防冲支架双层变径式吸能构件的结构优化及吸能特性

蒲志新; 韩瑞夫; 白杨溪; 董成; 廉嘉鹏

doi:10.11858/gywlxb.20251164

防冲支架双层变径式吸能构件的结构优化及吸能特性

doi: 10.11858/gywlxb.20251164

蒲志新^1,,
韩瑞夫^1,*, ,,
白杨溪¹,
董成²,
廉嘉鹏¹

1.
辽宁工程技术大学机械工程学院, 辽宁阜新　123000
2.
鞍山钢铁集团有限公司鞍钢股份, 辽宁鞍山　114009

基金项目: 国家自然科学基金（52204215）

详细信息

作者简介:
蒲志新（1973－），男，硕士，副教授，主要从事机电一体化研究. E-mail：19824845574@163.com

通讯作者:
韩瑞夫（1999－），男，硕士研究生，主要从事矿山压力与支护研究. E-mail：15241168661@163.com

中图分类号: TD353; O347.1; O521.9
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- 文章访问数: 364
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出版历程
- 收稿日期: 2025-08-18
- 修回日期: 2025-10-16
- 录用日期: 2026-01-08
- 网络出版日期: 2025-10-26

Structural Optimization and Energy Absorption Characteristics of Double-Layer Variable-Diameter Energy-Absorbing Components for Anti-Impact Brackets

1.
College of Mechanical Engineering, Liaoning Technical University, Fuxin 123000, Liaoning, China
2.
Anshan Iron and Steel Group Co., Ltd., Anshan 114009, Liaoning, China

摘要

摘要: 为有效缓解冲击地压对液压支架的破坏作用，基于单层变径式吸能构件研究基础，提出了一种具有更高吸能量的双层变径式吸能构件。基于能量法剖析了不同截面管件扩径与缩径变形的能量耗散理论，推导了波纹管与圆管不同组合形式下构件稳定变径过程的承载力计算公式；通过数值模拟得到了8种不同类型吸能构件的吸能量曲线、承载力曲线及变形规律，对比发现，内层波纹管、外层圆管的双层变径式吸能构件结构（SBY类型）具备较优的吸能性能；探究了不同结构参数对吸能效果的影响规律，其中，内管壁厚、外管壁厚、波纹半径和底座内倒角4种结构参数对吸能特性参数影响显著。根据拉丁超立方取样方法设计试验方案，利用Kriging代理模型，结合多目标粒子群优化算法对结构参数进行优化，最终选择优化后的结构参数组合为内管壁厚6.0 mm、外管壁厚2.9 mm、波纹半径6.9 mm、底座内倒角40°。据此，制作了吸能构件并进行了轴向准静态加压实验，验证了数值模拟分析及优化结果的准确性和有效性。结果表明：经参数优化后的双层变径式吸能构件的总吸能提高了54.2%，比吸能提高了55.6%，平均承载力提高了43.2%，载荷标准差提高了59.5%。所设计的构件具有更好的吸能性能，让位防冲过程更加可靠。本研究可为深部巷道支护液压支架的吸能构件设计提供理论依据和参考。
- 防冲支架 /
- 双层变径构件 /
- 能量吸收 /
- 参数优化 /
- 波纹管
Abstract: In order to effectively mitigate the destructive effects of impact ground pressure on hydraulic supports, a double-layer variable-diameter energy-absorbing component with enhanced energy absorption was proposed based on previous research on single-layer variable-diameter structures. Using the energy method, the energy dissipation theory of the expansion and reduction deformation of tubular components with different cross-sections was analyzed, and the bearing capacity formulas for stable diameter reduction processes under various combinations of corrugated and circular tubes were derived. Through numerical simulations, the energy absorption curves, bearing capacity curves, and deformation patterns of eight types of energy-absorbing components were obtained. Comparative analysis revealed that the double-layer variable-diameter energy-absorbing component structure (SBY-type), consisting of an inner corrugated tube and an outer circular tube, exhibited superior energy absorption performance. The influence of key structural parameters on the energy absorption characteristics was further investigated. Among these, inner tube thickness, outer tube thickness, corrugation radius, and inner chamfer angle of the base were found to have the most significant effects. A Latin hypercube sampling scheme was designed, and the parameters were optimized using a Kriging surrogate model coupled with a multi-objective particle swarm optimization algorithm. The optimal parameter combination was determined as follows: inner tube thickness of 6.0 mm, outer tube thickness of 2.9 mm, corrugation radius of 6.9 mm, and base chamfer angle of 40°. Subsequently, axial quasi-static compression tests were conducted to verify the accuracy and effectiveness of the numerical and optimization results. The results indicate that, the total energy absorption of the double-layer variable-diameter energy-absorbing component increased by 54.2%, the specific energy absorption increased by 55.6%, the average bearing capacity increased by 43.2%, and the load standard deviation increased by 59.5%. These enhancements demonstrate that the optimized component exhibits superior and more stable energy absorption performance, thereby improving the reliability of the yielding anti-impact process. This study provides an important theoretical basis and design reference for developing energy-absorbing components in hydraulic supports for deep roadway reinforcement.
- anti-impact bracket /
- double-layer variable-diameter component /
- energy absorption /
- parameter optimization /
- bellows

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图 1 双层变径式吸能构件及其变形过程

Figure 1. Double-layer variable-diameter energy-absorbing component and deformation process

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图 2 不同结构吸能构件

Figure 2. Energy-absorbing components with different structures

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图 3 波纹管截面尺寸

Figure 3. Cross-sectional dimensions of the bellows

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图 4 有限元模型

Figure 4. Finite element model

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图 5 网格收敛性验证

Figure 5. Grid convergence verification

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图 6 8组不同组合形式吸能构件的承载力曲线和吸能量曲线

Figure 6. Bearing capacity and energy absorption curves of eight types of energy-absorbing components with different structural combinations

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图 7 吸能构件变形过程

Figure 7. Deformation process of energy-absorbing components

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图 8 不同组合形式吸能构件的平均承载力预测结果及相对误差

Figure 8. Predicted average bearing capacity and corresponding errors of energy-absorbing components with different structural combinations

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图 9 单因素变化数值模拟结果

Figure 9. Simulation results of single factor variation

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图 10 优化后承载力和吸能量曲线

Figure 10. Optimized bearing capacity and energy absorption curves

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图 11 吸能构件

Figure 11. Energy-absorbing component

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图 12 不同速度条件下吸能构件的承载力曲线

Figure 12. Bearing capacity curves of energy-absorbing components at different velocities

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图 13 变形对比

Figure 13. Deformation comparison

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图 14 数值模拟与实验得到的承载力曲线

Figure 14. Bearing capacity curve obtained by simulation and experiment

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表 1 构件结构尺寸

Table 1. Structural dimensions of components

No.	H/mm	D_i,t/mm	D_o,t/mm	t/mm	R_p/mm	N_p	θ_b/(º)	L_r/mm	D_i,b/mm	D_o,b/mm	h/mm
DY0	200	140		4			25	10	130	180	210
D0Y	200		170	4			25	10	130	180	210
DB0	200	140		4	6	32	25	10	130	180	210
D0B	200		170	4	6	32	25	10	130	180	210
SYY	200	140	170	4			25	10	130	180	210
SYB	200	140	170	4	6	32	25	10	130	180	210
SBY	200	140	170	4	6	32	25	10	130	180	210
SBB	200	140	170	4	6	32	25	10	130	180	210

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表 2 45钢材料参数^[14]

Table 2. Material parameters of 45 steel^[14]

ρ/(kg·m⁻³)	E/GPa	$\nu $	A₀/MPa	B₀/MPa	C	n	m	$ \dot{{\varepsilon }}_{0}$/s⁻¹
7 800	210	0.3	507	320	0.064	0.28	1.06	1

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表 3 吸能构件结构参数设置

Table 3. Structural parameters of energy-absorbing components

Wall thickness/mm		Number of ripples	Corrugation radius/mm	Bevel angle/(°)		Tube expansion length/mm
Inner	Outer	Number of ripples	Corrugation radius/mm	Internal	Outer	Inner	Outer
2	2	20	4	10	10	4	4
3	3	24	5	15	15	6	6
4	4	28	6	20	20	8	8
5	5	32	7	25	25	10	10
6	6	36	8	30	30	12	12
7	7	40	9	35	35	14	14
8	8	44	10	40	40	16	16

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表 4 设计变量名称、范围及符号

Table 4. Design variable names, ranges and symbols

Variable	Range	Variable symbols
Inner wall thickness	2–6	t₂
Outer wall thickness	2–6	t₁
Corrugation radius	4–10	r
Internal bevel angle	10–40	θ₂

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表 5 设计方案与模拟试验结果

Table 5. Design scheme and simulation test results

Test No.	t₂/mm	t₁/mm	r/mm	θ₂/(°)	E_a/kJ	E_sa/(kJ·kg⁻¹)	F/kN	σ/kN
1	4.8	2.6	9.9	14	61.590	11.664	677.867	185.433
2	2.7	6.0	4.9	28	72.514	11.810	745.688	202.799
3	5.0	3.3	5.4	37	100.795	23.495	904.223	349.058
4	2.5	3.8	6.4	23	52.702	12.199	522.087	168.616
5	2.6	5.7	4.1	30	64.758	11.481	691.203	157.264
6	4.5	4.5	8.2	13	70.050	11.101	793.841	271.380
7	3.4	5.6	6.8	40	111.602	17.742	1 037.534	442.364
8	4.7	4.2	9.8	24	98.743	14.961	930.947	338.425
9	5.4	3.8	6.6	29	113.710	20.525	1 064.797	455.378
10	4.3	2.1	7.9	11	44.258	11.232	538.184	234.592
11	5.3	5.2	4.7	33	132.156	21.629	1 254.845	658.498
12	3.1	4.4	6.4	31	78.067	15.397	721.831	185.786
13	5.2	4.5	4.8	13	75.830	13.638	860.273	310.182
14	5.9	4.9	8.9	23	121.447	15.917	1 180.091	595.308
15	5.8	2.2	9.4	18	79.435	14.903	814.922	263.393
16	2.0	4.0	6.1	25	49.217	11.553	472.824	221.050
17	3.5	5.6	8.4	19	83.458	12.364	792.687	594.416
18	3.6	5.3	5.6	20	82.925	14.055	806.865	608.462
19	4.9	2.7	7.5	15	64.683	13.940	717.075	303.754
20	4.3	2.8	9.3	16	62.186	12.639	646.060	168.125
21	5.7	2.3	7.8	10	58.318	12.200	766.204	306.045
22	3.6	2.0	6.0	38	70.521	23.046	609.296	134.071
23	3.0	4.2	5.8	27	66.230	13.913	666.416	234.210
24	2.1	5.1	7.2	39	65.104	12.078	675.041	196.751
25	5.5	5.5	6.9	14	91.176	12.663	1 012.650	446.851
26	2.9	4.6	6.2	37	77.353	14.990	717.828	156.515
27	3.7	2.5	7.7	33	69.498	17.683	645.452	465.485
28	4.2	5.0	8.7	26	100.172	14.973	944.222	351.379
29	3.0	2.7	6.9	21	50.876	14.093	490.494	198.120
30	4.6	2.9	7.0	17	68.829	15.160	696.020	184.417
31	4.0	2.4	4.6	31	68.630	21.380	608.745	217.909
32	2.8	3.0	4.1	16	42.011	12.769	425.738	253.344
33	5.5	3.1	5.5	12	64.491	14.111	749.341	328.338
34	2.3	3.4	5.9	32	49.498	13.129	458.532	541.357
35	3.3	4.1	8.0	28	77.916	14.841	745.422	240.880
36	3.1	4.0	9.7	30	76.593	14.183	692.087	163.685
37	4.1	3.6	9.6	27	89.081	15.738	805.697	235.588
38	2.2	3.7	7.3	21	47.653	11.212	462.985	243.584
39	3.8	5.8	5.3	19	81.746	12.893	847.130	307.000
40	2.4	5.3	9.2	35	76.494	12.706	741.704	179.399
41	2.5	4.7	9.0	17	56.703	10.253	583.673	171.673
42	5.7	3.2	8.5	34	120.616	20.512	1 104.944	492.756
43	3.2	3.5	8.7	33	79.353	16.395	697.082	165.946
44	4.5	2.2	4.4	35	71.710	22.479	682.375	199.250
45	5.9	5.9	8.1	23	129.615	15.749	1 326.121	801.735
46	3.8	5.4	7.4	26	93.217	14.341	946.522	398.420
47	5.0	4.8	5.2	39	110.336	18.860	1 066.671	467.711
48	5.4	3.9	4.3	22	94.149	19.253	938.998	345.628
49	4.0	3.1	9.2	12	54.494	10.877	614.714	169.374
50	4.7	4.9	5.0	36	104.431	17.943	995.080	382.310

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表 6 代理模型评估指标

Table 6. Evaluation indicators of agent model

Parameter	R²
E_a	0.9513
E_sa	0.9425
F	0.9535
σ	0.9616

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表 7 吸能构件缩放前后尺寸

Table 7. Dimensions of energy-absorbing components before and after scaling

Scaling	H/mm	D_i,t/mm	D_o,t/mm	Inner wall thickness/mm	Outer wall thickness/mm	Corrugation radius/mm	N_p	h/mm
Before	200	140	170.0	6.0	2.9	6.9	32	210.0
After	50	35	42.5	2.4	1.2	1.7	32	52.5

Scaling	Inner tube expansion length/mm	Outer tube expansion length/mm	Base inner diameter/mm	Base outer diameter/mm	Internal bevel angle/(°)	Outer bevel angle/(°)	v/(m·s⁻¹)
Before	10.0	10.0	130.0	180.0	40	25	5.0
After	2.5	2.5	32.5	45.0	40	25	8.1

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