离心泵仿生减阻增效涂层的涂覆工艺参数优化
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摘要
仿生减阻功能表面应用于离心式水泵关键零部件的过流部位,可显著提升水泵效率。仿生减阻增效功能表面以海豚皮肤为仿生原形,包含刚性基底和涂层2部分,一般由高黏性聚氨酯在刚性基底表面浇注生成功能表面涂层。涂层厚度对泵效率影响最为显著,由于聚氨酯高黏性特征和传统涂覆工艺技术的限制,很难在叶轮复杂流道表面实现高效、高质的涂覆。针对上述难题,该文利用自制旋转涂覆设备,通过对聚氨酯材料的浇注温度、设备旋转速度、涂覆持续时间的优化控制涂层厚度,建立拟合方程并进行试验验证。试验结果表明,以200QJ50-26水泵叶轮为载体,影响功能表面涂层厚度的主次因素依次为设备旋转速度、浇注温度、涂覆持续时间。通过拟合方程预测出叶轮流道内表面涂层厚度为0.5 mm时的最佳涂覆参数组合:涂覆时间53.7 s、旋转速度401 rad/min、浇注温度90.1℃。涂覆试验检验结果表明,利用上述优化工艺参数控制的功能表面涂层厚度与拟合方程计算厚度相比,误差小于5%,计算结果可靠。研究结果可为离心泵仿生减阻增效功能表面面层材料涂覆的工程化施工提供参考。
Bionics is based on the structure of natural biological system and the process of life activities as the basis of technological innovation and design, and consciously imitates and replicates it. Through the coupling of 2 or more different factors, organisms can effectively realize various functional characteristics of organisms and fully display their best adaptability to habitats,this phenomenon of biological coupling is ubiquitous in the biological world. The multi-bionics of learning and simulating the coupling mechanism of organisms is called coupling bionics. The drag reduction mechanism of dolphin skin is a typical representative of the bio-binary coupling. Dolphin skin is composed of smooth elastic keraphyllous epidermis and hard dermis, which are intertwined with each other. The coupling effect of the 2 parts is one of the main reasons why dolphins can swim fast. According to the principle of bionic similarity, Jilin University has designed a coupling functional surface which imitates the skin structure of dolphins, and applied it to the surface of the key parts(centrifugal impeller) of centrifugal pump, which can significantly improve the pump efficiency. The specific method is to directly cast the ribbed structure similar to the dolphin skin dermis on the upper and lower cover plate of impeller by one-step casting technology, and then coat the cover plate with high viscous polyurethane as the surface material. The ribbed structure at the bottom and the polyurethane coating on the surface constitute a coupling bionic functional surface. The thickness parameters of surface material coating have the greatest influence on the efficiency of coatings, and polyurethane is the main material for coating, but because of the complicated and twisted space structure of the inner passage of centrifugal pump impeller, the high viscosity characteristics of polyurethane and the limitation of traditional coating technology, it is difficult to achieve high efficiency and high quality coating on the surface of complex impeller inner runners with coupling bionic functional surface layer materials. and it is difficult to control the thickness of the coating. In order to solve the above problems, a self-made rotating coating equipment by means of centrifugal force was introduced in this paper, using which, the coating thickness could be controlled by pouring temperature, rotating speed, coating time and other parameters. According to the combination design principle of Box-Behnken Design in Design-Expert software, taking the coating thickness of impeller runner as test index, a 3 factors and 3 levels orthogonal combination experiment was designed, the above parameters were optimized and the quadratic fitting equation was established. The test results showed that the main and secondary factors affecting the coating thickness were rotating speed of equipment, pouring temperature and coating duration. The comparative coating tests were carried out on the impeller of 200 QJ50-26 centrifugal pump, the results showed that the errors between tested coating thickness controlled by coating parameters and calculated value of quadratic fitting equation was less than 5%, the results were credible. According to the previous research results, when the coating thickness is 0.5 mm, the drag reduction and efficiency increasing of 200 QJ50-26 centrifugal pump is the best. The test results showed that the optimum coating parameters for 200 QJ50-26 centrifugal pump to obtain the optimum coating thickness of 0.5 mm were as follows: coating duration was 53.7 s, rotating speed was 401 rad/min, pouring temperature was 90.1℃. The research can provide a reference for the engineering construction of the coupling functional surface on the centrifugal pump.
Bionics is based on the structure of natural biological system and the process of life activities as the basis of technological innovation and design, and consciously imitates and replicates it. Through the coupling of 2 or more different factors, organisms can effectively realize various functional characteristics of organisms and fully display their best adaptability to habitats,this phenomenon of biological coupling is ubiquitous in the biological world. The multi-bionics of learning and simulating the coupling mechanism of organisms is called coupling bionics. The drag reduction mechanism of dolphin skin is a typical representative of the bio-binary coupling. Dolphin skin is composed of smooth elastic keraphyllous epidermis and hard dermis, which are intertwined with each other. The coupling effect of the 2 parts is one of the main reasons why dolphins can swim fast. According to the principle of bionic similarity, Jilin University has designed a coupling functional surface which imitates the skin structure of dolphins, and applied it to the surface of the key parts(centrifugal impeller) of centrifugal pump, which can significantly improve the pump efficiency. The specific method is to directly cast the ribbed structure similar to the dolphin skin dermis on the upper and lower cover plate of impeller by one-step casting technology, and then coat the cover plate with high viscous polyurethane as the surface material. The ribbed structure at the bottom and the polyurethane coating on the surface constitute a coupling bionic functional surface. The thickness parameters of surface material coating have the greatest influence on the efficiency of coatings, and polyurethane is the main material for coating, but because of the complicated and twisted space structure of the inner passage of centrifugal pump impeller, the high viscosity characteristics of polyurethane and the limitation of traditional coating technology, it is difficult to achieve high efficiency and high quality coating on the surface of complex impeller inner runners with coupling bionic functional surface layer materials. and it is difficult to control the thickness of the coating. In order to solve the above problems, a self-made rotating coating equipment by means of centrifugal force was introduced in this paper, using which, the coating thickness could be controlled by pouring temperature, rotating speed, coating time and other parameters. According to the combination design principle of Box-Behnken Design in Design-Expert software, taking the coating thickness of impeller runner as test index, a 3 factors and 3 levels orthogonal combination experiment was designed, the above parameters were optimized and the quadratic fitting equation was established. The test results showed that the main and secondary factors affecting the coating thickness were rotating speed of equipment, pouring temperature and coating duration. The comparative coating tests were carried out on the impeller of 200 QJ50-26 centrifugal pump, the results showed that the errors between tested coating thickness controlled by coating parameters and calculated value of quadratic fitting equation was less than 5%, the results were credible. According to the previous research results, when the coating thickness is 0.5 mm, the drag reduction and efficiency increasing of 200 QJ50-26 centrifugal pump is the best. The test results showed that the optimum coating parameters for 200 QJ50-26 centrifugal pump to obtain the optimum coating thickness of 0.5 mm were as follows: coating duration was 53.7 s, rotating speed was 401 rad/min, pouring temperature was 90.1℃. The research can provide a reference for the engineering construction of the coupling functional surface on the centrifugal pump.
引文
[1]秦宏波,胡寿根.泵系统测试方法的研究及其在系统优化中的应用[J].电机与控制应用,2010,37(7):58-59,63.Qin hongbo,Hu shougen.Study of pump system test method and its application in system optimization[J].Electric machines&control application,2010,37(7):58-59,63.(in Chinese with English abstract)
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[4]李万平,杨新祥.柔性壁减阻的试验研究[J].水动力学研究与进展(A辑),1991(S1):108-112.Li wanping,Yang xinxiang.An experimental study on the drag reduction of compliant walls[J].Journal of Hydrodynamics(Part A),1991(S1):108-112.(in Chinese with English abstract)
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[7]Endo T,Himeno R.Numerical analysis of flow around a sphere with active dimples[J].Transactions of the Japan Society of Mechanical Engineers B,2006,72(724):3037-3042.
[8]Luo H,Bewley T R.Accurate simulation of near-wall turbulence over a compliant tensegrity fabric[C]//Smart Structures and Materials.International Society for Optics and Photonics,2005:184-197.
[9]Zhang Hui,Yoshutake N,Hagiwara Y.Attenuati-on of turbulent flow separation in wavy wall by compliant surface[J].Advancesin Turbulence XI,2007(117):597-599.
[10]Yamahata T,Hanaoka T,Hagiwara Y,et al.Turbulence modification in the flow over a silicon rubber wall as a model of dolphin skin[C]//2nd Int.Symposi-um on Seawater Drag Reduction,2005:535-544.
[11]商延赓,金娥,可庆朋,等.仿海豚皮肤结构的功能表面提高离心泵效率[J].农业工程学报,2016,32(7)72-78.Shang Yangeng,Jin E,Ke Qingpeng,et al.Efficiency improvement of centrifugal pump with function surface imitating dolphin skin structure[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2016,32(7):72-78.(in Chinese with English abstract)
[12]任露泉,彭宗尧,陈庆海,等.离心式水泵仿生非光滑增效的试验研究[J].吉林大学学报:工学版,2007,37(3):101-103.Ren Luquan,Peng Zongyao,Chen Qinghai,et al.Experimental study on efficiency enhancement of centrifugal water pump by bionic non-smooth technique[J].Journal of Jilin University:Engineering and Technology Edition,2007,37(3):101-103.(in Chinese with English abstract)
[13]Ren Luquan.Progress in the bionic study on anti-adhesion and resistance reduction of terrain machines[J].Science China Technological Sciences,2009,52(2):273-284.
[14]田丽梅,高志桦,王银慈,等.形态/柔性材料二元仿生耦合增效减阻功能表面的设计与试验[J].吉林大学学报:工学版,2013,43(4):970-975.Tian Limei,Gao Zhihua,Wang Yinci,et al.The design and experimental study of bionic coupling functional surface caused by the dual factors of form and flexible material[J].Journal of Jilin University:Engineering and Technology Edition,2013,43(4):970-975.(in Chinese with English abstract)
[15]田丽梅,王银慈,高梽桦,等.镶嵌式仿生耦合功能表面流体介质控制机制研究[J].农业机械学报,2014,45(6):324-328.Tian Limei,Wang Yinci,Gao Zhihua,et al.Fluid control mechanism of mosaic bionic coupling functional surface[J].Transactions of the Chinese Society for Agricultural Machinery,2014,45(6):324-328.(in Chinese with English abstract)
[16]Tian Limei,Gao Zhihua,Ren Luquan,et al.The study of the efficiency enhancement of bionic coupling centrifugal pumps[J].Journal of the Brazilian Society of Mechanical Sciences and Engineering,2013,35(4):517-524.
[17]Lu Y X.Significance and progress of bionics[J].Bionic Eng,2004,1(1):1-3
[18]任露泉,梁云红.仿生学导论[M].北京:科学出版社,2016.
[19]Fish F E,Legac P,Terrie M,et al,Measurement of hydrodynamic force generation by swimming dolphins using bubble DPIV[J].The Journal of experimental biology.2014,217(2):252-260.
[20]田丽梅,梅浩然,李新红,等.基于耦合仿生功能表面的离心水泵增效机制研究[J].农业机械学报,2015,46(4),65-69.Tian limei,Mei haoran,Li xinhong,et al.Enhancement mechanism investigation of centrifugal pump based on bionic coupling functional surface[J].Transactions of The Chinese Society of Agricultural Machinery,2015,46(4):65-69.(in Chinese with English abstract)
[21]张世磊,易玉华.低游离聚氨酯预聚体的结构、性能及其应用[J].陕西科技大学学报,2011,2(29):77-81.Zhang shilei,Yi yuhua.Structure,properties and application of the prepolymers with low levels of free isocyanate monomer[J].Journal of Shaanxi University of Science,2011,2(29):77-81.(in Chinese with English abstract)
[22]李俊贤.反应注射成型技术及材料(连载五)[J].聚氨酯工业,1996(4):42-46.
[23]陈赛艳,陈蕴智.聚氨酯的应用发展现状[J].化工时代,2008,22(8):52-55.Chen saiyan,Chen yunzhi.The application and development of polyurethane coatings[J].Chemical Industry Times,2008,22(8):52-55.(in Chinese with English abstract)
[24]罗宁,黄峻,王得宁,等.MDI/聚醚二元醇预聚体的粘度-温度关系[J].聚氨酯工业,1994,9(3):28-30.
[25]和曼君,张红东,陈维孝.高分子物理[M].上海:复旦大学出版社,2007.
[26]代青华,刘秀生,黄虹等.聚氨酯预聚体黏度的影响因素探究[J].材料保护,2017,50(1),91-93.Dai Qinghua,Liu Xiusheng,Huang Hong,et al.Influence factors of polyurethane prepolymer Viscosity[J].Materials Protection,2017,50(1),91-93.(in Chinese with English abstract)
[27]易玉华,陈万滨.基于PTMG-TDI的低游离TDI浇注型PU弹性体的制备与性能研究[J].橡胶工业,2010,57(2):82-85.Yi Yuhua,Chen Wanbin.Preparation and property of PTMG-TDI based castable polyurethane elastomer with low free TDI monomer[J].China Rubber Industry,2010,57(2):82-85.(in Chinese with English abstract)
[28]任露泉.试验设计及其优化[M].北京:科学出版社,2009.
[29]任露泉.回归设计及其优化[M].北京:科学出版社,2009.
[30]金日光,华幼卿.高分子物理[M].北京:化学工业出版社,2012.
[2]任志安,张栋栋,孙治谦.耦合仿生技术在流体机械领域的应用[J].石油和化工设备,2012,15(3):17-19.
[3]Gray J.Studies in animal locomotion vi.the propulsive powers of the dolphin[J].Journal of Experimental Biology,1936,13(2):192-199.
[4]李万平,杨新祥.柔性壁减阻的试验研究[J].水动力学研究与进展(A辑),1991(S1):108-112.Li wanping,Yang xinxiang.An experimental study on the drag reduction of compliant walls[J].Journal of Hydrodynamics(Part A),1991(S1):108-112.(in Chinese with English abstract)
[5]W Bechert D,Bruse M,Hage W,et al.Fluid mechanics of biological surfaces and their technological application[J].Naturwissenschaften,2000,87(4):157-171.
[6]Choi K S,Yang X,Clayton B R,et al.Turbulent drag reduction using compliant surfaces[C]//Proceedings of the Royal Society of London A:Mathematical,Physical and Engineering Sciences.The Royal Society,1997,453(1965):2229-2240.
[7]Endo T,Himeno R.Numerical analysis of flow around a sphere with active dimples[J].Transactions of the Japan Society of Mechanical Engineers B,2006,72(724):3037-3042.
[8]Luo H,Bewley T R.Accurate simulation of near-wall turbulence over a compliant tensegrity fabric[C]//Smart Structures and Materials.International Society for Optics and Photonics,2005:184-197.
[9]Zhang Hui,Yoshutake N,Hagiwara Y.Attenuati-on of turbulent flow separation in wavy wall by compliant surface[J].Advancesin Turbulence XI,2007(117):597-599.
[10]Yamahata T,Hanaoka T,Hagiwara Y,et al.Turbulence modification in the flow over a silicon rubber wall as a model of dolphin skin[C]//2nd Int.Symposi-um on Seawater Drag Reduction,2005:535-544.
[11]商延赓,金娥,可庆朋,等.仿海豚皮肤结构的功能表面提高离心泵效率[J].农业工程学报,2016,32(7)72-78.Shang Yangeng,Jin E,Ke Qingpeng,et al.Efficiency improvement of centrifugal pump with function surface imitating dolphin skin structure[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2016,32(7):72-78.(in Chinese with English abstract)
[12]任露泉,彭宗尧,陈庆海,等.离心式水泵仿生非光滑增效的试验研究[J].吉林大学学报:工学版,2007,37(3):101-103.Ren Luquan,Peng Zongyao,Chen Qinghai,et al.Experimental study on efficiency enhancement of centrifugal water pump by bionic non-smooth technique[J].Journal of Jilin University:Engineering and Technology Edition,2007,37(3):101-103.(in Chinese with English abstract)
[13]Ren Luquan.Progress in the bionic study on anti-adhesion and resistance reduction of terrain machines[J].Science China Technological Sciences,2009,52(2):273-284.
[14]田丽梅,高志桦,王银慈,等.形态/柔性材料二元仿生耦合增效减阻功能表面的设计与试验[J].吉林大学学报:工学版,2013,43(4):970-975.Tian Limei,Gao Zhihua,Wang Yinci,et al.The design and experimental study of bionic coupling functional surface caused by the dual factors of form and flexible material[J].Journal of Jilin University:Engineering and Technology Edition,2013,43(4):970-975.(in Chinese with English abstract)
[15]田丽梅,王银慈,高梽桦,等.镶嵌式仿生耦合功能表面流体介质控制机制研究[J].农业机械学报,2014,45(6):324-328.Tian Limei,Wang Yinci,Gao Zhihua,et al.Fluid control mechanism of mosaic bionic coupling functional surface[J].Transactions of the Chinese Society for Agricultural Machinery,2014,45(6):324-328.(in Chinese with English abstract)
[16]Tian Limei,Gao Zhihua,Ren Luquan,et al.The study of the efficiency enhancement of bionic coupling centrifugal pumps[J].Journal of the Brazilian Society of Mechanical Sciences and Engineering,2013,35(4):517-524.
[17]Lu Y X.Significance and progress of bionics[J].Bionic Eng,2004,1(1):1-3
[18]任露泉,梁云红.仿生学导论[M].北京:科学出版社,2016.
[19]Fish F E,Legac P,Terrie M,et al,Measurement of hydrodynamic force generation by swimming dolphins using bubble DPIV[J].The Journal of experimental biology.2014,217(2):252-260.
[20]田丽梅,梅浩然,李新红,等.基于耦合仿生功能表面的离心水泵增效机制研究[J].农业机械学报,2015,46(4),65-69.Tian limei,Mei haoran,Li xinhong,et al.Enhancement mechanism investigation of centrifugal pump based on bionic coupling functional surface[J].Transactions of The Chinese Society of Agricultural Machinery,2015,46(4):65-69.(in Chinese with English abstract)
[21]张世磊,易玉华.低游离聚氨酯预聚体的结构、性能及其应用[J].陕西科技大学学报,2011,2(29):77-81.Zhang shilei,Yi yuhua.Structure,properties and application of the prepolymers with low levels of free isocyanate monomer[J].Journal of Shaanxi University of Science,2011,2(29):77-81.(in Chinese with English abstract)
[22]李俊贤.反应注射成型技术及材料(连载五)[J].聚氨酯工业,1996(4):42-46.
[23]陈赛艳,陈蕴智.聚氨酯的应用发展现状[J].化工时代,2008,22(8):52-55.Chen saiyan,Chen yunzhi.The application and development of polyurethane coatings[J].Chemical Industry Times,2008,22(8):52-55.(in Chinese with English abstract)
[24]罗宁,黄峻,王得宁,等.MDI/聚醚二元醇预聚体的粘度-温度关系[J].聚氨酯工业,1994,9(3):28-30.
[25]和曼君,张红东,陈维孝.高分子物理[M].上海:复旦大学出版社,2007.
[26]代青华,刘秀生,黄虹等.聚氨酯预聚体黏度的影响因素探究[J].材料保护,2017,50(1),91-93.Dai Qinghua,Liu Xiusheng,Huang Hong,et al.Influence factors of polyurethane prepolymer Viscosity[J].Materials Protection,2017,50(1),91-93.(in Chinese with English abstract)
[27]易玉华,陈万滨.基于PTMG-TDI的低游离TDI浇注型PU弹性体的制备与性能研究[J].橡胶工业,2010,57(2):82-85.Yi Yuhua,Chen Wanbin.Preparation and property of PTMG-TDI based castable polyurethane elastomer with low free TDI monomer[J].China Rubber Industry,2010,57(2):82-85.(in Chinese with English abstract)
[28]任露泉.试验设计及其优化[M].北京:科学出版社,2009.
[29]任露泉.回归设计及其优化[M].北京:科学出版社,2009.
[30]金日光,华幼卿.高分子物理[M].北京:化学工业出版社,2012.