基于超高压纯水射流的船壁除锈除漆关键技术与爬壁试验研究
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摘要
船舶工业是我国支柱工业之一,它是高技术密集区,也是重体力密集区。除锈是船舶工业劳动强度最大、污染严重、涉及面广、技术水平落后的一道必不可少的工艺。船舶壁面超高压水射流爬壁除锈成套设备,是以环保无污染的自来水为除锈介质,通过超高压大功率泵机组获得除锈能量。超高压水射流除锈是利用高压水射流的冲击作用和水撬作用,破坏锈蚀和涂层对钢板的附着力,具有高质、高效、清洁等适合船舶维修除锈的技术特性。
本文对超高压纯水射流的船舶壁面除锈机理、超高压纯水射流剥离冲击特性、及超高压纯水射流除漆除锈成套设备关键技术等方面进行研究,分析了锈层与船壁钢板之间的硬度关系,建立了超高压纯水射流喷射剥离冲击模型,并进行了剥离冲击射流流场的模拟和试验研究,设计了超高压水射流船舶壁面除锈设备试验台,进行了不同爬壁行进速度下的除漆试验对比分析,进行了实际除锈的显微研究,检测了除锈前后的钢质表面元素比例,分析了微观环境下超高压水射流的除锈效果,为船舶壁面除锈除漆的提供试验参考和依据。
本文研究了超高压纯水射流除锈的原理,建立了锈蚀和涂层表面的基本结构,探讨了水射流的特性,分析了剥离冲击的力学原理,建立了基本的冲击力学模型,研究其剥离冲击的有效工作方法,应用旋转射流方法进行了实验。提出了一种超高压纯水射流剥离冲击的数值模拟方法,建立了超高压纯水射流喷嘴的剥离冲击模型,采用湍流模式对超高压纯水射流的喷嘴的流场特性进行了数值模拟,提出了一种用于水射流的剥离冲击的速度核概念。模拟在不同射流压力和典型的不同射流靶距下的流场性能变化,分析出了超高压纯水射流的喷嘴剥离冲击的冲击流场的特性,以及不同射流压力下对纯水射流剥离冲击力的影响。根据不同压力的仿真,表明射流压力在200MPa时除漆效果最好；根据不同喷嘴口径的仿真,表明口径0.3mm的喷嘴射流冲击速度较大；理想状态下,靶距越大,冲击速度越高。
设计了船舶除锈超高压纯水射流成套系统,给出了系统的基本参数配置,论述了泵组系统、真空回收系统以及爬壁机器人等分系统的工作原理。分析了泵组系统能量损失和超高压密封技术,提出了一种试验台样机配置和基本元件布置,探讨真空吸干回收系统基本功能。应用所搭建的超高压纯水射流除漆除锈试验台进行不同行进速度下的除漆爬壁试验,并进行了对比分析,采用扫描电镜对真实除锈形貌进行了放大处理,进行了实际除锈的微观研究,并检测了除锈前后的钢质表面元素比例,分析了微观环境下超高压水射流的除锈效果。试验结果表明：在实际除锈试验中,采用超高压纯水射流除锈后,氧化物可以基本剥离干净,除锈效果达到除锈标准Sa2.5级。
Shipbuilding industry is one of the supporting industry in china, which is not only high-tech but also heavy workload concentrated regions. Rust removal is large labor intensity, serious pollution and covering a wide range, but it is the necessary process in shipbuilding industry. Complete equipment for ultrahigh pressure water jet hull rust removal uses pure water as medium, and gets the rust removal energy through ultrahigh pressure heavy power pump unit. Water hydraulics has advantages of environmental friendly, cleanness, safety, readily available, inexpensive, and easily disposable. Ultrahigh pressure water jet rust removal uses the impact action and water prying action to destructed the adhesive force between corrosion and ship wall, and it is suitable for hull rust removal with high quality, high efficient and clean.
In this thesis, the ultrahigh pressure pure water jet rust removal mechanism, the stripping impact characteristics, and the key technology of complete equipment ship rust removal were studied by theoretical analysis, prototype development and experimental study. The ultrahigh pressure pure water jet rust removal mechanism was analyzed, the ultrahigh pressure pure water jet modeling was established. The test bench of the ultrahigh pressure pure water jet rust removal was designed. The coating removal effects in different roatation of nozzle and climbing velocity were analyzed, and the rust removal effects in microscopic method were studied.
The impact modeling was established according to the mechanical principle, the rotation water jet experiment was shown. The ultrahigh pressure pure water jet modeling was established, and the stripping impact velocity field was simulated. The velocity experiment shows that the modeling is reliable. The flow field characteristics such as different pressure, different diameters and different target distance were analyzed. The analysis results show that, there is a velocity accumulation area with large energy in the velocity core, the best impact effect is the pressure 200MPa and the diameter 0.3mm, and the different target is bigger then the impact velocity is higher in the ideal state.
An ultrahigh pressure water jet pump package system for hull rust removal was designed. The main function, main parameters and design index was discussed. The water treatment unit before pump and electric control system were described. The energy loss and ultrahigh pressure sealing technology were analyzed. And a prototype structure was given. It provides a design reference for the study of ultrahigh pressure water jet pump package system for hull rust removal. The performance of the prototype through the SEM experiments were made, the rust and coating removal results show that, the effects of rust and coating removal with ultrahigh pressure pure water jet may reach the standard Sa2.5.
本文对超高压纯水射流的船舶壁面除锈机理、超高压纯水射流剥离冲击特性、及超高压纯水射流除漆除锈成套设备关键技术等方面进行研究,分析了锈层与船壁钢板之间的硬度关系,建立了超高压纯水射流喷射剥离冲击模型,并进行了剥离冲击射流流场的模拟和试验研究,设计了超高压水射流船舶壁面除锈设备试验台,进行了不同爬壁行进速度下的除漆试验对比分析,进行了实际除锈的显微研究,检测了除锈前后的钢质表面元素比例,分析了微观环境下超高压水射流的除锈效果,为船舶壁面除锈除漆的提供试验参考和依据。
本文研究了超高压纯水射流除锈的原理,建立了锈蚀和涂层表面的基本结构,探讨了水射流的特性,分析了剥离冲击的力学原理,建立了基本的冲击力学模型,研究其剥离冲击的有效工作方法,应用旋转射流方法进行了实验。提出了一种超高压纯水射流剥离冲击的数值模拟方法,建立了超高压纯水射流喷嘴的剥离冲击模型,采用湍流模式对超高压纯水射流的喷嘴的流场特性进行了数值模拟,提出了一种用于水射流的剥离冲击的速度核概念。模拟在不同射流压力和典型的不同射流靶距下的流场性能变化,分析出了超高压纯水射流的喷嘴剥离冲击的冲击流场的特性,以及不同射流压力下对纯水射流剥离冲击力的影响。根据不同压力的仿真,表明射流压力在200MPa时除漆效果最好；根据不同喷嘴口径的仿真,表明口径0.3mm的喷嘴射流冲击速度较大；理想状态下,靶距越大,冲击速度越高。
设计了船舶除锈超高压纯水射流成套系统,给出了系统的基本参数配置,论述了泵组系统、真空回收系统以及爬壁机器人等分系统的工作原理。分析了泵组系统能量损失和超高压密封技术,提出了一种试验台样机配置和基本元件布置,探讨真空吸干回收系统基本功能。应用所搭建的超高压纯水射流除漆除锈试验台进行不同行进速度下的除漆爬壁试验,并进行了对比分析,采用扫描电镜对真实除锈形貌进行了放大处理,进行了实际除锈的微观研究,并检测了除锈前后的钢质表面元素比例,分析了微观环境下超高压水射流的除锈效果。试验结果表明：在实际除锈试验中,采用超高压纯水射流除锈后,氧化物可以基本剥离干净,除锈效果达到除锈标准Sa2.5级。
Shipbuilding industry is one of the supporting industry in china, which is not only high-tech but also heavy workload concentrated regions. Rust removal is large labor intensity, serious pollution and covering a wide range, but it is the necessary process in shipbuilding industry. Complete equipment for ultrahigh pressure water jet hull rust removal uses pure water as medium, and gets the rust removal energy through ultrahigh pressure heavy power pump unit. Water hydraulics has advantages of environmental friendly, cleanness, safety, readily available, inexpensive, and easily disposable. Ultrahigh pressure water jet rust removal uses the impact action and water prying action to destructed the adhesive force between corrosion and ship wall, and it is suitable for hull rust removal with high quality, high efficient and clean.
In this thesis, the ultrahigh pressure pure water jet rust removal mechanism, the stripping impact characteristics, and the key technology of complete equipment ship rust removal were studied by theoretical analysis, prototype development and experimental study. The ultrahigh pressure pure water jet rust removal mechanism was analyzed, the ultrahigh pressure pure water jet modeling was established. The test bench of the ultrahigh pressure pure water jet rust removal was designed. The coating removal effects in different roatation of nozzle and climbing velocity were analyzed, and the rust removal effects in microscopic method were studied.
The impact modeling was established according to the mechanical principle, the rotation water jet experiment was shown. The ultrahigh pressure pure water jet modeling was established, and the stripping impact velocity field was simulated. The velocity experiment shows that the modeling is reliable. The flow field characteristics such as different pressure, different diameters and different target distance were analyzed. The analysis results show that, there is a velocity accumulation area with large energy in the velocity core, the best impact effect is the pressure 200MPa and the diameter 0.3mm, and the different target is bigger then the impact velocity is higher in the ideal state.
An ultrahigh pressure water jet pump package system for hull rust removal was designed. The main function, main parameters and design index was discussed. The water treatment unit before pump and electric control system were described. The energy loss and ultrahigh pressure sealing technology were analyzed. And a prototype structure was given. It provides a design reference for the study of ultrahigh pressure water jet pump package system for hull rust removal. The performance of the prototype through the SEM experiments were made, the rust and coating removal results show that, the effects of rust and coating removal with ultrahigh pressure pure water jet may reach the standard Sa2.5.
引文
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