斜流泵启动过程瞬态非定常内流特性及实验研究
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摘要
斜流泵快速启动过程表现出区别于稳态过程的特殊性质,其瞬态工作特性可为泵系统提供瞬时流体动力,但瞬态效应引起的水力激振、冲击负载和空化破坏将对泵装置和管路系统的安全稳定运行带来严重影响。因此,研究斜流泵启动过程瞬态水力特性和内流机理,建立斜流泵适用于瞬态工作环境的设计、优化和应用方法具有重要的理论意义和工程应用价值。
目前,斜流泵瞬态流动的研究理论十分缺乏。本文在斜流泵稳态工况非定常流动特性研究的基础上,优化设计具有较好稳态水力性能和汽蚀性能的研究模型,建立准稳态、瞬态启动内部流动的数值计算方法和叶轮转子动态特性的耦合模型,搭建斜流泵瞬态启动性能测试实验台。采用数值计算和实验研究相结合的方法,对斜流泵瞬态外特性和内部瞬态流动机理进行研究,为斜流泵瞬态工作过程中的非定常流动控制和优化提供理论依据。
1.采用二元理论优化设计了2种斜流泵模型,并通过稳态数值计算方法对斜流泵模型在不同转速下的外特性和汽蚀性能进行预测分析。由于方案a的无量纲外特性和汽蚀性能均优于方案b。因此,将具有良好稳态水力性能的方案a模型作为本文启动过程瞬态内流特性研究的水力模型。
2.采用准稳态数值计算方法分别对斜流泵模型在750、1150、1450r/min(?)急态转速下的外特性和内流场进行分析,并数值预测了1450r/min稳态转速下不同工况点的外特性和内流场分布。由于准稳态数值计算方法忽略了叶片旋转加速对外特性的影响,数值预测的瞬态外特性结果与实验瞬态外特性存在较大差别。对比准稳态工况与稳态转速不同流量下的内部非定常流动,准稳态工况内流场呈现一定的相似性,内部流动结构明显区别于稳态工况因流量变化引起的周期性非定常流动。
3.针对准稳态数值方法预测斜流泵启动过程瞬态水力特性准确性差的问题,建立了斜流泵启动过程瞬态性能的数值计算方法。提出采用滑移交界面对斜流泵启动过程进行数值模拟,通过CEL表达式控制叶轮加速度,通过改变变量赋值来达到不同的启动效果,瞬态数值计算方法预测的瞬态外特性与实验结果吻合较好,相比准稳态数值计算的内流场,瞬态数值计算方法解析的内部流动因考虑叶轮旋转加速度和流体惯性力的影响表现出更强烈的非定常性,并由此带来不同于准稳态工况的瞬态外特性。
4.基于瞬态流动的数值计算结果,首次采用双向交替流固耦合方法对斜流泵启动过程中的叶轮流场和结构场进行联合求解,获得了斜流泵启动过程瞬态效应对叶轮应力和应变的影响规律。叶轮旋转加速度带来的瞬时水流冲击对叶轮轮毂处造成了更大的应力集中,最大等效应力呈现几何倍数增长。动应力和变形量随转速变化趋势为斜流泵叶轮的瞬态水力特性优化设计及可靠运行提供理论参考。
5.建立斜流泵瞬态性能测试实验台,进行了瞬态外特性、PIV内流测量和瞬态压力脉动测量。通过改造进口管结构首次实现了对斜流泵垂直轴截面进口流场的PIV拍摄。实验得到的外特性结果、瞬态的速度矢量场和压力脉动数据为斜流泵瞬态流动机理的探索提供了真实有效数据,同时为检验数值计算方法的正确性提供参考。
6.研究结果表明,斜流泵瞬态流动的PIV测试和压力脉动结果与瞬态外特性实验结果较为吻合,斜流泵启动过程的瞬态效应是叶轮加速度、管阻特性、流体惯性与内部流动结构共同作用的结果,瞬态内部流动结构的演化直接表现为扬程、负载的瞬态冲击与瞬时流量的滞后效应。瞬态无量纲扬程曲线偏离稳态无量纲曲线,说明启动过程的瞬态水力特性不具有相似性,准稳态方法不适用于揭示斜流泵瞬态工作过程的内流特性。在获取瞬时流体动力的同时,瞬态效应对叶轮造成的水力冲击应该进行有效控制。本文的研究内容和结论可以为应用于瞬态工作过程中的水力机械的设计与优化提供理论参考和依据。
Mixed-flow pumps show special nature distinct from the steady-state process during rapid starting period and the transient characteristics can provide the instantaneous fluid dynamic for pump system. However, the effects of hydraulic exciting vibration, impact load and cavitation damage generated by transient effects on the safe and stable operation of pump device and piping system are serious. Therefore, the study of hydraulic characteristics and internal flow mechanism during the mixed-flow pump starting transient period and the establishment of design, optimization as well as application method for transient working environment have an important theoretical significance and application value.
At present, the study theory of mixed-flow pump transient flow is considerable inadequate. In this paper, based on the unsteady flow characteristics study of a mixed-flow pump under steady-state condition, the research models with good steady-state hydraulic and cavitation performance were optimized and the numerical computation method for internal flow of quasi-steady state, transient and the coupled models of impeller rotor dynamic characteristics were established, moreover the test-bed for mixed-flow pump transient starting performance was developed. The transient external characteristic and internal transient flow mechanism were investigated by combining Numerical simulation and experimental study, providing the theoretical foundation for the control and optimization of unsteady flow during transient working period.
1. Two mixed-flow pumps were optimized by using two-dimensional theory and the prediction and analysis of overall characteristics as well as cavitation performance of different speeds were conducted through steady Numerical simulation. As the dimensionless overall characteristics of case a are better than case b, then the case a of good steady-state hydraulic performance was employed as the hydraulic model for the starting transient internal flow characteristics study.
2. The overall characteristics and flow field distribution of the mixed-flow pump model were analyzed by using quasi steady-state Numerical simulation at the speeds of750rpm,1150rpm and1450rpm, respectively, and the overall characteristics and flow field distribution at different operating points for1450rpm steady speed were predicted.
There is a big difference in the transient overall characteristics of numerical prediction and that of experiment due to neglecting the effect of blade rotational acceleration on overall characteristics when using the quasi steady-state Numerical simulation method. Compared the inner unsteady flow under quasi steady-state and steady-state conditions, the flow fields of quasi steady-state presented a certain similarity, internal flow structure was distinct from periodic unsteady flow induced by flow rate changes of steady-state.
3. Numerical simulation methods of transient characteristics for mixed-flow pumps were developed aiming at the poor accurate prediction of transient hydraulic characteristics by quasi steady-state numerical method. The sliding interface for mixed-flow pump starting transient numerical simulation was introduced, in which impeller acceleration was controlled through the CEL expression and different starting effect was achieved by changing the variable assignment. The calculation results show that transient overall characteristics predicted by transient numerical simulation agreed well with the experiment data. Compared with the internal flow field of quasi steady-state numerical simulation, the internal flow analyzed by transient numerical simulation method shown a greater sense of unsteady due to considering the impeller rotating acceleration and fluid inertia force, and thus led to the transient overall characteristics differed from quasi steady-state.
4. Based on the results of numerical simulation of transient flow, the two-way alternating Fluid-Structure Interaction method was used for the combined solutions of impeller flow and structure field in the starting process of the mixed-flow pump, and obtained the effects of transient effect on the stress and strain of impeller during the starting period of the mixed-flow pump. The instantaneous water impact caused by impeller rotation acceleration led to a great stress concentration on the impeller hub, and the maximum equivalent stress increased in a geometrical progression. The change trend of dynamic stress as well as deformation with speed provides a theoretical reference for the optimized design of transient hydraulic characteristics as well as reliable operation.
5. The test-bed for mixed-flow pump transient starting performance was developed, and the transient overall characteristics, PIV internal flow and transient pressure pulsation were measured. The PIV shooting of inlet flow field on a vertical axis section of the mixed-flow pump was achieved for the first time through reforming the inlet pipe structure. The overall characteristics, transient velocity vector field and pressure pulsation data got from experiments can provide the real and effective data for exploring transient flow mechanism of the mixed-flow pump.
6. The research results show that, PIV measurements and pressure pulsation of the mixed-flow pump transient flow agree with the experiment results of transient external characteristics well. The transient effect of the mixed-flow pump during starting period is the result of impeller acceleration, pipe resistance characteristics and internal flow structure, the evolution of transient internal flow structure reflects the hysteresis effect of head, load and transient flow rate. The transient dimensionless head curve deviating from steady-state dimensionless curve shows that the transient hydraulic characteristics during starting period do not have a similarity, and the quasi steady-state method is not suitable for revealing the internal flow characteristics of the mixed-flow pump. When obtaining the instantaneous fluid dynamics, it is necessary to carry out the effective control of hydraulic impact of impeller caused by transient effects. The contents and conclusions of this study can provide a theoretical reference and basis for the design and optimization of hydraulic machinery applied in the transient working process.
目前,斜流泵瞬态流动的研究理论十分缺乏。本文在斜流泵稳态工况非定常流动特性研究的基础上,优化设计具有较好稳态水力性能和汽蚀性能的研究模型,建立准稳态、瞬态启动内部流动的数值计算方法和叶轮转子动态特性的耦合模型,搭建斜流泵瞬态启动性能测试实验台。采用数值计算和实验研究相结合的方法,对斜流泵瞬态外特性和内部瞬态流动机理进行研究,为斜流泵瞬态工作过程中的非定常流动控制和优化提供理论依据。
1.采用二元理论优化设计了2种斜流泵模型,并通过稳态数值计算方法对斜流泵模型在不同转速下的外特性和汽蚀性能进行预测分析。由于方案a的无量纲外特性和汽蚀性能均优于方案b。因此,将具有良好稳态水力性能的方案a模型作为本文启动过程瞬态内流特性研究的水力模型。
2.采用准稳态数值计算方法分别对斜流泵模型在750、1150、1450r/min(?)急态转速下的外特性和内流场进行分析,并数值预测了1450r/min稳态转速下不同工况点的外特性和内流场分布。由于准稳态数值计算方法忽略了叶片旋转加速对外特性的影响,数值预测的瞬态外特性结果与实验瞬态外特性存在较大差别。对比准稳态工况与稳态转速不同流量下的内部非定常流动,准稳态工况内流场呈现一定的相似性,内部流动结构明显区别于稳态工况因流量变化引起的周期性非定常流动。
3.针对准稳态数值方法预测斜流泵启动过程瞬态水力特性准确性差的问题,建立了斜流泵启动过程瞬态性能的数值计算方法。提出采用滑移交界面对斜流泵启动过程进行数值模拟,通过CEL表达式控制叶轮加速度,通过改变变量赋值来达到不同的启动效果,瞬态数值计算方法预测的瞬态外特性与实验结果吻合较好,相比准稳态数值计算的内流场,瞬态数值计算方法解析的内部流动因考虑叶轮旋转加速度和流体惯性力的影响表现出更强烈的非定常性,并由此带来不同于准稳态工况的瞬态外特性。
4.基于瞬态流动的数值计算结果,首次采用双向交替流固耦合方法对斜流泵启动过程中的叶轮流场和结构场进行联合求解,获得了斜流泵启动过程瞬态效应对叶轮应力和应变的影响规律。叶轮旋转加速度带来的瞬时水流冲击对叶轮轮毂处造成了更大的应力集中,最大等效应力呈现几何倍数增长。动应力和变形量随转速变化趋势为斜流泵叶轮的瞬态水力特性优化设计及可靠运行提供理论参考。
5.建立斜流泵瞬态性能测试实验台,进行了瞬态外特性、PIV内流测量和瞬态压力脉动测量。通过改造进口管结构首次实现了对斜流泵垂直轴截面进口流场的PIV拍摄。实验得到的外特性结果、瞬态的速度矢量场和压力脉动数据为斜流泵瞬态流动机理的探索提供了真实有效数据,同时为检验数值计算方法的正确性提供参考。
6.研究结果表明,斜流泵瞬态流动的PIV测试和压力脉动结果与瞬态外特性实验结果较为吻合,斜流泵启动过程的瞬态效应是叶轮加速度、管阻特性、流体惯性与内部流动结构共同作用的结果,瞬态内部流动结构的演化直接表现为扬程、负载的瞬态冲击与瞬时流量的滞后效应。瞬态无量纲扬程曲线偏离稳态无量纲曲线,说明启动过程的瞬态水力特性不具有相似性,准稳态方法不适用于揭示斜流泵瞬态工作过程的内流特性。在获取瞬时流体动力的同时,瞬态效应对叶轮造成的水力冲击应该进行有效控制。本文的研究内容和结论可以为应用于瞬态工作过程中的水力机械的设计与优化提供理论参考和依据。
Mixed-flow pumps show special nature distinct from the steady-state process during rapid starting period and the transient characteristics can provide the instantaneous fluid dynamic for pump system. However, the effects of hydraulic exciting vibration, impact load and cavitation damage generated by transient effects on the safe and stable operation of pump device and piping system are serious. Therefore, the study of hydraulic characteristics and internal flow mechanism during the mixed-flow pump starting transient period and the establishment of design, optimization as well as application method for transient working environment have an important theoretical significance and application value.
At present, the study theory of mixed-flow pump transient flow is considerable inadequate. In this paper, based on the unsteady flow characteristics study of a mixed-flow pump under steady-state condition, the research models with good steady-state hydraulic and cavitation performance were optimized and the numerical computation method for internal flow of quasi-steady state, transient and the coupled models of impeller rotor dynamic characteristics were established, moreover the test-bed for mixed-flow pump transient starting performance was developed. The transient external characteristic and internal transient flow mechanism were investigated by combining Numerical simulation and experimental study, providing the theoretical foundation for the control and optimization of unsteady flow during transient working period.
1. Two mixed-flow pumps were optimized by using two-dimensional theory and the prediction and analysis of overall characteristics as well as cavitation performance of different speeds were conducted through steady Numerical simulation. As the dimensionless overall characteristics of case a are better than case b, then the case a of good steady-state hydraulic performance was employed as the hydraulic model for the starting transient internal flow characteristics study.
2. The overall characteristics and flow field distribution of the mixed-flow pump model were analyzed by using quasi steady-state Numerical simulation at the speeds of750rpm,1150rpm and1450rpm, respectively, and the overall characteristics and flow field distribution at different operating points for1450rpm steady speed were predicted.
There is a big difference in the transient overall characteristics of numerical prediction and that of experiment due to neglecting the effect of blade rotational acceleration on overall characteristics when using the quasi steady-state Numerical simulation method. Compared the inner unsteady flow under quasi steady-state and steady-state conditions, the flow fields of quasi steady-state presented a certain similarity, internal flow structure was distinct from periodic unsteady flow induced by flow rate changes of steady-state.
3. Numerical simulation methods of transient characteristics for mixed-flow pumps were developed aiming at the poor accurate prediction of transient hydraulic characteristics by quasi steady-state numerical method. The sliding interface for mixed-flow pump starting transient numerical simulation was introduced, in which impeller acceleration was controlled through the CEL expression and different starting effect was achieved by changing the variable assignment. The calculation results show that transient overall characteristics predicted by transient numerical simulation agreed well with the experiment data. Compared with the internal flow field of quasi steady-state numerical simulation, the internal flow analyzed by transient numerical simulation method shown a greater sense of unsteady due to considering the impeller rotating acceleration and fluid inertia force, and thus led to the transient overall characteristics differed from quasi steady-state.
4. Based on the results of numerical simulation of transient flow, the two-way alternating Fluid-Structure Interaction method was used for the combined solutions of impeller flow and structure field in the starting process of the mixed-flow pump, and obtained the effects of transient effect on the stress and strain of impeller during the starting period of the mixed-flow pump. The instantaneous water impact caused by impeller rotation acceleration led to a great stress concentration on the impeller hub, and the maximum equivalent stress increased in a geometrical progression. The change trend of dynamic stress as well as deformation with speed provides a theoretical reference for the optimized design of transient hydraulic characteristics as well as reliable operation.
5. The test-bed for mixed-flow pump transient starting performance was developed, and the transient overall characteristics, PIV internal flow and transient pressure pulsation were measured. The PIV shooting of inlet flow field on a vertical axis section of the mixed-flow pump was achieved for the first time through reforming the inlet pipe structure. The overall characteristics, transient velocity vector field and pressure pulsation data got from experiments can provide the real and effective data for exploring transient flow mechanism of the mixed-flow pump.
6. The research results show that, PIV measurements and pressure pulsation of the mixed-flow pump transient flow agree with the experiment results of transient external characteristics well. The transient effect of the mixed-flow pump during starting period is the result of impeller acceleration, pipe resistance characteristics and internal flow structure, the evolution of transient internal flow structure reflects the hysteresis effect of head, load and transient flow rate. The transient dimensionless head curve deviating from steady-state dimensionless curve shows that the transient hydraulic characteristics during starting period do not have a similarity, and the quasi steady-state method is not suitable for revealing the internal flow characteristics of the mixed-flow pump. When obtaining the instantaneous fluid dynamics, it is necessary to carry out the effective control of hydraulic impact of impeller caused by transient effects. The contents and conclusions of this study can provide a theoretical reference and basis for the design and optimization of hydraulic machinery applied in the transient working process.
引文
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