环形密封和多级转子系统耦合动力学数值及实验研究
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摘要
在多级离心泵中,由于实现平衡压力及密封的需要,大量存在如密封口环、级间密封及平衡鼓等环形密封隙流道。上述密封流道一方面会造成泄漏,从而降低离心泵效率,另一方面会对离心泵的振动性能造成影响。七十年代,美国航天飞机的高压油泵转子曾出现过较大的转子涡动,导致转速达不到设计值,在将周向开槽的密封改为光滑环密封后,振动消失且转子达到了设计转速。由此可以看出,无论从提高效率还是安全生产的角度,都很难忽视小间隙流对离心泵性能的影响,并且很有必要把转子和环形密封动力学分析结合起来作为转子设计过程中的关键内容。
本文以考虑环形密封的多级转子系统为研究对象,分别针对环形密封、多级转子的动力学特性进行研究,设法在稳态和瞬态过程中考虑环形密封对转子性能的影响,并针对研究对象展开一系列试验研究以验证数值方法的可靠性。论文的主要内容包括以下五个方面：
1、介绍了环形密封动力学模型的建立过程,分析了若干关键密封参数,包括壁面摩擦因子、入口预旋及入口损失系数等对环形密封动力学特性的影响；基于CFD方法建立了环形密封流道模型并进行了网格无关性验证,计算了不同内壁转速、进口速度及轴向截面积下环形间隙入口损失系数的变化；基于本文实验测试所用密封参数建立了环形密封数学模型,计算了密封动力特性系数及密封参数对其的影响。
2、设计并搭建了国内首台环形密封流体力测试装置,可用于测试主轴任意偏心及涡动比状态下环形密封流道产生的径向流体力,研究各种密封形式及参数对流体作用力的影响等；介绍了该测试装置的设计思路及运行机理,着重介绍了其涡动调节原理；计算出测试装置所用环形密封的理论流体力,与实验测试结果进行比较,验证了环形密封动力学模型的可靠性。
3、为实现利用密封参数直接预测转子系统的振动性能,首先对转子系统进行建模,并以矩阵形式将密封动特性系数耦合到转子系统矩阵中,得到考虑密封支撑作用的转子系统运动方程；通过求解上述方程得到考虑密封支撑的转子系统临界转速及不平衡响应；基于考虑环形密封的多级转子动态响应实验台,测得不同密封压差下多级转子的临界转速,与计算结果进行了对比。
4、为研究环形密封对转子瞬态响应的影响,建立单转子模型并对其可靠性进行实验验证；基于湍流润滑理论建立环形间隙流动模型并给出三种湍流假设对应的数值结果,对环形间隙流道计算模型进行改进；通过对转子运动方程及湍流润滑方程分别求解,并在每个时间步内判断环形间隙的流动状态,实现环形间隙流场与转子系统的耦合,得到考虑流体力影响的转子瞬态响应结果。
5、由于多级离心泵中密封支撑位置多且部分密封长径比较大,使得在传统转子动力学分析中被认为对转子性能影响不明显的阻尼系数在转子系统中所占比重增加；以单转子及多转子系统为例,分析了密封阻尼变化时转子各阶固有频率及响应幅值的变化规律；针对长径比这一对密封阻尼有显著影响的密封参数,研究了其对转子系统稳定性的影响。
研究结果显示,密封流道长径比增加时各动特性系数均会增加,其中交叉刚度及主阻尼系数增幅最为明显,而密封间隙的增加会明显降低刚度及阻尼系数大小,入口预旋增加则会引起交叉刚度和交叉阻尼系数的增加及主刚度系数的降低；密封流体力的理论计算结果与测试结果相比偏小,即理论结果会低估密封对转子系统的支撑作用；采用本文方法计算得到的湿转子临界转速与实验结果吻合较好,当密封间隙在0.3-0.5mm范围内时,误差不超过5%；当考虑密封支撑时,转子系统临界转速变化较小但其对应响应幅值大幅减小；瞬态过程中,启动加速度的变化对转子响应幅值及响应峰值出现的时间有明显影响；密封阻尼的增加会引起转子临界转速及响应幅值的下降,密封流道长径比增加至一定范围时会引起转子在某一转速下失稳。
本文研究内容和结论为多级离心泵内转子系统的性能预测及优化设计提供参考依据。
Multi-stage centrifugal pumps employ several annular clearance channels, such as seal rings and balance pistons, which not only cause leakage and decreases in efficiency in the pumps but also obviously influence the vibration characteristics of their rotor systems. In the1970s, the rotating speed of the rotor of a high-pressure oil pump in an aerospace plane was unable to achieve the desired value due to the large vibration of the rotor. This problem was solved by replacing the circumferentially grooved seals by smooth seals. Thus, detailed studies of influence of annular seals on rotor behaviors in multi-stage centrifugal pumps are necessary.
Taking the multi-stage rotors which considering annular seals as the research object of this dissertation, the influence of annular seals on the multi-stage rotors was studied during the steady and transient process. An experiment facility was established to test the fluid induced forces of annular seals. The major contents of the current dissertation consist of the following five aspects.
First, the annular seal model and a few key parameters including the wall friction factor, the pre-swirl coefficient and inlet pressure-loss coefficient were introduced. Based on CFD methods annular clearance channel was modeled and grid independence was verified on this model. Numerical results of annular seal flow were obtained due to different inner wall velocity, inlet axial velocity and clearance sizes. An annular seal was modeled based on the seal parameters of the test facility, and dynamic coefficients of various seal parameters were calculated to see the influence of these parameters on dynamic Coefficients.
Second, there is still no fluid forces test facility of pump seals in the domestic. The author designed a test facility to test the radial fluid induced forces when the shaft under different eccentricity and whirling motion. The design concept and operation mechanism of the test facility were described and the adjusting mechanism of the whirling motion was emphasized. Based on the perturbation method, the fluid induced force was calculated using seal parameters of the test facility. Numerical and experiment results were compared to verify the reliability of theoretical methods, which established the foundation of the fluid-structure interaction method developed in this dissertation.
Third, to predict the vibration performance of multi-stage rotors directly, a fluid-structure interaction method was developed in the current paper, and the numerical method was verified by experiments conducted on a model rotor. In a typical FSI process, rotor systems were modeled based on the node-element method, and the motion equations were expressed in a type of matrix. To consider the influence of annular seals, dynamic coefficients of annular seals were introduced into the motion equations through matrix transformation. The test results of the model rotor showed good agreement with the calculated results.
Fourth, this dissertation studied the influence of annular seals on the rotors transient response during the start-up period of centrifugal pump. A single rotor system and three states of annular seal flow were modeled. These models were solved using numerical integration and finite difference methods. Numerical results were in good agreement with the experimental results. A fluid structure interaction method was developed. This method overcomes some shortcomings of the traditional FSI method by improving the data transfer process between two domains.
Fifth, in traditional rotor dynamics analysis it's generally believed that the stiffness coefficient plays a key role in determining the characteristics of the rotor system, and the effect of damping coefficient is not obvious. Due to the large number and large LID ratio of seal rings in the multi-stage pumps, it's found that damping coefficients have an important influence on the critical speed of the multi-stage rotors. Taking single rotors and multi-stage rotors as examples, the influence of damping coefficients on rotor performance was analyzed. The influence of LID ratio on the stability of rotor systems was studied by calculating the unstable rotating speed of rotors.
Research results indicate that, all dynamic coefficients increased with the increase of seal channel's LID ratio, while the increase of cross stiffness and damping coefficients were most obvious. The increase of seal clearance significantly reduced the stiffness and damping coefficients. The inlet pre-swirl caused the increase of cross stiffness and cross damping coefficients, and the decrease of principal stiffness coefficients. Test results of fluid induced forces were larger than the theoretical results, which indicated that the theoretical results underestimate the supporting role of seals on the rotor system. Based on the fluid structure interaction method developed in this paper, the numerical results of "wet" critical speed showed a good agreement with experimental results. The difference between calculated and experimental results was less than5%when the seal clearance was in the range of0.3-0.5mm. When considering the supporting role of seals in the rotor system, the change of critical speed was small but its corresponding response amplitude significantly reduced. In the transient process, vibration amplitude and critical speed largely changed when the acceleration of the rotor system increased. The increase of damping coefficients caused the decease of critical speed and vibration amplitude. When LID ratio of seal channels increased to a certain range, the rotor may become unstable under a certain rotating speed.
The content and conclusions of the current dissertation can provide references for the performance prediction, design optimization of the rotor systems in a multistage pump.
本文以考虑环形密封的多级转子系统为研究对象,分别针对环形密封、多级转子的动力学特性进行研究,设法在稳态和瞬态过程中考虑环形密封对转子性能的影响,并针对研究对象展开一系列试验研究以验证数值方法的可靠性。论文的主要内容包括以下五个方面：
1、介绍了环形密封动力学模型的建立过程,分析了若干关键密封参数,包括壁面摩擦因子、入口预旋及入口损失系数等对环形密封动力学特性的影响；基于CFD方法建立了环形密封流道模型并进行了网格无关性验证,计算了不同内壁转速、进口速度及轴向截面积下环形间隙入口损失系数的变化；基于本文实验测试所用密封参数建立了环形密封数学模型,计算了密封动力特性系数及密封参数对其的影响。
2、设计并搭建了国内首台环形密封流体力测试装置,可用于测试主轴任意偏心及涡动比状态下环形密封流道产生的径向流体力,研究各种密封形式及参数对流体作用力的影响等；介绍了该测试装置的设计思路及运行机理,着重介绍了其涡动调节原理；计算出测试装置所用环形密封的理论流体力,与实验测试结果进行比较,验证了环形密封动力学模型的可靠性。
3、为实现利用密封参数直接预测转子系统的振动性能,首先对转子系统进行建模,并以矩阵形式将密封动特性系数耦合到转子系统矩阵中,得到考虑密封支撑作用的转子系统运动方程；通过求解上述方程得到考虑密封支撑的转子系统临界转速及不平衡响应；基于考虑环形密封的多级转子动态响应实验台,测得不同密封压差下多级转子的临界转速,与计算结果进行了对比。
4、为研究环形密封对转子瞬态响应的影响,建立单转子模型并对其可靠性进行实验验证；基于湍流润滑理论建立环形间隙流动模型并给出三种湍流假设对应的数值结果,对环形间隙流道计算模型进行改进；通过对转子运动方程及湍流润滑方程分别求解,并在每个时间步内判断环形间隙的流动状态,实现环形间隙流场与转子系统的耦合,得到考虑流体力影响的转子瞬态响应结果。
5、由于多级离心泵中密封支撑位置多且部分密封长径比较大,使得在传统转子动力学分析中被认为对转子性能影响不明显的阻尼系数在转子系统中所占比重增加；以单转子及多转子系统为例,分析了密封阻尼变化时转子各阶固有频率及响应幅值的变化规律；针对长径比这一对密封阻尼有显著影响的密封参数,研究了其对转子系统稳定性的影响。
研究结果显示,密封流道长径比增加时各动特性系数均会增加,其中交叉刚度及主阻尼系数增幅最为明显,而密封间隙的增加会明显降低刚度及阻尼系数大小,入口预旋增加则会引起交叉刚度和交叉阻尼系数的增加及主刚度系数的降低；密封流体力的理论计算结果与测试结果相比偏小,即理论结果会低估密封对转子系统的支撑作用；采用本文方法计算得到的湿转子临界转速与实验结果吻合较好,当密封间隙在0.3-0.5mm范围内时,误差不超过5%；当考虑密封支撑时,转子系统临界转速变化较小但其对应响应幅值大幅减小；瞬态过程中,启动加速度的变化对转子响应幅值及响应峰值出现的时间有明显影响；密封阻尼的增加会引起转子临界转速及响应幅值的下降,密封流道长径比增加至一定范围时会引起转子在某一转速下失稳。
本文研究内容和结论为多级离心泵内转子系统的性能预测及优化设计提供参考依据。
Multi-stage centrifugal pumps employ several annular clearance channels, such as seal rings and balance pistons, which not only cause leakage and decreases in efficiency in the pumps but also obviously influence the vibration characteristics of their rotor systems. In the1970s, the rotating speed of the rotor of a high-pressure oil pump in an aerospace plane was unable to achieve the desired value due to the large vibration of the rotor. This problem was solved by replacing the circumferentially grooved seals by smooth seals. Thus, detailed studies of influence of annular seals on rotor behaviors in multi-stage centrifugal pumps are necessary.
Taking the multi-stage rotors which considering annular seals as the research object of this dissertation, the influence of annular seals on the multi-stage rotors was studied during the steady and transient process. An experiment facility was established to test the fluid induced forces of annular seals. The major contents of the current dissertation consist of the following five aspects.
First, the annular seal model and a few key parameters including the wall friction factor, the pre-swirl coefficient and inlet pressure-loss coefficient were introduced. Based on CFD methods annular clearance channel was modeled and grid independence was verified on this model. Numerical results of annular seal flow were obtained due to different inner wall velocity, inlet axial velocity and clearance sizes. An annular seal was modeled based on the seal parameters of the test facility, and dynamic coefficients of various seal parameters were calculated to see the influence of these parameters on dynamic Coefficients.
Second, there is still no fluid forces test facility of pump seals in the domestic. The author designed a test facility to test the radial fluid induced forces when the shaft under different eccentricity and whirling motion. The design concept and operation mechanism of the test facility were described and the adjusting mechanism of the whirling motion was emphasized. Based on the perturbation method, the fluid induced force was calculated using seal parameters of the test facility. Numerical and experiment results were compared to verify the reliability of theoretical methods, which established the foundation of the fluid-structure interaction method developed in this dissertation.
Third, to predict the vibration performance of multi-stage rotors directly, a fluid-structure interaction method was developed in the current paper, and the numerical method was verified by experiments conducted on a model rotor. In a typical FSI process, rotor systems were modeled based on the node-element method, and the motion equations were expressed in a type of matrix. To consider the influence of annular seals, dynamic coefficients of annular seals were introduced into the motion equations through matrix transformation. The test results of the model rotor showed good agreement with the calculated results.
Fourth, this dissertation studied the influence of annular seals on the rotors transient response during the start-up period of centrifugal pump. A single rotor system and three states of annular seal flow were modeled. These models were solved using numerical integration and finite difference methods. Numerical results were in good agreement with the experimental results. A fluid structure interaction method was developed. This method overcomes some shortcomings of the traditional FSI method by improving the data transfer process between two domains.
Fifth, in traditional rotor dynamics analysis it's generally believed that the stiffness coefficient plays a key role in determining the characteristics of the rotor system, and the effect of damping coefficient is not obvious. Due to the large number and large LID ratio of seal rings in the multi-stage pumps, it's found that damping coefficients have an important influence on the critical speed of the multi-stage rotors. Taking single rotors and multi-stage rotors as examples, the influence of damping coefficients on rotor performance was analyzed. The influence of LID ratio on the stability of rotor systems was studied by calculating the unstable rotating speed of rotors.
Research results indicate that, all dynamic coefficients increased with the increase of seal channel's LID ratio, while the increase of cross stiffness and damping coefficients were most obvious. The increase of seal clearance significantly reduced the stiffness and damping coefficients. The inlet pre-swirl caused the increase of cross stiffness and cross damping coefficients, and the decrease of principal stiffness coefficients. Test results of fluid induced forces were larger than the theoretical results, which indicated that the theoretical results underestimate the supporting role of seals on the rotor system. Based on the fluid structure interaction method developed in this paper, the numerical results of "wet" critical speed showed a good agreement with experimental results. The difference between calculated and experimental results was less than5%when the seal clearance was in the range of0.3-0.5mm. When considering the supporting role of seals in the rotor system, the change of critical speed was small but its corresponding response amplitude significantly reduced. In the transient process, vibration amplitude and critical speed largely changed when the acceleration of the rotor system increased. The increase of damping coefficients caused the decease of critical speed and vibration amplitude. When LID ratio of seal channels increased to a certain range, the rotor may become unstable under a certain rotating speed.
The content and conclusions of the current dissertation can provide references for the performance prediction, design optimization of the rotor systems in a multistage pump.
引文
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