均匀液滴喷射过程仿真与试验研究

针对液滴喷射增材制造试验参数调整困难、实施难度较大的现存问题,基于流体体积(Volume of fluid,VOF)两相流模型,建立均匀液滴喷射过程流场的计算模型。采用数值模拟的方法,对液滴喷射过程中的液滴流形态、压力场和速度场及其影响因素进行了研究,揭示了形成均匀液滴流的内在变化规律,得到了均匀液滴喷射过程的最优频率。在模拟结果的基础上,建立了液滴喷射装置并配置了相应的高速拍照系统,对射流断裂形态、喷射过程、喷射速度进行了试验研究。结果表明,射流速度主要取决于喷射压强,液滴流均匀性主要取决于扰动频率和扰动振幅,射流的压力场则呈周期性变化。模拟结果与试验结果吻合较好,说明所提出的建模方法是可行的,为不同情况下射流内部流场的计算提供了实用的方法,也为液滴喷射增材制造技术的应用奠定了理论基础。     

A study of signal noise reduction of the mass air flow sensor using the flow conditioner on the air induction system of heavy-duty truck

The mass air flow meter is a critical sensor that works based on thermal hot wire technology, used to determine the fuel to be injected into the cylinder and calculate the fuel-air ratio. In order to measure the airflow rate accurately, the flow should be uniform and smooth upstream of the sensor. The flow disturbance with a short straight length upstream of the flow meter results in the noise of the sensor signal. This noise causes unstable mass flow measurement on the system. Flow conditioners can be used to smooth the velocity profile of the flow. In this study, experimental and numerical methods were used to characterize the performance and operating accuracy of the mass flow meter used in heavy-duty truck applications. The flow conditioners were implemented to smooth the velocity profile around the mass flow meter that was disrupted by bends. The flow structures with and without flow conditioner were examined using Particle Image Velocimetry (PIV) to measure the time-averaged velocity. As well as the validated computational fluid dynamics (CFD) model provides data to understand the flow uniformity effect of the conditioner on the mass airflow (MAF) sensor. The optimization study was performed using a full factorial design of experiment (DOE) for flow conditioner design. A robust methodology was developed for the flow conditioner characteristics and mass airflow sensor implementation on the air induction system.     

单流程蒸发器表面温度场均匀性的影响因素研究

改善蒸发器表面温度场的均匀性对提高其换热效率具有决定性作用。设计出一种类似平行流蒸发器的圆管单流程蒸发器,改变其集液管和蒸发管衔接处的孔径大小以及制冷剂入口流速,并进行了蒸发器管路的水力计算和相应的实验研究,得出管路中间截面的温度分布。模拟结果表明:在结构一定的条件下,集液管内的制冷剂来流速度具有决定性作用。当集液管内的来流速度在0.04m/s时,蒸发器各支管的温度分布最为均匀;同时在制冷剂流量一定时,支管数及各蒸发管与集液管衔接处的孔径大小也影响着温度分布。试验结果证明了此结论:在一定的液态制冷剂集管入口流速下,最小孔径为0.4mm时,具有8根支管的单流程蒸发器比10根支管的单流程蒸发器具有均匀的温度场。研究结果为研发高效率的平行流蒸发器提供了一定的理论和试验基础。     

阻流块对薄壁空心铝型材挤压过程材料流速的影响

采用基于任意拉格朗日—欧拉(Arbitrary Largrang-Euler,ALE)算法的HyperXtrude软件模拟带有细小特征的薄壁空心铝型材挤压过程,以模孔出口处材料流速均方差作为衡量其均匀性的指标,通过设计一系列阻流块有效控制材料流速及型材变形。研究阻流块对流速均匀性的影响规律,提出阻流块设计的一般原则。结果表明,阻流块的截面形状对流速控制起着关键作用,应保证阻流块截面形状合理,再调整阻流块高度及其到模孔的距离,可有效控制材料流速及型材的变形,获得形状和尺寸符合要求的型材。在阻流块高度的一定范围内,增加其高度可增加型材整个截面上材料流速的均匀性,但阻流块的宽度对平衡材料流速作用不大。     

Effect of the convergence flow conditioner on rectifying eccentric jet flow induced by a ball valve

Installing a flow conditioner is an important method for rectifying irregular and unstable flow to stable flow state within a short flow distance in fluid transportation and control industrial applications. However, classical flow conditioners (such as Laws and Zanker flow conditioners in ISO 5167) with parallel pipeline axial orifices ineffectively rectify the distinct eccentric jet flow caused by valve regulation. The convergence flow conditioner with convergent orifices was innovatively designed for rectifying the eccentric jet flow caused by a ball valve in this study. Three convergent orifice angles (8°, 10°, and 12°) defined as angles between orifice and pipeline axes were considered to compare their effect on eccentric jet flow rectification as well as with the classical Laws flow conditioner (characterized by the convergent orifice angle of 0°) under different valve openings with an experimental setup for monitoring downstream pressures that develop along the pipeline and corresponding numerical simulation used. Pressure loss and throttling effect of installing convergence flow conditioners downstream the ball valve was assessed. Analysis of distributions of the pressure, velocity, and streamline for convergent flow conditioners showed that the flow conditioner with a large convergent orifice angle can effectively improve violent eccentric jet flows, especially under a small valve opening. The axial velocity on various downstream cross sections was extracted to evaluate the velocity uniformity. A dimensionless parameter of velocity eccentric ratio was used to quantify the rectification effect of eccentric jet flow evolving in the downstream pipeline. Results showed that a short pipeline length is needed to obtain additional symmetry and uniform flow field downstream of the flow conditioner with a high convergent orifice angle, that is, the convergence flow conditioner with a high convergent orifice angle demonstrated a strong effect of flow rectification on the valve-induced eccentric jet flow. This work can help understand characteristics of flow rectification on valve-induced eccentric jet flow in scientific research, and provide guidance for the flow conditioner design in fluid engineering.     

Co-Re MOCVD设备反应室流场的CFD数值仿真

以化学气相沉积Co-Re合金涂层为对象,建立反应室内部数学模型采用计算流体力学CFD方法对化学气相沉积制备Co-Re合金涂层反应室进行三维数值模拟分析,前处理采用ICEM软件划分网格,在fluent15.0中计算了反应室中基底附近流场分布,数值模拟采用非交错网格系统SIMPLE算法,以提高涂层表面均匀性为目的,研究了不同进气口形状、位置、流量大小以及压力对基底附近速度场的影响,模拟结果表明当选用直型喷头、进气口距离基底下表面L为150mm时,进气流量为150mL/min能够得到表面质量相对均匀的涂层,并且压力的变化对基底附近速度场影响不大。     

Investigation of a novel Couette flow with cylindrical baffles

The high-precision measure instrument for flow velocity is essential for industrial applications because the high-precision velocity can well reflect the physical characteristic of the flow. A restricted laminar Couette flow with cylindrical baffles, using a synthetic heat conduction liquid, was designed to obtain a steady vortex flow and wider work scope, according to Couette flow and Suspension flow characteristics. The heat transfer mechanism was investigated with a laminar flow model by the Fourier law. The research indicates that the heat transfer enhancement is related to the Temperature Boundary Layer (TBL). The TBL is affected by the Velocity Boundary Layer (VBL). The TBL thickness and Nusselt number (Nu) have a dependent relationship. The Reynolds number (Re) and the gap between the baffle and plate wall (Δh/h) can further affect Nu. The vortex flow generated by Couette flow can significantly enhance the heat transfer performance by a double spiral structure, which can rapidly mix heat fluxes and make the temperature converge to uniform. There is a sensitive and stable relationship between flow velocity and heat transfer. Notably, it is linear when Δh/h or Re is small, which can be used to design a high-precision thermal flow velocity meter.     

污水处理搅拌机的水力设计与试验研究

针对目前国内污水处理搅拌池内流场测试研究空白,为研究污水处理搅拌机性能,选用NACA翼型,应用升力法对污水处理搅拌机叶片进行水力设计,并对搅拌池内流体流场分布进行试验研究。在设计的试验台上,利用流速仪,通过空间布点测量了污水搅拌池内不同位置的流体速度。利用EXCEL软件绘制了污水处理搅拌池内不同位置截面上的流体速度分布图,分析了池内流体速度分布规律。流体速度沿着轴向传递明显,流体径向扩散相对较小,且污水搅拌池内流体的流速基本沿污水处理搅拌机轴对称分布。试验表明:该测量方法可行,且该污水处理搅拌机具有明显的轴向导流和减少池壁边界对池内流体的影响作用。     

二维超音速喷管型线设计仿真研究

采用计算软件FLUENT,对四种经典收缩段型线下的流场特性进行数值模拟,为选择超声速风洞收缩段的型线提供依据。基于特征线理论,利用解析法完成超音速喷管膨胀段型线设计,通过分析总压恢复系数及均匀度等流场参数,确定型线膨胀角角度及喷管长度。结果表明,收缩段型线选用双三次曲线,膨胀角度3.5°的情况下,超音速喷管出口达到了设计要求马赫数,并获得了较好的气流品质。     

口模压缩段对塑料挤出流动影响的有限元分析

在塑料挤出成形过程中，压缩段是调节模头流道各部分流量(流速)的主要区段，对熔体的流动具有重要影响。本文采用有限元数值分析方法，计算了熔体在口模内流动的速度场和压力场，定量分析了压缩比和压缩角等压缩段模具结构参数对挤出速度分布、挤出流量和挤出流动均匀性等的影响规律，为优化流道结构参数，提高挤出流动均匀性的研究提供了基础。     

Particle image velocimetry in a centrifugal pump: Details of the fluid flow at different operation conditions

Centrifugal pumps are present in the daily life of human beings. They are essential to several industrial processes that transport single- and multi-phase flows with the presence of water, gases, and emulsions, for example. When pumping low-viscous liquids, the flow behavior in impellers and diffusers may affect the centrifugal pump performance. For these flows, complex structures promote instabilities and inefficiencies that may represent a waste of energetic and financial resources. In this context, this paper aims at characterizing single-phase water flows in one complete stage of a centrifugal pump to improve our understanding of the relationship between flow behavior and pump performance. For that, a transparent pump prototype was designed, manufactured and installed in a test facility, and experiments using particle image velocimetry (PIV) were conducted at different conditions. The acquired images were then processed to obtain instantaneous flow fields, from which the flow characteristics were determined. Our results indicate that the flow morphology depends on the rotational speed of the impeller and water flow rate: (i) the flow is uniform when the pump works at the best efficiency point (BEP), with streamlines aligned with the blades, and low vorticity and turbulence in the impeller; (ii) the velocity field becomes complex as the pump begins to operate at off-design conditions, away from BEP. In this case, velocity fluctuations and energy losses due to turbulence increase to higher numbers. Those results bring new insights into the problem, helping validate numerical simulations, propose mathematical models, and improve the design of new impellers.     

Note: Ultrasonic liquid flow meter for small pipes

An ultrasonic flow meter for small pipes is presented. For metal pipe diameter smaller than 10 mm, clamp-on ultrasonic contrapropagation flow meters may encounter difficulties if cross talk or the short acoustic path contributes to large uncertainty in transit time measurement. Axial inline flow meters can avoid these problems, but they may introduce other problems if the transducer port is not properly positioned. Three types of pipe connecting tees are compared using the computational fluid dynamics (CFD) method. CFD shows the 45° tee has more uniform velocity distribution over the measuring section. A prototype flow meter using the 45° tee was designed and tested. The zero flow experiment shows the flow meter has a maximum of 0.002 m∕s shift over 24 h. The flow meter is calibrated by only 1 meter factor. After calibration, inaccuracy lower than 0.1% of reading was achieved in the laboratory, for a measuring range from 15 to 150 g∕s (0.29 to 2.99 m∕s; Re = 2688 to 26,876).     

Analysis and porthole die design for a multi-hole extrusion process of a hollow,thin-walled aluminum profile

The appropriate die design for multi-hole extrusion is still a challenging task because of the complicated circumstances and large material deformation during extrusion process. In the present study, the material flow during multi-hole extrusion process for producing a hollow and thin-walled profile was revealed by means of numerical simulation based on the Arbitrary Lagrangian Eulerian (ALE) method. The effects of eccentricity ratio, shape of the second-step welding chamber, and uneven bearing length on the exit velocity distribution of extrudate were synthetically investigated, and a two-hole porthole die was designed accordingly. The exit velocity and temperature on the extrudate in this optimized die were analyzed and compared with the initial die, and it was found that both of them exhibit better uniformity, which is beneficial for the enhancement of product quality. Through performing the current work, a logical and effective route for designing multi-hole porthole die was proposed as the guidance for die designers.     

LDV measurement,flow visualization and numerical analysis of flow distribution in a close-coupled catalytic converter

Results from an experimental study of flow distribution in a close-coupled catalytic converter (CCC) are presented. The experiments were carried out with a flow measurement system specially designed for this study under steady and transient flow conditions. A pitot tube was a tool for measuring flow distribution at the exit of the first monolith. The flow distribution of the CCC was also measured by LDV system and flow visualization. Results from numerical analysis are also presented. Experimental results showed that the flow uniformity index decreases as flow Reynolds number increases. In steady flow conditions, the flow through each exhaust pipe made some flow concentrations on a specific region of the CCC inlet. The transient test results showed that the flow through each exhaust pipe in the engine firing order, interacted with each other to ensure that the flow distribution was uniform. The results of numerical analysis were quali-tatively accepted with experimental results. They supported and helped explain the flow in the entry region of CCC.     

基于 C 4 D 技术的非满管液体流速测量方法研究

为满足目前小型化设备中液体流速测量的需求,通过将空间滤波测速与电容耦合非接触电导测量(C~4D)技术相结合,提出了一种适用于非满管液体流速测量的新方法。设计了一种轴向两电极结构的C~4D传感器,采用COMSOL仿真软件建立了传感器的三维仿真模型,并对其空间灵敏度分布特性进行了分析,然后基于该传感器的空间滤波效应对液体流速测量原理进行了理论推导,并采用等效峰值频率的方法得到了速度测量的数学表达式;在此基础上,设计了一套可适用于空间滤波的C~4D液体流速测量系统,并通过该测量系统验证了C~4D传感器具有良好的空间滤波效应,且实验结果表明,该测量方法具有良好的可行性,在1.39～2.35 m/s的速度范围内,测量速度的绝对误差均在5%以内。     

Effect of guide wall on jet impingement cooling in blade leading edge channel

The characteristics of fluid flow and heat transfer, which are affected by the guide wall in a jet impinged leading edge channel, have been investigated numerically using three-dimensional Reynolds-averaged Navier–Stokes analysis via the shear stress transport turbulence model and gamma theta transitional turbulence model. A constant wall heat flux condition has been applied to the leading edge surface. The jet-to-surface distance is constant, which is three times that of the jet diameter. The arrangement of the guide wall near the jet hole is set as a variable. Results presented in this study include the Nusselt number contour, velocity vector, streamline with velocity, and local Nusselt number distribution along the central line on the leading edge surface. The average Nusselt number and average pressure loss between jet nozzle and channel exit are calculated to assess the thermal performance. The application of the guide wall is aimed at improving heat transfer uniformity on the leading edge surface. Results indicated that the streamwise guide wall ensures the vertical jet impingement flow intensity and prevents the flow after impingement to reflux into jet flow. Thus, a combined rectangular guide wall benefits the average heat transfer, thermal performance and heat transfer distribution uniformity.     

空间细胞培养装置设计与流体动力学仿真优化

细胞培养装置可用于细胞生物学、空间生物技术和航天医学的研究。设计并制作了一种流加式细胞自动培养装置,可适用于空间、地面微重力环境下的细胞体外自动培养,定期给细胞培养板提供不同试剂定时定量的输入,满足空间细胞培养所要求的小型化、方便组装和高可靠性的要求。整体装置采用模块化的设计方法,利用Solid Works软件分别构建基础组件、试剂供应组件和培养组件三维模型,并使用Solid Works软件中Flow Simulation模块对细胞培养装置与细胞培养板连接的关键部件—针板,进行有限元分析和流体仿真结构优化,观察其内部通道的速度场和压力场,采用圆角替换直角的方法优化通道。仿真结果表明,该装置切实可行,能满足细胞培养装置所需条件,优化后的针板通道内流体稳定性更强,流速及压力分布更均匀。在地面环境中,优化后的针板在低、中、高流速下,流体在横向通道内的速度均匀度分别提升了95%、96%、94%,在纵向通道内的速度均匀度分别提升了68%、70%、72%。实验结果表明,流体在优化后针板通道出口流量更接近入口处泵的设定输出流量,设计的装置可用于空间生物技术研究。     

Flow regimes in wide-angle screened diffusers

The results of an experimental investigation into the use of screens and perforated plates to control the velocity profile emerging from wide-angle diffusers are reported. Tests were undertaken using two screens in diffusers of area ratio 10 and included angles of 45° and 60°. Without the use of screens to control the flow, highly non-uniform velocity profiles occur. Depending upon the porosity of the screens and their location within the diffuser, three principal types of exit velocity profile were found. These included (i) a regime characterized by high-velocity wall layers together with a depleted core region; and (ii) a regime involving a high-velocity region occupying a cruciform flow pattern, together with low-velocity corner regions. However, the most important finding of the work was that, with appropriate choice of porosity and location of the two screens, mean velocity profiles could be achieved which avoided flow separation and displayed a high degree of flow uniformity. These results extend significantly the range of area ratios in which two screens are sufficient to ensure uniformity of the velocity profile at the exit plane of wide-angle diffusers.     

涡流空气分级机圆弧形叶片转笼的设计

涡流空气分级机分级粒径主要受转笼转速与入口风速匹配关系的影响。入口风速一定时,转笼转速越高,分级粒径越小,但这会造成流场速度分布不均匀,而降低分级精度。利用Fluent软件对具有直叶片转笼结构的涡流空气分级机进行建模和数值模拟,分析转笼内流场特性,针对其流场不均匀及转笼入口冲角大等现象,对转笼叶片的形状及安装角进行改进,提出一种圆弧形叶片转笼的设计方法。通过数值模拟及物料试验对改进结果进行验证,数值模拟结果表明:圆弧形叶片转笼入口冲角减小,流道内流场更加均匀,分级粒径减小。碳酸钙分级试验结果与数值模拟结果吻合:设计工况即入口风速为12 m/s,转笼转速为1 200 r/min时,采用设计的圆弧形叶片转笼在保持分级精度不变的情况下,分级粒径减小了11.5%。     

锻件变形均匀性控制的研究

在已有研究工作的基础上，对控制变形均匀性的目标函数进行修改，考虑到单元体积的影响，把单元体积以权因子的方式加入目标函数，可以应用于复杂的变形过程。给出了目标函数的表达形式，详细推导了目标函数，单元体积、单元节点坐标对优化设计变量的灵敏度。应用该方法对圆柱体平模镦粗工艺进行预成形优化设计。给 出了相应的优化设计结果，与没有优化的情况进行了比较，结果表明优化取得了良好的效果。