非球形催化剂颗粒撞击构件的数值计算分析

研究催化裂化过程中壁面遭受磨损的问题。采用有限元方法建立单颗和多颗催化剂颗粒撞击构件壁面的有限元模型,运用ABAQUS有限元分析软件作为前处理器,并将颗粒形态设定为非球形(椭球形)。在有限元模型中选取相应的材料本构模型,模拟不同参数(入射速度、撞击角度和撞击次数)的催化剂颗粒撞击构件壁面的过程,建立构件壁面的质量损失与催化剂颗粒参数间的关系,并对模拟结果进行分析。撞击过程中的不同参数对构件壁面的磨损量会产生较大的影响,构件壁面的磨损量随着入射速度、撞击角度和撞击次数的增大而增大,且催化剂颗粒以45°的形态撞击所造成的构件壁面磨损量最小。构件壁面在使用过程中很容易被冲击而造成磨损,且颗粒在不同情况下造成的磨损状况不同。     

催化剂颗粒撞击壁面的有限元分析

针对催化裂化过程中催化剂颗粒大量跑损的问题,采用有限元的方法建立了单颗催化剂颗粒撞击壁面的有限元模型,并运用Abaqus作为前处理器。催化剂颗粒是一种典型的脆性材料,在有限元模型中选取了相应的材料本构模型,模拟了不同参数(撞击形态、入射速度、入射角度)的催化剂颗粒撞击壁面的过程,建立了催化剂颗粒的质量损失与催化剂颗粒参数间的关系,并对模拟结果进行了分析。最后,根据数值模拟的结果,优化了催化剂颗粒的参数,提出了减少催化剂跑损的措施。研究结果表明,撞击过程中的不同催化剂颗粒参数对催化剂的磨损量会产生较大的影响,催化剂颗粒的磨损量随着入射速度和入射角度的增大而增大,当催化剂颗粒以45°的形态撞击壁面时,磨损量最小。     

颗粒流撞击壁面的离散元模拟

为了解决催化裂化装置中催化剂颗粒的磨损、撞碎等问题,首要解决催化剂颗粒的运动特性问题,为此将离散元数值模拟的技术应用到催化剂颗粒撞击壁面的模型中,简化了催化剂颗粒撞击壁面的模型为颗粒流撞击壁面模型,开展了颗粒流撞击壁面的离散元分析;建立了颗粒流中随机标记颗粒的速度与时间、位移与时间的关系,及整个颗粒流的动能与时间的关系;追踪了标记颗粒的运动轨迹,解释了颗粒流撞击壁面产生不规则分布的原因;提出了分段区间随机取样求得壁面平均应力的方法,在不同入射速度下对壁面产生的平均应力大小进行了对比分析。研究结果表明,入射颗粒流的速度对壁面应力的影响呈不稳定性,不同的入射速度影响壁面的平均应力大小,且在一定范围内入射速度越大,壁面的应力越大。     

耦合DEM-CFD法双入口磨粒流动力学模拟及加工试验

针对单入口磨粒流加工装置光整不均匀问题,提出了双入口磨粒流加工装置,为了解决传统CFD软件不能跟踪颗粒撞击壁面问题,结合DEM和CFD方法,通过耦合PFC和CCFD软件,利用DMP颗粒运动模型和标准k-ε湍流模型来模拟磨粒在流场中的运动.仿真中,通过PFC记录磨粒撞击壁面的速度和次数,通过CCFD记录流场运动状态,并应用Abaqus中Johnson-Cook模型分析了撞击速度和撞击次数对靶材质量损失的影响.数值模拟结果表明,双入口装置内两股流体撞击使得磨粒运动更为无序,磨粒撞击壁面次数大大增加,同时撞击壁面速度大于40 m/s的次数达到1 382次,远大于单入口的563次,使得加工面的材料去除速度更快.加工试验结果表明,加工30 h后,双入口装置加工的工件表面粗糙度Ra=0.35 μm,单入口装置工件表面粗糙度Ra=0.65 μm,加工效率明显提高.     

混凝土泵送中管壁磨损过程的离散元模拟研究

建立了混凝土离散元模型,并通过L箱流动实验校核了该模型,得到了计算参数。采用该模型及得到的参数对混凝土泵送过程进行数值模拟,其中,以颗粒对管壁的冲击力和平均力表征壁面磨损程度,对泵送过程中管壁磨损过程进行研究。分析了泵送速度、弯管角度等因素对管壁磨损分布的影响,预测了最易磨损位置。结果表明：弯管管壁磨损随着泵送速度的增大而增大,随着弯管角度的增大而增大,模拟结果与实际泵送过程中观测到的最易磨损位置吻合较好。     

单颗磨粒的冲击磨损理论及实验研究

针对螺旋式约束磨粒流抛光的机理研究,基于ANSYS建立了单颗磨粒的冲击模型,选用铝合金作为工件的材料,并建立相应的Johnson-Cook弹塑性模型,分析单颗磨粒对材料的冲击磨损情况,并对颗粒的冲击磨损特性进行了实验研究。结果表明:对于弹塑性金属材料,撞击初期主要是发生弹塑性变形,形成压坑与变形唇,经多次碰撞挤压后,最终以小块金属剥落而产生磨损。在一定冲击角度(颗粒冲击轨迹与水平面的夹角)下工件表面材料磨损量较高,随着磨粒碰撞速度和碰撞次数的增加材料磨损量增大。螺旋式约束磨粒流通过改变颗粒的冲击轨迹能有效提高工件表面的加工效率与质量。     

爆炸喷涂CrC涂层耐固体粒子侵蚀性能研究

为研究不同状态下固体颗粒对爆炸喷涂CrC涂层性能的影响,改善产品耐固体颗粒的冲中蚀性能,采用爆炸喷涂技术制备涂层,研究了不同温度、颗粒速度、冲击角度下涂层的磨损率,分析温度、固体颗粒速度、粒子冲击角度对涂层抗冲蚀性能的影响.结果表明：爆炸喷涂CrC涂层在不同温度和速度下磨损率都表现出随角度的增大而增加的趋势,在90＆#176;时达到最大,表现为典型脆性材料的磨损特性.     

砂粒粒径对航空涡轴发动机压气机叶片冲蚀磨损的影响研究

高原、沙漠和沿海等服役环境中不同粒径的砂粒不可避免地对涡轴发动机压气机叶片造成冲蚀磨损,破坏叶片叶型和动力学特性,严重危及涡轴发动机使用寿命和直升机飞行安全。基于Finnie冲蚀磨损理论推导了颗粒对金属表面的磨损率表达式,分析颗粒粒径对材料冲蚀磨损率的影响,以某型涡轴发动机压气机动叶和静叶为研究对象,设计搭建砂粒冲击速度测试装置和钛合金冲蚀磨损实验装置,通过典型砂粒粒径下冲蚀磨损实验获取磨损率表达式中与靶材材料和冲击速度相关的关键参数,结合气固两相流动力学分析开展砂粒粒径对压气机动叶和静叶冲蚀磨损的影响研究。结果表明：砂粒粒径与冲击速度存在内在关联,材料冲蚀磨损率与砂粒冲击速度呈幂函数关系。实验条件下,砂粒粒径由177 μm增至423 μm时,其冲击速度平均降低约17%。压气机动叶和静叶的磨损集中区域不随砂粒粒径的改变而变化,但磨损程度差异明显,其中177 μm砂粒对动叶和静叶造成的最大冲蚀磨损率浓度值相比423μm砂粒分别增加91%和131%。研究结果为涡轴发动机压气机叶片抗磨损设计提供了理论参考。     

颗粒浓度对离心泵性能及磨损影响的研究

为研究颗粒浓度对离心泵性能及磨损的影响规律,采用CFD-DEM(Computational Fluid Dynamics-Discrete Element Method)对离心泵内部固液两相流进行数值计算.通过监测过流部件的磨损率和颗粒的运动,分析了不同颗粒浓度时叶片的磨损率、颗粒的平均速度、颗粒与壁面的接触次数和接触...     

液动压悬浮抛光固液两相流CFD数值模拟及PIV验证

针对液动压悬浮抛光固-液两相流中固相颗粒与工件表面撞击的过程,对不同加工工况下的固相颗粒与工件表面的撞击角度和速度进行了研究。采用计算流体力学方法建立了液动压悬浮抛光流场的三维模型,并输出了固相颗粒撞击工件表面的速度场;同时使用粒子图像测速方法对不同工况下的抛光流场进行了试验观测。研究结果表明:CFD模拟获得的撞击速度值与PIV观测值非常接近,且随转速增加,PIV观测值受固相颗粒之间的撞击效应影响越大;抛光过程中固相颗粒撞击工件表面的角度非常小,近似于在工件表面平行摩擦,且抛光盘转速和抛光液浓度对撞击角度的影响很小。     

催化裂化中可压缩湍流气固两相数值模拟

为了解决石油催化裂化中催化剂颗粒气体动力学难以进行实验的问题,采用基于大涡数值模拟(LES)的研究方法,在一定程度上克服了DNS法的超大计算量和RANS法的通用性小的缺点,对流场湍流有较高的仿真精度。利用工程常见的直管作为仿真对象,采用PFC-CCFD软件,对催化剂颗粒的运动和力学特征,气场的运动进行研究。分析仿真结果,得到管道内催化剂颗粒的速度分布、气场对颗粒的曳力、气场的运动状态、颗粒与颗粒的碰撞次数、颗粒和管壁的碰撞次数、颗粒动能的变化。通过PIV观测试验,研究颗粒运动轨迹,结合理论研究,揭示了管道内催化剂颗粒动力学特征。     

Numerical Study of Impact Behaviors of Angular Particles on Metallic Surface Using Smoothed Particle Hydrodynamics

Modeling and studying the impact behaviors of angular particles is critical in understanding the mechanisms of erosive wear on solid surfaces. This article focuses on effective mesh-free model based on the smoothed particle hydrodynamics (SPH) method to simulate impacts of angular particles on metallic surfaces. The predicted results are compared with the available experimental data, and good agreement has been achieved. Our simulations under different incident conditions successfully reproduce the general impact behaviors of angular particles, including rotating behavior and rebound behavior, which enables detailed examinations of erosion mechanisms. We find that the rotating behaviors are mainly determined by initial orientation and impact angle, whereas impact velocity has little effect. For backward impact involving a prying-off action, there generally exsits a critical impact velocity below which the cutting process would never be finished, which may result in a rebound angle greater than 90°. Further, multiple and overlapping impacts are simulated to reveal the effect of a pre-created crater on the subsequent impact. The results demonstrate the ability of the present model to handle the extremely deformed surface by overlapping impacts. The proposed SPH model and the present study could be useful in the study of erosive wear on the surface of metal devices that carry granular substances.     

FEM analysis of erosive wear

Surface damage caused by the impact of dispersed particles in gas or liquid flow is called “erosion”. Much attention has been paid to this phenomenon as one of the most serious problems to be solved, particularly concerning pipe-bends or valves in pneumatic conveying systems. But the phenomena of erosive wear are so complicated and vary depending on the factors of not only the kinds of material, hardness, shapes, sizes and mechanical properties of the particles, but also of blasting angles and velocity.

For the purpose of this study, mild steel was prepared and erosion wear tests were carried out. Steel grits were impacted against target materials at different incident angles. The results showed that the wear losses varied markedly as a function of the impact angles, and that the maximum wear occurred at specific angles. Maximum wear occurred at 20–30° for mild steel, and 60° for ductile iron. This impact angle dependence of wear was simulated by Tabor’s theory and FEM which could analyze the plastic deformation of alloy surface as a result of a single particle impact. In the case of both mild steel and ductile cast iron, it was found that the impact angles play a very important and valid role in the corrosion process.     

The anti-slurry erosion properties of polyethylene for sewerage pipe use

Sewerage systems are more common in Japan. The pipes and fittings in the systems are exposed not only to a corrosive environment, but also to the impact by solid particles contained in mud drains, resulting in an erosive wear on the surface. A strategy for coping with these problems involves replacing the more traditionally used iron and steel pipes with polymeric materials, which have excellent anti-corrosion properties. In this study, a slurry erosion test were carried out using a jet-in-slit apparatus on seven types of polyethylenes, three other types of polymers, and two types of iron and steels, thoroughly taking into account the fact that erosion damage is highly dependent on the impact angle of the particles. As a result, all the polyethylenes proved to have excellent anti-erosion properties, compared with the other materials over the entire range of particle impact angle. Further, a model was proposed to account the impact angle dependency of the erosion damage. The model aided in clarifying the reasons why the erosion rate of the polyethylenes is satisfactorily correlated with a complex parameter in which the fracture energy and the elastic modulus are combined.     

Erosive wear properties of unidirectional carbon fiber reinforced PEEK composites

The erosive wear properties of unidirectional carbon fiber (CF) reinforced polyetheretherketone (PEEK) composites were studied. A semi-ductile erosive wear manner was found regardless of the CF orientation. Wear mechanism analysis revealed that both cutting and deformation mechanisms existed in the erosion of the composites, although different damaging forms were involved depending on the impingement angles and CF orientation. To give further support on the erosion mechanisms, a special procedure was designed to observe the cross-sectional surface of the eroded composites, and the surface temperature variation was registered. It increased with increasing impingement angle, indicating higher energy dissipation by deformation, which is consistent with the revealed shift of the main erosive wear mechanism from cutting to deformation and “wholesale” fiber fracture.     

Gas–Solid Erosive Wear of Biomimetic Pattern Surface Inspired from Plant

Gas–solid erosive wear is a phenomenon in which serious mechanical damage is caused by the impact of solid particles on a wall. In this study, we investigated the erosive wear characteristics and mechanism of biomimetic groove surfaces in gas–solid erosive wear. Orthogonal experimental results showed that the order of the factors that influenced the erosive wear of the biomimetic groove surface was morphology > space > feature size. The V-shaped groove surface exhibited the best erosive wear resistance over the smooth, square, and U-shaped groove surfaces. The surface microstrain calculated by X-ray diffraction lines was used to study the mechanism of erosive wear resistance enhancement of the biomimetic surface. The microstructure of the eroded surface was analyzed by scanning electron microscopy. The appearance of ribs on the biomimetic groove surface increased the erosive wear of the surface in a distal position with respect to the ribs themselves. This article shows more opportunities for bionic application in improving the anti-erosion performance of moving parts that work under dirt and sand particle environments.     

透射电子显微技术在RIPP炼油催化剂表征中的应用

利用透射电子显微技术对加氢催化剂以及积炭催化裂化催化剂进行了表征。扫描透射电子结合X射线能谱技术确定了氧化态加氢催化剂中的微粒为活性金属组分的适度聚集；能量过滤透射显微技术获得了积炭催化裂化催化剂的Al、C的元素分布像。     

Influence of alumina dispersoid and test parameters on erosive wear behaviour of a cast zinc–aluminium alloy

Observations made pertaining to the erosive wear characteristics of a cast zinc-based alloy and its composite containing 10 wt.% (corresponding to 11.2 vol.%) alumina particles have been presented in this study. Matrix alloy has also been tested under identical test conditions in order to examine the role played by second phase alumina particles on the erosive wear resistance of the matrix alloy. Eroded surfaces and subsurface regions of the specimens were also characterized to understand the operating wear mechanisms.The composite exhibited higher erosive wear resistance (inverse of erosive wear rate) than the unreinforced matrix alloy in general. Further, the wear rate increased with increasing impingement velocity as also evident from higher surface damage. Increasing angle of impingement at lower impinging velocity led to reduced erosive wear rate. On the contrary, the erosive wear rate increased initially with impingement angle, attained the peak and then decreased at still higher angles at the higher impingement velocity. The eroded surfaces showed more abrasion grooves at lower impingement angle and greater tendency of crater formation at higher angles of attack. In case of the composite, protrusion and fracture of the dispersoid phase was also noted. The composite also revealed less severe surface and subsurface damage than the matrix alloy.