科创中国

With the increasing noise pollution,low noise optimization of centrifugal pimps has become a hot topic.However,experimental study on this problem is unacceptable for industrial applications due to unsustainable cost.A hybrid method that couples computational fluid dynamics(CFD)with computational aeroacoustic software is used to predict the flow-induced noise of pumps in order to minimize the noise of centrifugal pumps in actual projects.Under Langthjem's assumption that the blade surface pressure is the main flow-induced acoustic source in centrifugal pumps,the blade surface pressure pulsation is considered in terms of the acoustical sources and simulated using CFX software.The pressure pulsation and noise distribution in the near-cutoff region are examined for the blade-passing frequency(BPF)noise,and the sound pressure level(SPL)reached peaks near the cutoff that corresponded with the pressure pulsation in this region.An experiment is performed to validate this prediction.Four hydrophones are fixed to the inlet and outlet ports of the test pump to measure the flow-induced noise from the four-port model.The simulation results for the noise are analyzed and compared with the experimental results.The variation in the calculated noise with changes in the flow agreed well with the experimental results.When the flow rate was increased,the SPL first decreased and reached the minimum near the best efficient point(BEP);it then increased when the flow rate was further increased.The numerical and experimental results confirmed that the BPF noise generated by a blade-rotating dipole roughly reflects the acoustic features of centrifugal pumps.The noise simulation method in current study has a good feasibility and suitability,which could be adopted in engineering design to predict and optimize the hydroacoustic behavior of centrifugal pumps.

The T-junction model of engine exhaust manifolds significantly influences the simulation precision of the pressure wave and mass flow rate in the intake and exhaust manifolds of diesel engines. Current studies have focused on constant pressure models, constant static pressure models and pressure loss models. However, low model precision is a common disadvantage when simulating engine exhaust manifolds, particularly for turbocharged systems. To study the performance of junction flow, a cold wind tunnel experiment with high velocities at the junction of a diesel exhaust manifold is performed, and the variation in the pressure loss in the T-junction under different flow conditions is obtained. Despite the trend of the calculated total pressure loss coefficient, which is obtained by using the original pressure loss model and is the same as that obtained from the experimental results, large differences exist between the calculated and experimental values. Furthermore, the deviation becomes larger as the flow velocity increases. By improving the Vazsonyi formula considering the flow velocity and introducing the distribution function, a modified pressure loss model is established, which is suitable for a higher velocity range. Then, the new model is adopted to solve one-dimensional, unsteady flow in a D6114 turbocharged diesel engine. The calculated values are compared with the measured data, and the result shows that the simulation accuracy of the pressure wave before the turbine is improved by 4.3% with the modified pressure loss model because gas compressibility is considered when the flow velocities are high. The research results provide valuable information for further junction flow research, particularly the correction of the boundary condition in one-dimensional simulation models.

In precision machining of complex curved surface parts with high performance, geometry accuracy is not the only constraint, but the performance should also be met. Performance of this kind of parts is closely related to the geometrical and physical parameters, so the final actual size and shape are affected by multiple source constraints, such as geometry, physics, and performance. These parts are rather difficult to be manufactured and new manufacturing method according to performance requirement is urgently needed. Based on performance and manufacturing requirements for complex curved surface parts, a new classification method is proposed, which divided the complex curved surface parts into two categories: surface re-design complex curved surface parts with multi-source constraints(PRCS) and surface unique complex curved surface parts with pure geometric constraints(PUCS). A correlation model is constructed between the performance and multi-source constraints for PRCS, which reveals the correlation between the performance and multi-source constraints. A re-design method is also developed. Through solving the correlation model of the typical part's performance-associated surface, the mapping relation between the performance-associated surface and the related removal amount is obtained. The explicit correlation model and the method for the corresponding related removal amount of the performance-associated surface are built based on the classification of surface re-design complex curved surface parts with multi-source constraints. Research results have been used in the actual processing of the typical parts such as radome, common bottom components, nozzle, et al., which shows improved efficiency and accuracy of the precision machining for the surface re-design parts with complex curved surface.

The existing research on improving the hydraulic performance of centrifugal pumps mainly focuses on the design method and the parameter optimization.The traditional design method for centrifugal impellers relies more on experience of engineers that typically only satisfies the continuity equation of the fluid.In this study,on the basis of the direct and inverse iteration design method which simultaneously solves the continuity and motion equations of the fluid and shapes the blade geometry by controlling the wrap angle,three centrifugal pump impellers are designed by altering blade wrap angles while keeping other parameters constant.The three-dimensional flow fields in three centrifugal pumps are numerically simulated,and the simulation results illustrate that the blade with larger wrap angle has more powerful control ability on the flow pattern in impeller.The three pumps have nearly the same pressure distributions at the small flow rate,but the pressure gradient increase in the pump with the largest wrap angle is smoother than the other two pumps at the design and large flow rates.The pump head and efficiency are also influenced by the blade wrap angle.The highest head and efficiency are also observed for the largest angle.An experiment rig is designed and built to test the performance of the pump with the largest wrap angle.The test results show that the wide space of its efficiency area and the stability of its operation ensure the excellent performance of the design method and verify the numerical analysis.The analysis on influence of the blade wrap angle for centrifugal pump performance in this paper can be beneficial to the optimization design of the centrifugal pump.

Blade vibration failure is one of the main failure modes of compressor wheel of turbocharger for vehicle application.The existing models for evaluating the reliability of blade vibration of compressor wheel are static,and can not reflect the relationship between the reliability of compressor wheel with blade vibration failure mode and the life parameter.For the blade vibration failure mode of compressor wheel of turbocharger,the reliability evaluation method is studied.Taking a compressor wheel of turbocharger for vehicle application as an example,the blade vibration characteristics and how they change with the operating parameters of turbocharger are analyzed.The failure criterion for blade vibration mode of compressor wheel is built with the Campbell diagram,and taking the effect of the dispersity of blade natural vibration frequency and randomness of turbocharger operating speed into account,time-dependent reliability models of compressor wheel with blade vibration failure mode are derived,which embody the parameters of blade natural vibration frequency,turbocharger operating speed,the blade number of compressor wheel,life index and minimum number of resonance,etc.Finally,the rule governing the reliability and failure rate of compressor wheel and the method for determining the reliable life of compressor with blade vibration is presented.A method is proposed to evaluate the reliability of compressor wheel with blade vibration failure mode time-dependently.

As the two most important indexes of bearing raceway,surface roughness and roundness have significant influence on bearing noise.Some researchers have carried out studies in this field,however,reason and extent of the influence of raceway surface geometric characteristics on bearing running noise are not perfectly clear up to now.In this paper,the raceway of 6309 type bearing's inner and outer ring is machined by floating abrasive polishing adopting soft abrasive pad.Surface roughness parameters,arithmetical mean deviation of the profile Ra,the point height of irregularities Rz,maximum height of the profile Rmax and roundness f of raceways,are measured before and after machining,and the change rules of the measured results are studied.The study results show that the floating abrasive polishing can reduce the surface geometric errors of bearing raceway evidently.The roundness error is reduced by 25%,Rmax value is reduced by 35.5%,Rz value is reduced by 22%and Ra value is reduced by 5%.By analyzing the change of the geometrical parameters and the shape difference of the raceway before and after machining,it is found that the floating abrasive polishing method can affect the roundness error mainly by modifying the local deviation of the raceway's surface profile.Bearings with different raceway surface geometrical parameter value are assembled and the running noise is tested.The test results show that Ra has a little,Rmax and Rz have a measurable,and the roundness error has a significant influence on the running noise.From the viewpoint of controlling bearings'running noise,raceway roundness error should be strictly controlled,and for the surface roughness parameters,Rmax and Rz should be mainly controlled.This paper proposes an effective method to obtain the low noise bearing by machining the raceway with floating abrasive polishing after super finishing.

Natural frequency characteristics of a thin-walled multiple layered cylindrical shell under lateral pressure are studied.The multiple layered cylindrical shell configuration is formed by three layers of isotropic material where the inner and outer layers are stainless steel and the middle layer is aluminum.The multiple layered shell equations with lateral pressure are established based on Love's shell theory.The governing equations of motion with lateral pressure are employed by using energy functional and applying the Ritz method.The boundary conditions represented by end conditions of the multiple layered cylindrical shell are simply supported-clamped(SS-C),free-clamped(F-C)and simply supported-free(SS-F).The influence of different lateral pressures,different thickness to radius ratios,different length to radius ratios and effect of the asymmetric boundary conditions on natural frequency characteristics are studied.It is shown that the lateral pressure has effect on the natural frequency of multiple layered cylindrical shell and causes the natural frequency to increase.The natural frequency of the developed multilayered cylindrical shell is validated by comparing with those in the literature.The proposed research provides an effective approach for vibration analysis shell structures subjected to lateral pressure with an energy method.

The 3D inverse design method,which methodology is far superior to the conventional design method that based on geometrical description,is gradually applied in pump blade design.However,no complete description about the method is outlined.Also,there are no general rules available to set the two important input parameters,blade loading distribution and stacking condition.In this sense,the basic theory and the mechanism why the design method can suppress the formation of secondary flow are summarized.And also,several typical pump design cases with different specific speeds ranging from centrifugal pump to axial pump are surveyed.The results indicates that,for centrifugal pump and mixed pump or turbine,the ratio of blade loading on the hub to that on the shroud is more than unit in the fore part of the blade,whereas in the aft part,the ratio is decreased to satisfy the same wrap angle for hub and shroud.And the choice of blade loading type depends on the balancing of efficiency and cavitation.If the cavitation is more weighted,the better choice is aft-loaded,otherwise,the fore-loaded or mid-loaded is preferable to improve the efficiency.The stacking condition,which is an auxiliary to suppress the secondary flow,can have great effect on the jet-wake outflow and the operation range for pump.Ultimately,how to link the design method to modern optimization techniques is illustrated.With the know-how design methodology and the know-how systematic optimization approach,the application of optimization design is promising for engineering.This paper summarizes the 3D inverse design method systematically.

Current researches show that mechanical deformation of seal ring face makes fluid film clearance decrease at high pressure side, thus a divergent clearance is formed and face wear occurs more seriously at the high pressure side than that on the low pressure side. However, there is still lack of published experimental works enough to prove the theoretical results. In this paper, a spiral groove dry gas seal at high pressures is experimentally investigated so as to prove the face wear happened at the high pressure side of seal faces due to the face mechanical deformation, and the wear behavior affected by seal ring structure is also studied. The experimental results show that face wear would occur at the high pressure side of seal faces due to the deformation, thus the leakage and face temperature increase, which all satisfies the theoretical predictions. When sealed pressure is not less than 5 MPa, the pressure can provide enough opening force to separate the seal faces. The seal ring sizes have obvious influence on face wear. Face wear, leakage and face temperature of a dry gas seal with the smaller cross sectional area of seal ring are less than that of a dry gas seal with bigger one, and the difference of leakage rate between these two sizes of seal face width is in the range of 24%–25%. Compared with the effect of seal ring sizes, the effect of secondary O-ring seal position on face deformation and face wear is less. The differences between these two types of dry gas seals with different secondary O-ring seal positions are less than 5.9% when the rotational speed varies from 0 to 600 r/min. By linking face wear and sealing performance changes to the shift in mechanical deformation of seal ring, this research presents an important experimental method to study face deformation of a dry gas seal at high pressures.

Current research on the operational reliability of centrifugal pumps has mainly focused on hydrodynamic instability. However, the interaction between the fluid and structure has not been sufficiently considered; this interaction can cause vibration and dynamic stress, which can affect the reliability. In this study, the dynamic stresses in a single-blade centrifugal pump impeller are analysed under different operating conditions; the two-way coupling method is used to calculate the fluid–structure interaction. Three-dimensional unsteady Reynolds-averaged Navier-Stokes equations are solved with the SST k–ω turbulence model for the fluid in the whole flow passage, while transient structure dynamic analysis is used with the finite element method for the structure side. The dynamic stresses in the rotor system are computed according to the fourth strength theory. The stress results show that the highest stress is near the loose bearing and that the equivalent stress increases with the flow rate because the dynamic stresses are closely related to the pressure load. The stress distributions on the blade pressure side, suction side, leading edge, and trailing edge are each analysed for different flow rates; the highest stress distribution is found on the pressure side. On the blade pressure side, a relatively large stress is found near the trailing edge and hub side. Based on these results, a stress distribution prediction method is proposed for centrifugal pumps, which considers the interaction between the fluid and structure. The method can be used to check the dynamic stress at different flow rates when optimising the pump design to increase the pump reliability.