离心泵瞬态水力激振流固耦合机理及流动非定常强度研究
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摘要
本文的研究工作在国家杰出青年科学基金项目“离心泵基础理论和节能关键技术研究”(50825902)、国家科技支撑计划项目“百万千瓦级核电离心泵关键技术研究”(2011BAF14804)和江苏省博士科研创新计划“基于流固耦合的离心泵三维非定常湍流诱导振动特性研究”(CX10B262Z)的资助下展开。
泵是重要的能量转换装置和流体输送设备,其中离心泵应用最为广泛,其比例约占泵类设备总量的70%。离心泵不仅应用在石油、化工、水利、灌溉等工农业领域,而且是核电、航空、舰船和潜艇等高技术领域的关键设备。随着社会进步和科学技术的发展,离心泵的可靠性越来越受到重视,泵内部的瞬态水力激振现象是影响可靠性的关键因素之一。水力激振伴随着复杂的流固耦合作用,即水力激励作用在结构上会改变结构的动力学特性,并使结构发生变形,这反过来会影响内部流场的分布。文中采用试验研究和数值计算相结合的方法,以两台典型离心泵为研究对象,对叶轮的瞬态水力激振规律、流固耦合机理以及泵内部非定常流动特性进行了研究。本研究的主要工作和创造性成果有：
(1)系统总结了三维流固耦合求解方法相关理论的研究进展和发展趋势。根据离心泵转子系统的振动特性以及内部非定常流动特性,并考虑目前流固耦合求解方法在不同复杂系统中的适用性,最终确定了求解离心泵瞬态水力激振流固耦合问题的耦合求解方式,即外载荷传递的分块式(Partitioned)求解策略。
(2)首次提出了离心泵转子系统水力激振测量方案以及数据采集处理方法。发展了适用于离心泵的电涡量非接触式转子振动测量系统,并搭建了离心泵转子水力激振测量试验台,建立了一套可以消除其他因素诱导的转子系统振动的数据处理方法；成功地获得了各个转速及流量工况下离心泵转子系统周期性水力激振位移轨迹,并分析了影响该测量结果准确性的主要因素,可为研究离心泵瞬态水力激振现象提供试验依据。
(3)提出了动、静坐标系下流固耦合振动计算结果的转换公式。基于离心泵瞬态水力激振测量结果,对可能影响离心泵瞬态流固耦合求解的关键参数进行了分析,结果表明：流固耦合面数据传递方式、阻尼系数、流体网格刚度、数据传递的松弛因子和数据传递过程的收敛目标等参数是影响流固耦合计算结果的主要因素。论文初步建立了高精度离心泵流固耦合计算的参数组合。
(4)首次实现了对离心泵瞬态流固耦合求解的试验验证。对比结果表明,在所考察的转速和流量下,计算和测量的振动幅值及相位吻合较好,但在小流量工况下也存在一定的差异。定量研究了单叶片离心泵双向流固耦合的水力径向力,对作用在叶轮不同位置的径向力进行了分析。获得了各工况下转子系统的等效应力分布,分析了叶片等效应力随时间的变化规律。
(5)根据单叶片离心泵内部周期性非定常流动特性,在求解URANS方程的基础上,首次定义了压力脉动强度系数、相对速度非定常强度系数、绝对速度非定常强度系数以及湍流强度系数,初步获得了模型泵内部流动的非定常强度特征。采用高精度瞬态压力传感器对模型泵蜗壳内的非定常压力场进行了测量,获得了1个叶轮旋转周期内相平均压力结果。将不同转速和流量工况下的数值计算结果与试验结果进行对比,两者吻合较好,验证了CFD求解的可靠性。
(6)采用分块式耦合求解策略,对蜗壳式普通离心泵转子系统进行了流固耦合求解。分析了不同工况下转子系统的周期性振动特性、等效应力分布以及水力径向力随时间的变化情况等,初步揭示了普通离心泵转子的瞬态流固耦合规律。在考虑流动三维效应的基础上,定义了三维速度非定常强度以及三维湍流强度,以全新的视角对普通离心泵内部周期性非定常压力场、非定常速度场以及湍流场特性进行了研究。获得了整个旋转周期内的压力脉动强度、三维速度非定常强度以及三维湍流强度的分布规律。
通过本文的研究工作,初步掌握了离心泵流固耦合水力激振特性,为离心泵流固耦合分析提供了数值和试验方法；所提出的流动非定常强度分析方法可以确定周期性流动非定常强度的分布,可为优化泵的非定常特性提供基础。
This work is supported by the National Outstanding Young Scientists Funds of China (Grant No.50825902), National Science&Technology Pillar Program (Grant No.2011BAF14B04) and Jiangsu Provincial Project for Innovative Postgraduates of China (Grant No. CX10B_262Z).
Pumps, of which70%are centrifugal pumps, are important energy conversion devices and fluid delivery equipment. Centrifugal pump is widely used not only in all industrial and agricultural applications like petroleum, chemistry, water resources and irrigation, but also in high-tech applications as key equipment like nuclear industry, aviation, ships and submarine, et al. As the society develops and technology advances, the reliability of centrifugal pump has been paid more and more attention. Unsteady flow-induced vibration is one of the most important reasons that cause negative effect on pump reliability. The fluid-structure interaction (FSI), which can lead to increased potential for flow-induced vibration, exists between complex inner flow and structures of centrifugal pumps. That means hydraulic excitation will change dynamic characteristics of structures and lead to deformation, meanwhile the distribution of pump inner flow field will be affected by the deformation as well. Based on numerical and experimental methods, two different kinds of centrifugal pumps were systematically studied in the aspects of unsteady flow-induced impeller oscillations, fluid-structure interaction effects and inner flow unsteadiness behaviors. The main work and creative achievements of this dissertation were:
1. Advances and development trends of research on3D fluid-structure coupling methods have been systematically summarized and analyzed. Based on rotor vibration behaviors and unsteady flow characteristics, considering the applicability of coupling methods for different fluid-structure systems, the final coupling strategy, partitioned coupling method with external load transfer between fluid and structure fields, for unsteady flow-induced impeller oscillation with FSI effect has been selected for centrifugal pumps.
2. Experiment scheme and data acquisition method of transient flow-induced impeller oscillation measurement of centrifugal pump were established for the first time, and the test rig based on non-contact rotor vibration measurement chain under eddy current principle has been built. Data processing method, which can exclude the vibration induced by non-fluid phenomenon, was put forward. The orbit curve results of impeller deflection induced only by periodically unsteady flow have been successfully obtained considering different rotating speeds and flow rates, and primary factors that can influence the accuracy of the measurement results have been studied.
3. A conversion formula between the results in stationary and rotating coordinate frames, which lays a foundation for analyzing the vibration results in different expression forms, was derived. The key parameters influencing the accuracy of transient fluid-structure coupling results for centrifugal pump impeller were analyzed based on the measurement results initially. The results showed that the mapping methods on the fluid-structure interfaces, damping coefficients in the FSI solving procedure, fluid mesh stiffness, under relaxation factor for the load transfer procedure and load transfer convergence target were main factors that can influence the FSI solving results, and a parameter combination for FSI solution with high accuracy has been primarily obtained.
4. The transient FSI calculation results for centrifugal pump was validated by the measured vibration results firstly, and the comparison between numerical and experimental results showed that good agreements in both aspects of vibration magnitude and phase, can be observed for all examined rotating speeds and flow rates. Some deviations, however, can also be found, especially for low flow rate. In addition, hydrodynamic force results based on two-way coupling effect for the single-blade centrifugal pump were quantitively analyzed for every rotating speed and flow rate condition, and the force components acting on different part of the impeller were studied. Equivalent stresses in the pump impeller for multi-condition were analyzed, and the time-variant equivalent stresses were studied.
5. The periodic flow unsteadiness in single-blade pump has been quantitatively investigated in detail by defining pressure fluctuation intensity, velocity unsteadiness intensity and turbulence intensity based on solving URANS equations. To validate the reliability of the CFD calculation, transient pressure measurement for the model pump has been carried out using transient pressure sensor with high-precision. Periodic pressure results for one impeller revolution were obtained, and good agreements can be observed between numerical and measured pressure results for different rotating speeds and flow rates.
6. FSI simulation under partitioned coupling strategy for a centrifugal pump with multi-blade impeller was done to analyze impeller periodical oscillation, stress distribution and hydrodynamic force results for different operational conditions, and FSI effects for multi-blade impeller has been initially revealed.3D flow unsteadiness analysis method for centrifugal pump with twisted blades was established. Based on the unsteady flow calculation results within whole flow passage for the centrifugal pump, the3D velocity unsteadiness intensity and3D turbulence intensity were defined to study the unsteady flow from a new point of view. The magnitude and location of the pressure fluctuation intensity,3D velocity unsteadiness intensity and turbulence intensity have been obtained.
Through this study, the flow-induced vibration behaviors with FSI effect were preliminary obtained, and numerical and experimental methods used can be a reference for FSI analysis in centrifugal pump. The proposed analysis method for flow unsteadiness can determine the periodic flow unsteadiness strength distribution, and can provide basis for optimization of pump on unsteady flow behaviors.
泵是重要的能量转换装置和流体输送设备,其中离心泵应用最为广泛,其比例约占泵类设备总量的70%。离心泵不仅应用在石油、化工、水利、灌溉等工农业领域,而且是核电、航空、舰船和潜艇等高技术领域的关键设备。随着社会进步和科学技术的发展,离心泵的可靠性越来越受到重视,泵内部的瞬态水力激振现象是影响可靠性的关键因素之一。水力激振伴随着复杂的流固耦合作用,即水力激励作用在结构上会改变结构的动力学特性,并使结构发生变形,这反过来会影响内部流场的分布。文中采用试验研究和数值计算相结合的方法,以两台典型离心泵为研究对象,对叶轮的瞬态水力激振规律、流固耦合机理以及泵内部非定常流动特性进行了研究。本研究的主要工作和创造性成果有：
(1)系统总结了三维流固耦合求解方法相关理论的研究进展和发展趋势。根据离心泵转子系统的振动特性以及内部非定常流动特性,并考虑目前流固耦合求解方法在不同复杂系统中的适用性,最终确定了求解离心泵瞬态水力激振流固耦合问题的耦合求解方式,即外载荷传递的分块式(Partitioned)求解策略。
(2)首次提出了离心泵转子系统水力激振测量方案以及数据采集处理方法。发展了适用于离心泵的电涡量非接触式转子振动测量系统,并搭建了离心泵转子水力激振测量试验台,建立了一套可以消除其他因素诱导的转子系统振动的数据处理方法；成功地获得了各个转速及流量工况下离心泵转子系统周期性水力激振位移轨迹,并分析了影响该测量结果准确性的主要因素,可为研究离心泵瞬态水力激振现象提供试验依据。
(3)提出了动、静坐标系下流固耦合振动计算结果的转换公式。基于离心泵瞬态水力激振测量结果,对可能影响离心泵瞬态流固耦合求解的关键参数进行了分析,结果表明：流固耦合面数据传递方式、阻尼系数、流体网格刚度、数据传递的松弛因子和数据传递过程的收敛目标等参数是影响流固耦合计算结果的主要因素。论文初步建立了高精度离心泵流固耦合计算的参数组合。
(4)首次实现了对离心泵瞬态流固耦合求解的试验验证。对比结果表明,在所考察的转速和流量下,计算和测量的振动幅值及相位吻合较好,但在小流量工况下也存在一定的差异。定量研究了单叶片离心泵双向流固耦合的水力径向力,对作用在叶轮不同位置的径向力进行了分析。获得了各工况下转子系统的等效应力分布,分析了叶片等效应力随时间的变化规律。
(5)根据单叶片离心泵内部周期性非定常流动特性,在求解URANS方程的基础上,首次定义了压力脉动强度系数、相对速度非定常强度系数、绝对速度非定常强度系数以及湍流强度系数,初步获得了模型泵内部流动的非定常强度特征。采用高精度瞬态压力传感器对模型泵蜗壳内的非定常压力场进行了测量,获得了1个叶轮旋转周期内相平均压力结果。将不同转速和流量工况下的数值计算结果与试验结果进行对比,两者吻合较好,验证了CFD求解的可靠性。
(6)采用分块式耦合求解策略,对蜗壳式普通离心泵转子系统进行了流固耦合求解。分析了不同工况下转子系统的周期性振动特性、等效应力分布以及水力径向力随时间的变化情况等,初步揭示了普通离心泵转子的瞬态流固耦合规律。在考虑流动三维效应的基础上,定义了三维速度非定常强度以及三维湍流强度,以全新的视角对普通离心泵内部周期性非定常压力场、非定常速度场以及湍流场特性进行了研究。获得了整个旋转周期内的压力脉动强度、三维速度非定常强度以及三维湍流强度的分布规律。
通过本文的研究工作,初步掌握了离心泵流固耦合水力激振特性,为离心泵流固耦合分析提供了数值和试验方法；所提出的流动非定常强度分析方法可以确定周期性流动非定常强度的分布,可为优化泵的非定常特性提供基础。
This work is supported by the National Outstanding Young Scientists Funds of China (Grant No.50825902), National Science&Technology Pillar Program (Grant No.2011BAF14B04) and Jiangsu Provincial Project for Innovative Postgraduates of China (Grant No. CX10B_262Z).
Pumps, of which70%are centrifugal pumps, are important energy conversion devices and fluid delivery equipment. Centrifugal pump is widely used not only in all industrial and agricultural applications like petroleum, chemistry, water resources and irrigation, but also in high-tech applications as key equipment like nuclear industry, aviation, ships and submarine, et al. As the society develops and technology advances, the reliability of centrifugal pump has been paid more and more attention. Unsteady flow-induced vibration is one of the most important reasons that cause negative effect on pump reliability. The fluid-structure interaction (FSI), which can lead to increased potential for flow-induced vibration, exists between complex inner flow and structures of centrifugal pumps. That means hydraulic excitation will change dynamic characteristics of structures and lead to deformation, meanwhile the distribution of pump inner flow field will be affected by the deformation as well. Based on numerical and experimental methods, two different kinds of centrifugal pumps were systematically studied in the aspects of unsteady flow-induced impeller oscillations, fluid-structure interaction effects and inner flow unsteadiness behaviors. The main work and creative achievements of this dissertation were:
1. Advances and development trends of research on3D fluid-structure coupling methods have been systematically summarized and analyzed. Based on rotor vibration behaviors and unsteady flow characteristics, considering the applicability of coupling methods for different fluid-structure systems, the final coupling strategy, partitioned coupling method with external load transfer between fluid and structure fields, for unsteady flow-induced impeller oscillation with FSI effect has been selected for centrifugal pumps.
2. Experiment scheme and data acquisition method of transient flow-induced impeller oscillation measurement of centrifugal pump were established for the first time, and the test rig based on non-contact rotor vibration measurement chain under eddy current principle has been built. Data processing method, which can exclude the vibration induced by non-fluid phenomenon, was put forward. The orbit curve results of impeller deflection induced only by periodically unsteady flow have been successfully obtained considering different rotating speeds and flow rates, and primary factors that can influence the accuracy of the measurement results have been studied.
3. A conversion formula between the results in stationary and rotating coordinate frames, which lays a foundation for analyzing the vibration results in different expression forms, was derived. The key parameters influencing the accuracy of transient fluid-structure coupling results for centrifugal pump impeller were analyzed based on the measurement results initially. The results showed that the mapping methods on the fluid-structure interfaces, damping coefficients in the FSI solving procedure, fluid mesh stiffness, under relaxation factor for the load transfer procedure and load transfer convergence target were main factors that can influence the FSI solving results, and a parameter combination for FSI solution with high accuracy has been primarily obtained.
4. The transient FSI calculation results for centrifugal pump was validated by the measured vibration results firstly, and the comparison between numerical and experimental results showed that good agreements in both aspects of vibration magnitude and phase, can be observed for all examined rotating speeds and flow rates. Some deviations, however, can also be found, especially for low flow rate. In addition, hydrodynamic force results based on two-way coupling effect for the single-blade centrifugal pump were quantitively analyzed for every rotating speed and flow rate condition, and the force components acting on different part of the impeller were studied. Equivalent stresses in the pump impeller for multi-condition were analyzed, and the time-variant equivalent stresses were studied.
5. The periodic flow unsteadiness in single-blade pump has been quantitatively investigated in detail by defining pressure fluctuation intensity, velocity unsteadiness intensity and turbulence intensity based on solving URANS equations. To validate the reliability of the CFD calculation, transient pressure measurement for the model pump has been carried out using transient pressure sensor with high-precision. Periodic pressure results for one impeller revolution were obtained, and good agreements can be observed between numerical and measured pressure results for different rotating speeds and flow rates.
6. FSI simulation under partitioned coupling strategy for a centrifugal pump with multi-blade impeller was done to analyze impeller periodical oscillation, stress distribution and hydrodynamic force results for different operational conditions, and FSI effects for multi-blade impeller has been initially revealed.3D flow unsteadiness analysis method for centrifugal pump with twisted blades was established. Based on the unsteady flow calculation results within whole flow passage for the centrifugal pump, the3D velocity unsteadiness intensity and3D turbulence intensity were defined to study the unsteady flow from a new point of view. The magnitude and location of the pressure fluctuation intensity,3D velocity unsteadiness intensity and turbulence intensity have been obtained.
Through this study, the flow-induced vibration behaviors with FSI effect were preliminary obtained, and numerical and experimental methods used can be a reference for FSI analysis in centrifugal pump. The proposed analysis method for flow unsteadiness can determine the periodic flow unsteadiness strength distribution, and can provide basis for optimization of pump on unsteady flow behaviors.
引文
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