高速旋流旧砂再生装置设计参数的优化研究
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摘要
近几年,我国年均铸件产量都在3000万吨以上,将铸造旧砂进行回收再生,可以减少环境污染和资源浪费,实现绿色生产。再生后的旧砂具有粒度均匀、表面光滑、耐热度好等优点,可以提高型砂和铸件的质量。
目前的旧砂再生设备存在再生率低、砂粒破碎率高、耗能大、再生工艺繁琐、耗时长等缺点。因此需要寻找新的方法、开发新的设备来提高旧砂再生能力,满足旧砂再生的要求。旋流式旧砂再生装置的提出是以热法和气流式再生机理为基础,采用旋动射流的气流为动力源的新型旧砂再生装置。
本文通过对不同旧砂再生方法优、缺点的对比指出干法是一种经济、有效的再生方法,而气流再生法又以其工作稳定、可靠,维修方便等优点已成为干法再生中的主流方法。通过对旋动射流相关理论的研究发现旋动射流的气体在强旋度的情况下存在很强的卷吸能力从而产生很强的掺混作用,这样会使砂粒与砂粒间发生相互摩擦,这有利于提高旧砂的再生效果。并根据横吹式旧砂再生机存在的砂粒易破碎、回收率低等现象和旋转的射流打击力随偏转角增大而递减的规律分析以后,提出了采用热法与旋动射流气流撞击法相结合的再生新方法。
本文采用气流式旧砂再生机理及低温加热脆化方法针对粘土混合型旧砂的再生提出了旋流式旧砂再生装置的设计方案。在详细分析了旋流发生方式以后,采用管内导流法设计了该装置的旋流发生器。并通过Fluent软件的大量模拟仿真分析,得知圆弧板翼型叶片的导叶会使直流射流的气流产生强旋度的旋动射流。并指出在同一安装轴上,选择适当弧度、安装角、叶片数、弦长,叶片高度的圆弧板翼型叶片的旋流发生器,将产生更强旋度的旋动射流气流,并指出圆弧板翼型的安装角、弧度和叶片数量对气流的影响最强。又根据仿真结果提出入砂漏斗应尽量布置在靠近旋流发生器喷嘴的位置上,这有利于提高砂粒的流动速度和磋磨作用。并对入砂漏斗、入风口进行了详细的分析设计,使入砂量可以调节、入风口入风均匀。并应用Fluent软件提供的离散相模型,对砂粒的流动轨迹、流动速度进行了分析。最后对高速旋流旧砂再生设备的工艺步骤和优点做出了详细的分析。
In recent years, Chinese annually casting output is above 30 million tons. Green sand reclamation can reduce environmental pollution and resources waste, and realize green production. Green sand reclamation have epigranular, smooth surface, good refractoriness and so on. That will improve foundry sand and casting quality.
At present, green sand equipment exist low regeneration rate, high broken rate, high energy consumption, complex regeneration technology, persistent and so on. So a new method is needed to look for in order to improve green sand reclamation competent and meet the requirements of green sand reclamation. Rotary stream equipment for green sand reclamation base hot method and current reclamation mechanism. The new green sand reclamation equipment apply for rotary stream for power source.
In this paper, by comparing advantage and disadvantage of different method of green sand reclamation, dry process is an economic and effective method. Air current regeneration have the advantages of steady, reliable and maintain. So it become the main method. By researching the theory of rotary stream jet, rotary stream jet air with strong rotation have strong entrainment ability and blending effect. The rotary stream jet air with strong rotation make green sand mutual scrub. That is in favor of reclamation effect. Transversal blow reclamation equipment exist the phenomenon of particles easily broken and low productivity. And it is found out that hitting power decrease with decrescence of deflection angle. So the new method of rotary stream green and hot process is proposed.
In this paper, rotary stream equipment base current green sand reclamation mechanism and low temperatures heating method for clay combination green sand. After minutely analyzing rotary stream happened method, guide blade rotation method apply to the stream happened equipment in the equipment. And through plenty of simulation result of Fluent, guide blade leaf with rounded airfoil can produce strong rotary stream jet. On the same mounting axel, proper radian, installation angle, the number of leaves, length of chord, and height of leaf all can make strong rotary stream jet, especially radian, installation angle, and the number of leaves can make strong effect for rotation. By the result of simulation, the funnel of green sand should be fix up near the inlet of rotary stream happened equipment. That is in favor of green sand friction effect and raising green sand velocity. And By designing inlet of green sand funnel and intake of air, the quantity of green sand can be adjusted, and homogeneous quantity of air can be obtained. And By using dispersed phase model in Fluent, floating track and flow velocity of green sand is analyzed. Finally, processing step and advantage of the equipment with rotary stream in high speed is analyzed.
目前的旧砂再生设备存在再生率低、砂粒破碎率高、耗能大、再生工艺繁琐、耗时长等缺点。因此需要寻找新的方法、开发新的设备来提高旧砂再生能力,满足旧砂再生的要求。旋流式旧砂再生装置的提出是以热法和气流式再生机理为基础,采用旋动射流的气流为动力源的新型旧砂再生装置。
本文通过对不同旧砂再生方法优、缺点的对比指出干法是一种经济、有效的再生方法,而气流再生法又以其工作稳定、可靠,维修方便等优点已成为干法再生中的主流方法。通过对旋动射流相关理论的研究发现旋动射流的气体在强旋度的情况下存在很强的卷吸能力从而产生很强的掺混作用,这样会使砂粒与砂粒间发生相互摩擦,这有利于提高旧砂的再生效果。并根据横吹式旧砂再生机存在的砂粒易破碎、回收率低等现象和旋转的射流打击力随偏转角增大而递减的规律分析以后,提出了采用热法与旋动射流气流撞击法相结合的再生新方法。
本文采用气流式旧砂再生机理及低温加热脆化方法针对粘土混合型旧砂的再生提出了旋流式旧砂再生装置的设计方案。在详细分析了旋流发生方式以后,采用管内导流法设计了该装置的旋流发生器。并通过Fluent软件的大量模拟仿真分析,得知圆弧板翼型叶片的导叶会使直流射流的气流产生强旋度的旋动射流。并指出在同一安装轴上,选择适当弧度、安装角、叶片数、弦长,叶片高度的圆弧板翼型叶片的旋流发生器,将产生更强旋度的旋动射流气流,并指出圆弧板翼型的安装角、弧度和叶片数量对气流的影响最强。又根据仿真结果提出入砂漏斗应尽量布置在靠近旋流发生器喷嘴的位置上,这有利于提高砂粒的流动速度和磋磨作用。并对入砂漏斗、入风口进行了详细的分析设计,使入砂量可以调节、入风口入风均匀。并应用Fluent软件提供的离散相模型,对砂粒的流动轨迹、流动速度进行了分析。最后对高速旋流旧砂再生设备的工艺步骤和优点做出了详细的分析。
In recent years, Chinese annually casting output is above 30 million tons. Green sand reclamation can reduce environmental pollution and resources waste, and realize green production. Green sand reclamation have epigranular, smooth surface, good refractoriness and so on. That will improve foundry sand and casting quality.
At present, green sand equipment exist low regeneration rate, high broken rate, high energy consumption, complex regeneration technology, persistent and so on. So a new method is needed to look for in order to improve green sand reclamation competent and meet the requirements of green sand reclamation. Rotary stream equipment for green sand reclamation base hot method and current reclamation mechanism. The new green sand reclamation equipment apply for rotary stream for power source.
In this paper, by comparing advantage and disadvantage of different method of green sand reclamation, dry process is an economic and effective method. Air current regeneration have the advantages of steady, reliable and maintain. So it become the main method. By researching the theory of rotary stream jet, rotary stream jet air with strong rotation have strong entrainment ability and blending effect. The rotary stream jet air with strong rotation make green sand mutual scrub. That is in favor of reclamation effect. Transversal blow reclamation equipment exist the phenomenon of particles easily broken and low productivity. And it is found out that hitting power decrease with decrescence of deflection angle. So the new method of rotary stream green and hot process is proposed.
In this paper, rotary stream equipment base current green sand reclamation mechanism and low temperatures heating method for clay combination green sand. After minutely analyzing rotary stream happened method, guide blade rotation method apply to the stream happened equipment in the equipment. And through plenty of simulation result of Fluent, guide blade leaf with rounded airfoil can produce strong rotary stream jet. On the same mounting axel, proper radian, installation angle, the number of leaves, length of chord, and height of leaf all can make strong rotary stream jet, especially radian, installation angle, and the number of leaves can make strong effect for rotation. By the result of simulation, the funnel of green sand should be fix up near the inlet of rotary stream happened equipment. That is in favor of green sand friction effect and raising green sand velocity. And By designing inlet of green sand funnel and intake of air, the quantity of green sand can be adjusted, and homogeneous quantity of air can be obtained. And By using dispersed phase model in Fluent, floating track and flow velocity of green sand is analyzed. Finally, processing step and advantage of the equipment with rotary stream in high speed is analyzed.
引文
[1]郭景纯,郭思福.铸造旧砂再生利用及污染处理.广州：中山大学出版社,2011
[2]李传拭.粘土潮型砂技术讲座第一讲粘土湿型砂的特点.机械加工,2011,11(01):46-47
[3]谢名师主编.铸造手册-造型材料(第二版).北京：机械工业出版社,2002
[4]丁波,张方,李莉等.铸造混合旧砂粘接剂膜的形貌及组成.铸造,2009,6(7):17-20
[5]鲁永杰.铸造废砂再生处理与节能技术的应用.铸造,2008,57(8):830-833
[6]中国机械工程学会铸造分会.铸造手册造型材料.北京：机械工业出版社,2003
[7]S.Fiore,M.C.Zanetti.Industrial treatment processes for recycling of green foundry sands.International Journal Cast Metals Research,2008,21(6):435-438
[8]Diter S Leidel.Toward the Closed System by Reclaming Green Sand.AFS Trans, 1983,16(05):303-308
[9]AFS.What the Literature Says about Sand Reclamation.AFS 92nd Casting Congress.London,1987
[10]Takashi Yokoyama,Yasuo Suzuki,Hajime Akiyama.Improvements and Recent Technology for Fluidized Bed Waste Incinerators.NKK TECHNICAL REVIEW.2001,51 (85):38-43
[11]Yadi Fimi.Spoilt of Choice at GIFA.Foundry Trade Journal,1994,299 (09):483-488
[12]郭景纯.旧砂再生园地-国外动态.铸造设备研究,2001,16(5):53-54
[13]Fallon M.J.Prospects of Reclaiming Green for Core Making Use.Foundry Trade Journal,1993,69(7):992-999
[14]William L Tordoff. Could Cryogenics Crystallize an Option for Sand Reclamation. Modem Casting,1998.152(8):35-42
[15]李珊,张方郭思福.旧砂再生综述(国内2007年度),铸造设备研究,2008,12(3):42-45
[16]郭景纯,张方.郭思福.3t/h横吹式旧砂气流再生机的研制.铸造机械,1984,16(1)：14-21
[17]令军科.CRG粘土旧砂再生系统的应用.铸造技术,2004,25(10):754-755
[18]鲁永杰,郭名传,卢杰等.铸造废砂再生处理与节能技术的应用.铸造,2008,57(8)：830-833
[19]丁波.磨轮式粘土(混合)旧砂再生方法的理论与应用研究[硕士学位论文].昆明：昆明理工大学,2009
[20]周静一,韩伟.第37次(2002年)世界铸件产量调查.铸造,2004,53(3):244-246
[21]中国铸造协会,2008年中国铸件产量和分行业铸件产量报导.中国铸造装备与技术,2009,9(4):61-66
[22]Paul Carey.Sand Binder Sand Preparation & Core Making.Foundry M&T,1999, 27(1):16-22
[23]刘学欣,郭静.清洁生产在铸造业应用初布分析.环境保护科学,2006,12(1)：58-59.
[24]王其东.旧砂再生技术的发展及设备选用.工程建设与设计,2004,8(10):44-46
[25]张曙,刘海波.21世纪的挑战-可持续发展的制造战略可持续发展的制造战略.机电一体化,1998,220(08):4-7
[26]吴剑.论旧砂再生及工艺设备.铸造设备研究,2003,4(2):4-8
[27]胡刚.叶片式磨轮再生机改进设计研究及离散元分析[硕士学位论文],昆明,昆明理工大学,2011
[28]J C Davis, W A Jassen.Report on sand Reclamation Investigation of the American Steel Foundries.AFS Trans,1992,121(25):743-752
[29]Longeville D.L.Core Sand Reclamation at Elevated Temperature.AFS Tram,194 3,11(63):198-208
[30]Herfloy W.L.Thermal Process of Core Sand Reclamation.AFS Trans,1943, 22(51):207-210
[31]Jeter E.C.Sand Reclamation for Ferrous Foundry.Foundry,1946,3(8):86-98
[32]Curtis GH.Sand Reclamation in the Combination System.AFS Trans,1953, 51(18):222-228
[33]Den Breejen A.C.Sand Reclamation-Past,Present,Future.AFS Trans,1974,192 (8):16-25
[34]Diter S Leidel.Toward the Closed System by Reclaming Green Sand.AFS Trans, 1983,28(06):303-308
[35]孔刚.立式行星磨轮旧砂再生装置设计及动力学仿真[硕士学位论文].昆明：昆明理工大学,2010
[36]曹兴全,林文兰,郭景纯.旧砂再生机理探讨.云南省铸造学会五届学术会议论文,昆明,1987
[37]张小明,郭根喜,陶启友等.高压水射流水下洗网机旋转射流打击力计算.渔业现代化,2010,37(1):25-28
[38]董志勇,刘文国.射流力学.北京：科学出版社,2005
[39]周雪漪.计算水力学.北京：清华大学出版社,1995
[40]陶文铨,吴海言,戴智辉.数值传热(第二版).西安：西安交通大学出版社,2001
[41]郭鸿志.传输过程数值模拟.北京：冶金工业出版社,1998
[42]王福军.计算流体力学分析：北京：清华大学出版社,1995
[43]张凯,王瑞金,王刚Fluent技术基础与应用实例：北京：清华大学出版社,2003
[44]S.V.Patanker,D.B.Spalding,A calculation processure for heat,mass and momentum transfer in three-dimensional parabolic flows.Int J Heat Mass Transfer,1972,92(42):1787-1806
[45]J.P.Van Doormaal,G.G. Raithby.Enhancements of the SIMPLE method for predicting incompressible fluid flows.Numerical Heat Transfer,1984,5(65): 147-163
[2]李传拭.粘土潮型砂技术讲座第一讲粘土湿型砂的特点.机械加工,2011,11(01):46-47
[3]谢名师主编.铸造手册-造型材料(第二版).北京：机械工业出版社,2002
[4]丁波,张方,李莉等.铸造混合旧砂粘接剂膜的形貌及组成.铸造,2009,6(7):17-20
[5]鲁永杰.铸造废砂再生处理与节能技术的应用.铸造,2008,57(8):830-833
[6]中国机械工程学会铸造分会.铸造手册造型材料.北京：机械工业出版社,2003
[7]S.Fiore,M.C.Zanetti.Industrial treatment processes for recycling of green foundry sands.International Journal Cast Metals Research,2008,21(6):435-438
[8]Diter S Leidel.Toward the Closed System by Reclaming Green Sand.AFS Trans, 1983,16(05):303-308
[9]AFS.What the Literature Says about Sand Reclamation.AFS 92nd Casting Congress.London,1987
[10]Takashi Yokoyama,Yasuo Suzuki,Hajime Akiyama.Improvements and Recent Technology for Fluidized Bed Waste Incinerators.NKK TECHNICAL REVIEW.2001,51 (85):38-43
[11]Yadi Fimi.Spoilt of Choice at GIFA.Foundry Trade Journal,1994,299 (09):483-488
[12]郭景纯.旧砂再生园地-国外动态.铸造设备研究,2001,16(5):53-54
[13]Fallon M.J.Prospects of Reclaiming Green for Core Making Use.Foundry Trade Journal,1993,69(7):992-999
[14]William L Tordoff. Could Cryogenics Crystallize an Option for Sand Reclamation. Modem Casting,1998.152(8):35-42
[15]李珊,张方郭思福.旧砂再生综述(国内2007年度),铸造设备研究,2008,12(3):42-45
[16]郭景纯,张方.郭思福.3t/h横吹式旧砂气流再生机的研制.铸造机械,1984,16(1)：14-21
[17]令军科.CRG粘土旧砂再生系统的应用.铸造技术,2004,25(10):754-755
[18]鲁永杰,郭名传,卢杰等.铸造废砂再生处理与节能技术的应用.铸造,2008,57(8)：830-833
[19]丁波.磨轮式粘土(混合)旧砂再生方法的理论与应用研究[硕士学位论文].昆明：昆明理工大学,2009
[20]周静一,韩伟.第37次(2002年)世界铸件产量调查.铸造,2004,53(3):244-246
[21]中国铸造协会,2008年中国铸件产量和分行业铸件产量报导.中国铸造装备与技术,2009,9(4):61-66
[22]Paul Carey.Sand Binder Sand Preparation & Core Making.Foundry M&T,1999, 27(1):16-22
[23]刘学欣,郭静.清洁生产在铸造业应用初布分析.环境保护科学,2006,12(1)：58-59.
[24]王其东.旧砂再生技术的发展及设备选用.工程建设与设计,2004,8(10):44-46
[25]张曙,刘海波.21世纪的挑战-可持续发展的制造战略可持续发展的制造战略.机电一体化,1998,220(08):4-7
[26]吴剑.论旧砂再生及工艺设备.铸造设备研究,2003,4(2):4-8
[27]胡刚.叶片式磨轮再生机改进设计研究及离散元分析[硕士学位论文],昆明,昆明理工大学,2011
[28]J C Davis, W A Jassen.Report on sand Reclamation Investigation of the American Steel Foundries.AFS Trans,1992,121(25):743-752
[29]Longeville D.L.Core Sand Reclamation at Elevated Temperature.AFS Tram,194 3,11(63):198-208
[30]Herfloy W.L.Thermal Process of Core Sand Reclamation.AFS Trans,1943, 22(51):207-210
[31]Jeter E.C.Sand Reclamation for Ferrous Foundry.Foundry,1946,3(8):86-98
[32]Curtis GH.Sand Reclamation in the Combination System.AFS Trans,1953, 51(18):222-228
[33]Den Breejen A.C.Sand Reclamation-Past,Present,Future.AFS Trans,1974,192 (8):16-25
[34]Diter S Leidel.Toward the Closed System by Reclaming Green Sand.AFS Trans, 1983,28(06):303-308
[35]孔刚.立式行星磨轮旧砂再生装置设计及动力学仿真[硕士学位论文].昆明：昆明理工大学,2010
[36]曹兴全,林文兰,郭景纯.旧砂再生机理探讨.云南省铸造学会五届学术会议论文,昆明,1987
[37]张小明,郭根喜,陶启友等.高压水射流水下洗网机旋转射流打击力计算.渔业现代化,2010,37(1):25-28
[38]董志勇,刘文国.射流力学.北京：科学出版社,2005
[39]周雪漪.计算水力学.北京：清华大学出版社,1995
[40]陶文铨,吴海言,戴智辉.数值传热(第二版).西安：西安交通大学出版社,2001
[41]郭鸿志.传输过程数值模拟.北京：冶金工业出版社,1998
[42]王福军.计算流体力学分析：北京：清华大学出版社,1995
[43]张凯,王瑞金,王刚Fluent技术基础与应用实例：北京：清华大学出版社,2003
[44]S.V.Patanker,D.B.Spalding,A calculation processure for heat,mass and momentum transfer in three-dimensional parabolic flows.Int J Heat Mass Transfer,1972,92(42):1787-1806
[45]J.P.Van Doormaal,G.G. Raithby.Enhancements of the SIMPLE method for predicting incompressible fluid flows.Numerical Heat Transfer,1984,5(65): 147-163