基于三维流场数值解的液力变矩器轴向力研究
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摘要
本文以DT265型液力变矩器为研究对象,基于三维流动理论与计算流体动力学(CFD)模拟其内部流场获得数值解。在此基础上,计算液力变矩器各叶轮轴向力。目的是通过更详细的了解液力变矩器的内流场来更加准确的计算液力变矩器的轴向力,并探讨影响轴向力的主要因素,为进一步减小轴向力、提高轴承等易损件的寿命提供有效途径。研究的主要内容有:
①介绍了基于传统一维理论液力变矩器轴向力的计算方法,分析一维算法的不足,给出了基于三维流场数值解的液力变矩器轴向力研究方法;
②介绍了CFD软件模拟液力变矩器内流场的方法,并针对DT265型液力变矩器,用Unigraphics建立其流道的三维绕流式几何模型,然后导入Gambit中建立网格模型,并根据它的实际工作情况设置计算边界条件;
③对DT265型液力变矩器在不同工况下的三维流场进行计算,简要分析了在起动工况下、中速比工况下及高速比工况下变矩器泵轮、涡轮和导轮的内流场,为进一步的轴向力研究提供条件;
④基于三维流场数值解计算了DT265型液力变矩器的轴向力,分析了影响轴向力大小的因素,介绍了减小轴向力的一般方法,为减小轴向力、优化液力变矩器结构、提高轴承和液力变矩器使用寿命奠定了基础;
⑤对比了两种计算轴向力方法的计算结果,证明了基于三维流场数值解的液力变矩器轴向力计算方法具有更高的计算精度,有更高的工程实用价值;
⑥总结研究中存在的不足,展望了需进一步研究的主要问题和改进研究的方向。
Hydrodynamic torque converter is a kind of automatic continuously variable speed device which uses liquid as its work medium. It has excellent automatic adaptability to external load and can change speed and moment automatically with the change of working condition of vehicle or working machinery, improve stability of low-speed in transmission, the starting characteristic and the overload protection performance. As hydrodynamic torque converter uses liquid as its working medium, it can absorb or eliminate the twist vibration from engine and the shock from machinery. So it can prolong the service life of the engine and components of the transmission. Besides, hydrodynamic torque converter also has performance that can improve passability and travelling comfort of vehicle, makes vehicle operate simply, start smoothly and avoid engine miss.
Because the working medium is liquid, there is no mechanical friction in hydrodynamic elements themselves. But mechanical friction still exists in some other parts such as bearings and oil seals, which makes these parts be wearing parts and decrease the service life of hydrodynamic torque converter.
When a torque converter is designed, the axial force must be taken into account and it should be reduced as far as possible. Because of the complexity of the internal flow, there was no good method to calculate axial force of hydrodynamic torque converter accurately in the past years. Traditional method based on one-dimensional flow theory has many defects. The calculation method of axial force based on similarity theory is limited by geometric similarity and model experimental data .The axial force can be got also by experiment, and there were some experiments about axial force of torque converter both domestic and foreign. But the axial force has direct relation with the shape of impeller and vane and the structure of torque converter, so it is uneconomical and difficult to get axial force all by experiment. And the choice of bearing at the design stage asks for a better calculation method of axial force.
With the development of CFD and computer technology, three-dimensionalflow field in torque converter can be calculated accurately. Basic computational methods of flow field by CFD are briefly introduced in this paper. 3-D circumfluence geometric model of flow passage in torque converter is built in UG. Then mesh model is built in Gambit. Boundary conditions are set on the basis of the real working situation of torque converter. Flow field in torque converter is calculated under different work conditions. Flow field in pump, turbine and stator are analyzed respectively under starting condition, middle speed ratio condition and high speed ratio condition, which provide theoretical foundation for further study of axial force. Based on the result of numerical simulation of flow field, axial force on each impeller is calculated. Compared with traditional results based on one-dimensional flow theory, the computational method on axial force in hydrodynamic torque converter based on numerical solution of three-dimensional flow field has higher precision and more practical value in engineering. Factors that influence axial force size are analyzed briefly and the general method of how to decrease axial force is introduced. These fruits settled the foundation for the further study.
Some conclusions drew from this paper are as followings:
①Due to approximate calculation of the axial force caused by interior flow in flow passage, the calculated results based on one-dimensional flow theory are smaller than practical case. The calculated results based on numerical solution of three-dimensional flow field have higher precision and the calculation method can be used for engineering purposes.
②Axial force caused by interior flow in turbine is positive, and the value of axial force in high speed ratio condition is larger than in low speed ratio. Axial force caused by interior flow in pump and stator are negative. The value of axial force caused by interior flow in pump shows the gradually decreasing trend. While axial force caused by interior flow in stator is comparatively stable and negative.
③Overall axial force on pump is positive, it made pump to approach turbine; Overall axial force on turbine is negative, it made turbine to approach pump; Overall axial force on stator was negative, it made stator to approach pump; Overall axial force on stator has the same direction with the axial force caused by interior flow; But the overall axial force on pump and turbine are contrary to theaxial force caused by interior flow in their flow passage.
④Axial force on pump is bigger than on turbine and on stator, and it is descending slowly; Axial force both on pump and on turbine have the maximum under the state of starting condition; Axial force on stator is small all and has a downward trend while i swells.
⑤Axial force on stator mainly comes from the interior flow in its flow passage, and axial force caused by no equilibrium area is small and has little effect on stator. But both pump and turbine are influenced by the flow in cavity of ab, cd, ef, gh greatly, both the direction and the magnitude of the axial force of them changed greatly.
⑥Axial force in DT265 torque converter changes smoothly while speed ratio i swells, and all the axial force keeps their direction. This will be beneficial to its bearings.
①介绍了基于传统一维理论液力变矩器轴向力的计算方法,分析一维算法的不足,给出了基于三维流场数值解的液力变矩器轴向力研究方法;
②介绍了CFD软件模拟液力变矩器内流场的方法,并针对DT265型液力变矩器,用Unigraphics建立其流道的三维绕流式几何模型,然后导入Gambit中建立网格模型,并根据它的实际工作情况设置计算边界条件;
③对DT265型液力变矩器在不同工况下的三维流场进行计算,简要分析了在起动工况下、中速比工况下及高速比工况下变矩器泵轮、涡轮和导轮的内流场,为进一步的轴向力研究提供条件;
④基于三维流场数值解计算了DT265型液力变矩器的轴向力,分析了影响轴向力大小的因素,介绍了减小轴向力的一般方法,为减小轴向力、优化液力变矩器结构、提高轴承和液力变矩器使用寿命奠定了基础;
⑤对比了两种计算轴向力方法的计算结果,证明了基于三维流场数值解的液力变矩器轴向力计算方法具有更高的计算精度,有更高的工程实用价值;
⑥总结研究中存在的不足,展望了需进一步研究的主要问题和改进研究的方向。
Hydrodynamic torque converter is a kind of automatic continuously variable speed device which uses liquid as its work medium. It has excellent automatic adaptability to external load and can change speed and moment automatically with the change of working condition of vehicle or working machinery, improve stability of low-speed in transmission, the starting characteristic and the overload protection performance. As hydrodynamic torque converter uses liquid as its working medium, it can absorb or eliminate the twist vibration from engine and the shock from machinery. So it can prolong the service life of the engine and components of the transmission. Besides, hydrodynamic torque converter also has performance that can improve passability and travelling comfort of vehicle, makes vehicle operate simply, start smoothly and avoid engine miss.
Because the working medium is liquid, there is no mechanical friction in hydrodynamic elements themselves. But mechanical friction still exists in some other parts such as bearings and oil seals, which makes these parts be wearing parts and decrease the service life of hydrodynamic torque converter.
When a torque converter is designed, the axial force must be taken into account and it should be reduced as far as possible. Because of the complexity of the internal flow, there was no good method to calculate axial force of hydrodynamic torque converter accurately in the past years. Traditional method based on one-dimensional flow theory has many defects. The calculation method of axial force based on similarity theory is limited by geometric similarity and model experimental data .The axial force can be got also by experiment, and there were some experiments about axial force of torque converter both domestic and foreign. But the axial force has direct relation with the shape of impeller and vane and the structure of torque converter, so it is uneconomical and difficult to get axial force all by experiment. And the choice of bearing at the design stage asks for a better calculation method of axial force.
With the development of CFD and computer technology, three-dimensionalflow field in torque converter can be calculated accurately. Basic computational methods of flow field by CFD are briefly introduced in this paper. 3-D circumfluence geometric model of flow passage in torque converter is built in UG. Then mesh model is built in Gambit. Boundary conditions are set on the basis of the real working situation of torque converter. Flow field in torque converter is calculated under different work conditions. Flow field in pump, turbine and stator are analyzed respectively under starting condition, middle speed ratio condition and high speed ratio condition, which provide theoretical foundation for further study of axial force. Based on the result of numerical simulation of flow field, axial force on each impeller is calculated. Compared with traditional results based on one-dimensional flow theory, the computational method on axial force in hydrodynamic torque converter based on numerical solution of three-dimensional flow field has higher precision and more practical value in engineering. Factors that influence axial force size are analyzed briefly and the general method of how to decrease axial force is introduced. These fruits settled the foundation for the further study.
Some conclusions drew from this paper are as followings:
①Due to approximate calculation of the axial force caused by interior flow in flow passage, the calculated results based on one-dimensional flow theory are smaller than practical case. The calculated results based on numerical solution of three-dimensional flow field have higher precision and the calculation method can be used for engineering purposes.
②Axial force caused by interior flow in turbine is positive, and the value of axial force in high speed ratio condition is larger than in low speed ratio. Axial force caused by interior flow in pump and stator are negative. The value of axial force caused by interior flow in pump shows the gradually decreasing trend. While axial force caused by interior flow in stator is comparatively stable and negative.
③Overall axial force on pump is positive, it made pump to approach turbine; Overall axial force on turbine is negative, it made turbine to approach pump; Overall axial force on stator was negative, it made stator to approach pump; Overall axial force on stator has the same direction with the axial force caused by interior flow; But the overall axial force on pump and turbine are contrary to theaxial force caused by interior flow in their flow passage.
④Axial force on pump is bigger than on turbine and on stator, and it is descending slowly; Axial force both on pump and on turbine have the maximum under the state of starting condition; Axial force on stator is small all and has a downward trend while i swells.
⑤Axial force on stator mainly comes from the interior flow in its flow passage, and axial force caused by no equilibrium area is small and has little effect on stator. But both pump and turbine are influenced by the flow in cavity of ab, cd, ef, gh greatly, both the direction and the magnitude of the axial force of them changed greatly.
⑥Axial force in DT265 torque converter changes smoothly while speed ratio i swells, and all the axial force keeps their direction. This will be beneficial to its bearings.
引文
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[2] 李有义. 液力传动[M].机械工业出版社.2000.86~101
[3] 陈应坚.液力变矩器轴向力的理论分析及实验研究[D].吉林工业大学硕士毕业论文. 1987
[4] 王奎升,刘东福,张青振.石油钻机液力变矩器轴向力的分析与计算[J].石油大学学报(自然科学学报).1999,第 23 卷,第 5 期
[5] 罗邦杰.工程机械液力传动[M].机械工业出版社.1991
[6] 龙洙,张文祥.变矩器轴向推力计算[J].铁道部大连热力机车研究所.1963
[7] 范洁川等.流动显示与测量[D].机械工业出版社.1997
[8] 王福军.计算流体动力学分析[D].清华大学出版社.2005
[9] B. V. Marathe,B. Lakshminarayana,D. G. Maddock.Experimental Investigation of Steady and Unsteady Flow Field Downstream of Automotive Torque Converter Turbine and Inside the Stator Part Ⅰ: Flow at the Exit of Turbine[J].ASME 95-GT-231
[10] B. V. Marathe,B. Lakshminarayana,D. G. Maddock.Experimental Investigation of Steady and Unsteady Flow Field Downstream of Automotive Torque Converter Turbine and Inside the Stator Part Ⅱ: Unsteady Pressure on the Stator Blade Surface[J].ASME 95-GT-232
[11] J. Gandham.CFD on Torque Converter: Validation of Computational Results.3rd Symposium of CFD on Torque Converter[J].General Motors
[12] 张斌,罗邦杰,吴淑荣.液力变矩器叶轮内流场计算的无粘-有粘迭代法[J].汽车工程.1993(5).285~290
[13] 褚亚旭.基于 CFD 的液力变矩器设计方法的理论与实验研究[D].吉林大学博士毕业论文.2006
[14] K. Abe,T. Kondoh,K. Fukumura,M. Kojima.Three-dimensional Simulation of the Flow in a Torque Converter[C].SAE 910800
[15] R. R. By,R. Kunz,B. Lakshminarayana.Navier-Stokes Analysis of the Pump Flow Field of an Automotive Torque Converter[J] . ASME Journal of Fluids Engineering.1995.Vol.117.116~122
[16] H. Schulz,R. Greim,W. Volgmann.Calculation of Three-dimensional Viscous Flow in Hydrodynamic Torque Converter[J].ASME 94-GT-208
[17] J. D. Denton.The Calculation of Three-dimensional Viscous Flow through Multistage Turbomachines[J].ASME 90-GT-19
[18] 田华,葛安林,马文星等.液力变矩器流场损失的分析[J].吉林大学学报(工学版).2004 (4).559～ 563
[19] 赵红,马文星,王大志.液力变矩器动态特性辨识方法的探讨[J].工程机械.2002(7).28~31
[20] 赵志新.液力变矩器流场数值分析[D].吉林大学硕士学位论文.2003
[21] 齐迎春.数值模拟技术在液力变矩器流场分析中的应用[D].吉林大学硕士学位论文.2004
[22] 闫国军,董泳,陆肇达.导轮可调式液力变矩器数学模型的建立[J].哈尔滨工业大学学报.2001(2).200~202
[23] 严鹏,吴光强,谢硕.液力变矩器泵轮流场数值分析[J].汽车工程.2004(2).183~186
[24] 吴晓栋、谢硕.轿车液力变矩器改进设计方法的研究[J].汽车研究与开发.2002(6).19~23
[25] 吴子牛.计算流体力学基本原理[M].科学出版社.2001.2
[26] L. Bai,A. Kost,N. K. Mitra,M. Fiebig.Numerical Investigation of Unsteady Incompressible 3-D Turbulent Flow and Torque Transmission in Fluid Couplings[J].ASME 94-GT-69
[27] Fluent Inc..FLUENT User’s Guide[M]. Fluent Inc., 2003
[28] H.K. Versteeg, W. Malalasekera.An Introduction to Computational Fluid Dynamics: The Finite Volume Method[M]. Wiley, New York, 1995
[29] Marzio Piller, Enrico Nobile, J. Thomas.DNS study of turbulent transport at low Prandtl numbers in a channel flow[J]. Journal of Fluid Mechanics, (458):419-441, 2002
[30] J.G. Wissink.DNS of separating low Reynolds number flow in a turbine cascade with incoming wakes[J]. International Journal of Heat and Fluid Flow, 24(4):626-635, 2003
[31] V. Michelassi, J.G. Wissink, W. Rodi.Direct numerical simulation, large eddy simulation and unsteady Reynolds-averaged Navier-Stokes simulations of periodic unsteady flow in a low-pressure turbine cascade: A comparison[J]. Journal of Power and Energy, 217(4):403-412, 2003
[32] V. Stephane, Local mesh refinement and penalty methods dedicated to the Direct Numerical Simulation of incompressible multiphase flows[J]. Proceedings of the ASME/JSME Joint Fluids Engineering Conference: 1299-1305, 2003
[33] F. Felten, Y. Fautrelle, Y. Du Terrail, O. Metais, Numerical modeling of electrognetically-riven turbulent flows using LES methods[M]. Applied Mathematical Modelling, 28(1):15-27, 2004
[34] M. B. Abbott, D. R. Basco, Computational Fluid Dynamics-An Introduction for Engineers[M]. Longman Scientific & Technical, Harlow, England, 1989
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