 7 0.106 6 0.152 3 0.185 1 0.467 0 0.111 3 0.083 4 0.117 7 0.060 4 0.198 1 0.161 8 0.133 9 0.088 5 0.125 7 0.190 9 0.186 4 0.169 0 0.126 9 0.119 4 0.115 4 0.121 6 0.191 7 0.250 3 0.111 3 0.054 3 0.106 6 0.081 9 0.265 7 0.114 6 0.119 2 0.110 1 0.117 7 0.211 5 0.243 6 0.189 4 0.109 4 0.123 2 0.160 0 0.204 9 0.206 4 0.189 8 0.199 5 0.119 0 0.187 1 0.200 8 0.198 1 0.109 5 0.119 2 0.115 9 0.128 1 0.093 5 0.193 9 0.278 1 0.162 6 0.234 3 0.163 2 0.050 6 0.257 3 0.220 5 0.131 9 0.191 5 0.123 0 0.079 2 0.193 6 0.256 9 0.214 9 0.254 1 0.125 7 0.148 7 0.208 8 0.188 8 0.167 1 0.224 9 0.145 4 0.085 3 0.195 5 0.191 7 0.140 7 0.183 7 0.085 6 0.040 0 0.197 3 0.248 0
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