汽轮机转子加工工艺分析

汽轮机转子是汽轮机的关键部件,其结构很复杂,且尺寸精度和跳动要求很高,加工难度较大,依据汽轮机转子结构和工艺特点,阐述了汽轮机转子的装夹方法,对汽轮机转子叶根槽及轴颈和推力面关键结构的加工工艺进行分析研究,并针对在加工过程中产生的问题提出了合理的加工方法,从而保证了转子的加工精度和表面粗糙度要求。     

汽轮机低压转子末级叶轮的齿型叶根槽加工及测量方法

介绍了某重点项目汽轮机低压转子末级叶轮的叶根槽型线(现称之为齿型叶根槽)的加工和测量方法,保证了转子齿型叶根槽型线的对称性和准确性,为同行业转子齿型叶根槽加工提供了经验。     

核电转子专用轮槽数控铣床结构布局特点分析

分析了核电转子的圆弧槽特点及加工难点,简单介绍了轮槽的加工工艺流程,并对专用轮槽数控铣床的结构布局进行了简要分析。根据专用轮槽数控铣床的特点,所设计制造的专用机床满足了机床在初加工时的强度要求,在加工实践中取得了成功的应用,解决了核电转子圆弧槽铣削的难题。     

一种高效车削磨机耳轴零件轴颈的工艺方法

针对传统车削轴颈粗糙度与技术要求存在的问题,通过对磨机耳轴类零件的轴颈面传统加工方式的分析及槽刀加工轴颈方案设计实施,总结和整理了一套使用非标槽刀代替传统的车刀进行轴颈面切削的工艺方法,此方法可提升精加工表面粗糙度,从而减少磨削量达到提高加工质量及效率的目的。     

轴颈外圆磨削成圆过程的双转子耦合模型及仿真算法

主轴轴颈外圆的圆度对机床主轴部件的回转精度具有直接而重要的影响。磨削加工是实现轴颈外圆高精度加工的最重要的手段。虽然磨削技术在主轴外圆加工上已长期应用,但是利用现有的研究成果,还难以对一个既定的磨削系统的磨削成圆过渡过程进行完整有效的定量仿真,也难以对磨削工件的最终圆度进行科学合理的预测。在吸收国内外磨削转子系统模型成果的基础上,进一步考虑外圆磨削过程中砂轮和工件之间的相互耦合作用、材料去除、转子振动及变形协调规律,建立了外圆磨削系统的双转子耦合振动模型,提出了模拟轴颈材料去除和圆度变化的"磨削力-瞬时磨削深度"迭代算法。利用所建立的双转子模型和迭代算法,对不同磨削策略下轴颈外圆成圆的过渡过程进行了定量仿真,再现了轴颈材料去除和外圆轮廓变化的全过程;比较研究了不同磨削策略对磨削效率和最终加工圆度的影响规律。进行了相应的磨削试验和对比验证,试验结果证实了所提出的轴颈外圆磨削的双转子模型和迭代算法的有效性和合理性。     

汽轮机转子枞树型轮槽的一种修复方法

介绍了采用转子叶片装配常用的枞树型叶根结构的修复方法,首先将转子叶轮轮槽加工错误部分去掉,然后在叶轮去除部分底部的主轴上加工枞树型轮槽。根据去除部分结构尺寸设计专用镶块,镶块底部采用叶片的枞树型叶根结构,然后利用枞树型轮槽将镶块安装到转子上。修复方法简单易于操作,经实践证明轮槽修复后转子可以重新使用。     

风力涡轮机轮槽成形车刀的设计

转子是风力涡轮机关键部件之一,其加工质量直接关系到风力涡轮机的性能。而转子加工中最为关键、最为困难的是轮槽的加工,保证了轮槽的加工质量,就从根本上保证了转子的加工质量。齿形轮槽的加工,在我公司通常采用车削加工,合理选配成形车刀将直接关系到轮槽型线尺寸精度和表面粗糙度。     

大型轮槽铣刀组的研制

汽轮机转子轮槽的加工是转子加工中最为关键、最为复杂的工序。转子轮槽要有很严密的尺寸精度和较好的表面光洁度。加工汽轮机转子轮槽的枞树形轮槽铣刀齿形曲线复杂,尺寸精度高。过去,轮槽铣刀是从美国西屋公司引进的,随着我国电力事业的不断发展,对汽轮机的要求不断提高。超临界、超超临界、核电站等机组的末极、次末极轮槽切削深度长,齿距多且尺寸大、精度高。现有的铣刀在切削平稳性,切削性能以及效率和耐用度等方面都无法满足汽轮机行业的发展需要。     

数控汽轮机转子轮槽中心支架介绍

通过对汽轮机转子的加工制造图纸及实际工况研究,设计了用于加工汽轮机转子轮槽的支撑和分度用数控汽轮机转子轮槽中心支架,使汽轮机转子转槽中心支架的加工精度及效率大大提高。     

超超临界汽轮机轮槽铣刀的设计与应用

1 引言 转子是汽轮机关键部件之一,其加工质量直接关系到汽轮机性能.而转子加工中最为关键、最为困难的是轮槽的加工,保证了轮槽的加工质量,就从根本上保证了转子的加工质量.     

汽轮机转子叶根勾槽的塞规研究

介绍了汽轮机转子叶根槽的样式和加工工艺方法。针对勾槽深度检验测量困难的问题,通过实例,阐述了利用尺寸链知识和光滑极限量规技术条件设计塞规的方法。     

径向螺旋槽空气轴承起飞速度与承载能力试验研究

起飞转速是空气轴承的重要性能指标。以螺旋槽空气轴承为研究对象,运用摄动法求解等温可压缩条件下螺旋槽气体润滑轴承压力分布的微分方程,得到空气轴承压力分布及承载力等特性;以最大承载力为目标,计算螺旋槽空气轴承的结构参数,并对设计的空气轴承进行试验,探究其不同载荷下的起飞速度。试验结果表明：空载状态下,转速约为1 200 r/min时空气轴承的转子与轴承套脱离接触,达到起飞速度;螺旋槽空气轴承的起飞速度与起飞转矩均随着的载荷的增加而逐渐升高,随着转速的升高,轴承的承载能力也越来越大。研究表明所设计的螺旋槽空气轴承具有良好的性能,为后续螺旋槽轴承设计优化及实际应用提供了理论与实践基础。     

储能飞轮转子轴承系统动力学设计与试验研究

飞轮储能系统通过飞轮升速和降速来实现电能储存和释放,研究飞轮转子轴承系统固有频率预计、临界转速设计、动平衡等动力学问题。采用永磁轴承与螺旋槽动压轴承的混合支承方式,建立储能飞轮强度、动力学和充放电特性试验研究装置,进行了动平衡、阻尼支承调整、飞轮储能系统损耗和发电量测试等试验,试验飞轮达到设计转速42.0 kr/min,总储能497 W·h,从42.0 kr/min降速到13.8 kr/min,可用放电能达到290 W·h。     

Eulerian laser Doppler vibrometry: Online blade damage identification on a multi-blade test rotor

Laser Doppler vibrometry enables the telemetry-free measurement of online turbomachinery blade vibration. Specifically, the Eulerian or fixed reference frame implementation of laser vibrometry provides a practical solution to the condition monitoring of rotating blades. The short data samples that are characteristic of this measurement approach do however negate the use of traditional frequency domain signal processing techniques. It is therefore necessary to employ techniques such as time domain analysis and non-harmonic Fourier analysis to obtain useful information from the blade vibration signatures. The latter analysis technique allows the calculation of phase angle trends which can be used as indicators of blade health deterioration, as has been shown in previous work for a single-blade rotor.This article presents the results from tests conducted on a five-blade axial-flow test rotor at different rotor speeds and measurement positions. With the aid of artificial neural networks, it is demonstrated that the parameters obtained from non-harmonic Fourier analysis and time domain signal processing on Eulerian laser Doppler vibrometry signals can successfully be used to identify and quantify blade damage from among healthy blades. It is also shown that the natural frequencies of individual blades can be approximated from the Eulerian signatures recorded during rotor run-up and run-down.     

调心球轴承外圈车加工方法改进

采用专用车床加工调心球轴承外圈沟道倒角时偶尔出现毛刺现象,经热处理后影响到磨削外滚道质量,造成轴承装配时划伤钢球,影响旋转灵活性及调心性能。针对此问题,对外滚道与倒角工序的关系进行了分析,调整了加工顺序,改变了加工方法,避免了倒角毛刺的产生。     

吹瓶机用双列深沟球轴承单向注油孔加工方法

针对某型号非标准双列深沟球轴承单向注油孔加工过程中,由于油孔细长且精度要求较高,造成加工困难、效率低下、满足不了生产要求的问题,设计了加工辅具并改进了加工方法,保证了加工精度,提高了加工效率。     

Measured stiffness and displacement coefficients of a stationary rotor hydrostatic bearing

A hydrostatic bearing is described whereby the oil pockets and capillary feeds are incorporated in a stationary central shaft to support an external rotor. Observations are given on general published design recommendations for hydrostatic bearings with which the bearing was designed. Experiments were carried out with the rotor supported and not rotating which appeared to validate performance predicted by the design recommendations, including direct stiffness. It was also found, by invoking recently devised measurement techniques, that the bearing exhibited displacement coefficients, including cross terms, which implied significantly different stiffness values.     

一种大直径三元流径向销联接转子的加工技术

分析了大直径三元流径向销联接转子的结构和加工难点,利用NX软件探索出三元流叶片建模的新方法,型面误差小,曲面质量好;利用有限元软件研究叶片展开技术,计算结果唯一,精度高;设计制造接长刀杆,避开叶轮的干涉,实现径向孔的加工。实践证明,该转子完全满足机组的正常运行,实现了国产化制造。     

Numerical simulation and experimental research on passive hydrodynamic bearing in a blood pump

The current research of hydrodynamic bearing in blood pump mainly focuses on the bearing structure design.Compared with the typical plane slider bearing and Rayleigh step bearing,spiral groove bearing has excellent performance in load-carrying capacity.However,the load-carrying capacity would decrease significantly with increasing flow rate in conventional designs.In this paper,the special treatment is made to the upper spiral groove bearing to make sure that both the circulatory flowing and load-carrying capacity are high.Three-dimensional computational fluid dynamics(CFD) models in the space between rotor and shaft are developed by using FLUENT software.Effects of groove number,film height and groove depth on load-carrying capacity of the spiral groove bearings are investigated by orthogonal experiment design.The experimental results show that film height is the most remarkable factor to the load-carrying capacity.The variation tendency of load-carrying capacity reveals that the best combination of geometry is the one with groove number of 8,film height 0.03 mm and groove depth 0.08 mm.The velocity and pressure distributions in spiral groove bearings are also analyzed,and the analysis result shows that the distributions are in conformity with the design of the blood pump based on the principle of hydrodynamic bearing.The displacement of the rotor with the best combination parameters is tested by using laser displacement sensors,the testing result shows that the suspending performance is satisfactory both in axial and radial directions.This research proposes a bearing design method which has sufficient load-carrying capacity to support rotor as an effective passive hydrodynamic bearing.     

汽轮机转子动叶围带滚压机的设计与实践

针对公司汽轮机转子动叶围带的产出供应不足问题,指出铸钢动叶围带制造工艺的局限性是影响动叶围带生产效率的关键原因。根据动叶围带的特点,设计了一台简单实用的动叶围带滚压机,通过结构改进提高了设备的性能。经过实际使用,证明滚压的动叶围带成本低、质量可靠、性能稳定,完全可以取代铸钢动叶围带。