叶顶间隙对轴流式叶轮机械性能及噪声的影响研究进展

在轴流式叶轮机械中转子与机壳之间存在一定的间隙,该间隙的大小对叶轮机械的全压、效率和噪声等均有很大影响。结合近年来在叶顶间隙领域开展的研究,详细综述了国内外在叶顶间隙对轴流式叶轮机械性能及噪声的影响等方面的研究进展,并对叶顶间隙在今后的发展方向进行了展望,为叶轮性能的优化提供参考。     

Influence of tip clearance on pressure fluctuations in an axial flow pump

Rotor-stator interaction in axial pumps can produce pressure fluctuations and further vibrations even damage to the pump system in some extreme case. In this paper, the influence of tip clearance on pressure fluctuations in an axial flow water pump has been investigated by numerical method. Three-dimensional unsteady flow in the axial flow water pump has been simulated with different tip clearances between the impeller blade tip and the casing wall. In addition to monitoring pressure fluctuations at some typical points, a new method based on pressure statistics was proposed to determine pressure fluctuations at all grid nodes inside the whole pump. The comparison shows that the existence of impeller tip clearance magnifies the pressure fluctuations in the impeller region, from the hub to shroud. However, the effect on pressure fluctuation in the diffuser region is not evident. Furthermore, the tip clearance vortex has also been examined under different tip clearances.     

磁悬浮压缩机顶隙调压模型与实验

风压紊乱是造成压缩机旋转失速、喘振等故障的直接原因,磁悬浮压缩机具有主动控制磁悬浮转子轴向位移对风压进行调控的优势。通过建立主动磁轴承轴向控制的动力学方程,首先,分析了磁悬浮转子稳定悬浮及轴向位移调整原理;其次,采用对磁悬浮压缩机风压性能有决定性影响的转速、叶轮高度、叶轮顶端间隙等参数,建立了磁悬浮压缩机叶轮顶隙与蜗壳出口风压之间关系的数学模型;最后,以30kW磁悬浮压缩机为实验对象,在叶轮顶隙分别改变0.1mm及0.2mm时,对出口风压及流量进行采集与分析。实验结果表明,磁悬浮压缩机蜗壳出口风压在数值上与所建数学模型的解算值契合度较高,并且叶轮顶隙对其有显著影响。针对压缩机不同故障状态,可依据数学模型选择不同叶轮顶隙进行调节。     

Centrifugal compressor tip clearance and impeller flow

Compressors consume a considerable portion of the electricity used in the industrial sector. Hence, improvements in compressor efficiency lead to energy savings and reduce environmental impacts. The efficiency of an unshrouded centrifugal compressor suffers from leakage flow over the blade tips. The effect of tip leakage flow on the passage flow differs between the full and splitter blade passages. In this study, the differences in the flow fields between the full and splitter blade passages were studied numerically in detail. An industrial high-speed compressor with a design pressure ratio of 1.78 was modelled. Numerical studies were conducted with six different tip clearances and three different diffuser widths. The results show that increasing tip clearance considerably increases the reversed flow into the impeller with an unpinched diffuser. The reversed flow then partly mixes into the flow in the same blade passage it entered the impeller and the rest migrates over the blade, mixing with the tip clearance flow. Furthermore, as the reversed and clearance flow mix into the wake, the wake is weakened. As pinch reduces both the reversed flow and clearance flow, the passage wakes are stronger with pinches. However, the pinch is beneficial as the losses at the impeller outlet decrease.

     

Numerical study on unsteadiness of tip clearance flow and performance prediction of axial compressor

Numerical calculations were performed to investigate unsteady features of tip clearance leakage flow in an axial compressor. The first stage rotor of a low speed axial compressor with a large tip clearance was examined. It was confirmed that the numerically calculated performance data were in good agreement with the experimentally measured performance data. Using frequency analysis, the flow characteristic near the casing induced by tip clearance leakage flow was found to be not associated with the rotating speed of the rotor. This characteristic is called rotating instability or self-induced unsteadiness. We found that the circumferential length scale of the rotating instability of the compressor was longer than a pitch of a blade passage; therefore, a multi-blade passage was adopted to study the flow structure more precisely. The flow characteristic was described by the frequency, the circumferential length, and the phase velocity, and was changed by operating points toward stall. The behavior of the flow was characterized by circumferentially traveling waves. Hence, the mechanism governing the development of the unsteady feature was further examined in terms of the rotating wave pattern of the pressure distribution. Furthermore, the unsteady feature of the tip clearance leakage flow affected the prediction of compressor performance by altering blockage, flow turning, and loss near the casing.     

对旋轴流风机叶顶间隙对其性能的影响

为了探究改变对旋轴流风机两级叶轮的叶顶间隙对其性能的影响，建立不同叶顶间隙下风机三维模型，利用Fluent进行数值模拟，并结合风机性能试验验证仿真的正确性。分析压升、效率、轴功率、湍流动能和叶顶泄漏涡随两级叶轮叶顶间隙的变化情况，结果表明：在相同流量下，压升、效率随间隙的增大而减小；与第一级叶轮相比，间隙对第二级叶轮的轴功率、湍流动能及泄漏涡影响更加显著；随间隙增大，叶顶泄漏涡的强度和影响区域越大。     

对旋轴流风机叶顶形态对其性能的影响

为了探究改变叶顶结构对风机性能的影响，采用Fluent对不同叶顶形态的对旋轴流风机性能进行数值模拟。分析了不同叶顶形态对风机效率、全压、叶顶泄漏流和泄漏涡的影响。结果表明：风机效率随叶顶开槽长度的增加而增大。在开槽长度和深度相同时，与第一级叶轮相比，改变第二级叶轮的叶顶形态对风机性能的改善更加显著。与后缘相比，在叶顶前缘开槽对风机性能改善更大。叶顶开槽后，间隙处形成泄漏涡，且叶顶泄漏流入口处涡流强度明显提高，可有效削弱叶顶泄漏流的发展，改善风机性能。     

Analyzing the shape parameter effects on the performance of the mixed-flow fan using CFD & Factorial design

Fans are representative turbo-machinery widely used for ventilation throughout the industrial world. Recently, as the importance of energy saving has been magnified with the fans, the demand for the fans with high efficiency and performance has been increasing. The representative method for enhancing the performance includes design optimization; in practice, fan performance can be improved by changing the shape parameters such as those of meridional plane, impeller, and diffuser. Before optimizing the efficient design, a process of screening to select important design parameters is essential. The present study aimed to analyze the effects of mixed-flow fans’ shape parameters on fan performance (static pressure and fan static efficiency) and derive optimum models based on the results. In this study, the shape parameters considered in the impeller domain are as follows: tip clearance, number of blades, beta angle of Leading edge (LE) in the blade, and beta angle of Trailing edge (TE) in the blade. The shape parameters considered in the diffuser domain are as follows: meridional length of the Guide vane (GV), number of GV, beta angle of LE in the GV and beta angle of TE in the GV. The effects of individual shape parameters were analyzed using the CFD (Computational fluid dynamic) and DOE (Design of experiments) methods. The reliability of CFD was verified through the comparison between preliminary fan model’s experiment results and CFD results, and screening processes were implemented through 2^4-1 fractional factorial design. From the analysis of DOE results, it could be seen that the tip clearance and the number of blades in the impeller domain greatly affected the fan performance, and the beta angle of TE at the GV in the diffuser domain greatly affected the fan performance. Finally, the optimum models with improved fan performance were created using linear regression equations derived from 2^4-1 fractional factorial design.     

发动机地面起动时涡轮叶尖间隙动态变化规律

基于涡轮叶尖间隙主动控制的需要,本文分析了涡轮叶尖间隙的变化机理,建立了机匣、叶片和转子的简化模型,同时基于某型发动机试车数据计算了涡轮叶尖间隙,研究了发动机地面起动时涡轮叶尖间隙动态变化规律。结果表明:地面起动时涡轮叶尖间隙呈减小趋势,机匣形变量上升速率最大,叶片变化量对叶尖间隙变化影响最小,可为发动机地面起动时涡轮叶尖间隙控制策略的设计提供参考。     

转子对高压涡轮叶尖间隙变化规律的影响

基于涡轮叶尖间隙主动控制的需要,初步分析了涡轮叶尖间隙的变化机理,建立了机匣、叶片和转子的简化模型。在此基础上,分别仿真计算转速变化和发动机起动过程瞬态温度下转子的径向变化,讨论了转子在飞行器机动飞行情况下的振动幅值对叶尖间隙的影响。结果表明,转子振动幅值和径向位移对叶尖间隙变化有重要作用。     

不同形式高速离心叶轮内部流动的数值模拟

为分析叶轮结构对于叶轮内部流动的影响,对8叶片的闭式和半开式两种形式低比转速高速离心复合叶轮进行研究.采用S-A湍流模型和雷诺时均N-S方程,对叶轮内部的流动进行三维紊流数值计算和分析,并对离心泵进行试验研究.数值计算结果表明,两种形式叶轮内部都存在回流,其中半开式叶轮内部的回流区域较少,液流在间隙里的相对流动大致为圆周方向;叶轮内部的静压力都是由叶片进口到出口逐渐升高,等静压曲线几乎是沿圆周方向,半开式叶轮叶片顶部的静压力低于相应位置根部的静压力,闭式叶轮出口的压力系数高于半开式叶轮.试验结果表明,半开式叶轮离心泵的效率较高,说明叶轮内部的回流是影响离心泵性能的重要因素.     

变转速工况下离心泵蜗舌处压力波动的试验研究

对某一单吸离心泵在变转速工况下蜗舌处的压力波动进行了测量与分析。该离心泵的叶轮为半开式叶轮并具有背叶片,它由原叶轮车削后得到,从而使得叶轮出口离蜗舌距离较大。结果显示:随着转速的提高,离心泵的流量及效率线性增大,而扬程以二次曲线形式增加。该离心泵蜗舌附近的压力波动频谱以叶轮转动频率整数倍的离散分量为主,特别是叶片通过频率及其二次谐波。最大波动分量的幅度占参考动压ρv22/2(v2为叶轮出口周向速度)的0.5%左右。随着转速的增大,压力波动的增加速度比转速提高速度快,且宽频波动幅度的提高比离散分量显著。另外,频谱分量中存在叶轮转动频率非整数倍的离散分量,以及与转速无关而取决于流体系统固有振动特性的离散分量。     

Performance prediction and flow field calculation for airfoil fan with impeller inlet clearance

The performance prediction of an airfoil fan using a commerical code, STAR/CD, is verified by comparing the calculated results with measured performance data and velocity fields of an airfoil fan. The effects of inlet tip clearance on performance are investigated. The calculations overestimate the pressure rise performance by about 10–25 percent. However, the performance reduction due to tip clearance is well predicted by numerical simulations. Main source of performance decrease is not only the slip factor but also impeller efficiency. The reduction in performance is 12–16 percent for 1 percent gap of the diameter. The calculated reductions in impeller efficiency and slip factor are also linearly proportional to the gap size. The span-wise distributions of phase averaged velocity and pressure at the impeller exit are strongly influenced by the radial gap size. The radial component of velocity and the flow angle increase over the passage as the gap increases. The slip factor decreases and the loss increases with the gap size. The high velocity of leakage jet affects the impeller inlet and passage flows. With a larger clearance, the main stream moves to the impeller hub side and high loss region extends from the shroud to the hub.     

Unsteady Turbulent Simulation and Pressure Fluctuation Analysis for Centrifugal Pumps

The pressure fluctuation in the flow passage of both impeller and casing is addressed on design condition. The initial conditions for the unsteady turbulent simulation are resulted from the steady calculations, and the three dimensional unsteady turbulent simulation concerning the rotor-stator interaction is executed by a Navier-Stoke solver embedded with k -ε turbulence model and with appropriate moving interface boundary conditions. Detecting points are distributed in the flow passage in different radial and circumferential positions to capture the static pressure fluctuation character for one cycle of the impeller. The time-domain spectrums show that the static pressure curves are periodic and have five peaks and five valleys. With the radius increasing, the pressure fluctuation peak-to-peak values in the impeller are increasing, and reach the maximum value on the interface. In the casing flow passage, those values are about 7% of local static pressure except some ones near the tongue. The values become decreasingly in the diffuser pipe. The frequency spectrums transformed by fast Fourier transform (FFT) show that the dominant frequency is approximate with the blade passing frequency, and the pressure fluctuations in impeller passage have high frequency content while those in casing ones have no such information.     

An experimental study of the performance characteristics with four different rotor blade shapes on a small mixed-type turbine

A small mixed-type turbine with a diameter of 19.9 mm has been substituted for a rotational part of pencil-type air tool. Usually, a vane-type rotor is applied to the rotational part of the air tool. However, the vane-type rotor has some problems, such as friction, abrasion, and necessity of accurate assembly etc.,. These problems make the life time of the vane-type air tool short, but air tools operated by mixed-type turbines are free of friction and abrasion because the turbine rotor dose not contact with the casing. Moreover, it is assembled easily because of no axis offset. These characteristics are merits for using air tools, but loss of power is inevitable on a non-contacting type rotor due to flow loss, tip clearance loss, and profile loss etc.,. In this study, four different rotors are tested, and their characteristics are investigated by measuring the specific output power. Additionally, optimum nozzle location against the rotor is studied. Output powers are obtained through measured pressure, temperature, torque, rotational speed, and flow rate. The experimental results obtained with four different rotors show that the rotor blade shape greatly influences to the performance, and the optimum nozzlc location exists near the mid span of the rotor.     

Microhaemodynamics within the blade tip clearance of a centrifugal turbodynamic blood pump

A persistent challenge facing the quantitative design of turbodynamic blood pumps is the great disparity of spatial scales between the primary and auxiliary flow paths. Fluid passages within journals and adjacent to the blade tips are often on the scale of several blood cells, confounding the application of macroscopic continuum models. Yet, precisely in these regions there exists the highest shear stress, which is most likely to cause cellular trauma. This disparity has motivated these microscopic studies to visualize the kinematics of the blood cells within the small clearances of a miniature turbodynamic blood pump. A transparent model of a miniature centrifugal pump having an adjustable tip clearance (50-200 microm) was prepared for direct optical visualization of the region between the impeller blade tip and the stationary housing. Synchronized images of the blood cells were obtained by a microscopic visualization system, consisting of an inverted microscope fitted with long-working-distance objective lens (40x), mercury lamp, and high-resolution charge-coupled device camera electronically triggered by the rotation of the impeller. Experiments with 7 microm fluorescent particles revealed the influence of the gap dimension on the trajectory across the blade thickness. The lateral component of velocity (perpendicular to the blade) was dramatically enhanced in the 50 microm gap compared with the 200 microm gap, thereby reducing the exposure time. Studies with diluted bovine blood (Ht = 0.5 per cent) showed that the concentration of cells traversing the gap is also reduced dramatically (30 per cent) as the blade tip clearance is reduced from 200 microm to 50 microm. These results motivate further investigation into the microfluidic phenomena responsible for cellular trauma within turbodynamic blood pumps.     

汽轮机再热后级内颗粒冲蚀特性

汽轮机再热后级内叶片受到固体颗粒冲蚀,严重影响着汽轮机的安全经济运行。以某超临界汽轮机再热后第1+1/2级(第一级与相邻级的喷嘴)扭叶片为研究对象,通过拉格朗日法模拟不同粒径颗粒三维运动轨迹,并采用Finnie冲蚀模型,研究不同动静轴向间隙及不同负荷下颗粒对叶片的冲蚀特性。结果表明,由于动叶高速旋转,颗粒撞击到动叶时会获得与主流方向相反的速度,进而又反弹回静叶。较大粒径颗粒在动静叶片轴向间隙内"反复反弹"是造成再热后级内冲蚀的主要原因。适当增大动静轴向间隙可以有效地减少反弹回静叶的颗粒数量。当动静轴向间隙为5 mm时,反弹回静叶的颗粒为10%,轴向间隙增大为8 mm时,没有颗粒反弹回静叶。当机组负荷降低时,固体颗粒撞击叶片后的反弹角增大、反弹回静叶的数量增多,颗粒在动叶和下级静叶轴向间隙内反弹后,只有极少颗粒能够流出下级静叶。     

径向间隙对离心压气机性能影响的数值研究

通过自主开发的CFD求解器NUAA Turbo,对带有楔形扩压器的离心压气机进行定常和非定常数值研究,通过改变叶轮和扩压器间的径向间隙,研究其对离心压气机性能的影响.研究发现:较小的径向间隙能够抑制扩压器压力面的分离,高载荷压力面的卸载提升了扩压器叶片通道的扩压能力.     

叶顶间隙对低比转速混流泵性能及内部流场影响的数值研究

为了解叶顶间隙对低比转速混流泵性能及内部流场的影响,选取无叶顶间隙和叶顶间隙δ分别为0.25 mm、0.75 mm和1 mm共四种方案,基于ANSYS-CFX对一比转速为149的混流泵进行了全流道数值模拟。计算域采用ICEM-CFD和TurboGrid进行结构化网格划分。利用Tecplot对计算结果进行处理,得到叶顶间隙对外特性参数、轮缘泄漏、流道中心S2流面流场等的影响。结果显示,叶顶间隙对大流量工况（1.25Q_d和1.5Q_d）下性能参数的影响大于小流量工况（0.5Q_d和0.75Q_d）,且效率减小量与叶顶间隙变化量的比值（Δη/Δδ）和相对流量m之间近似呈二次抛物线关系;当间隙为0.75 mm时,随着流量的增加,在叶轮流道进口附近形成的旋涡逐渐向出口方向移动,且旋涡强度及其对主流的影响范围均增大;当间隙进一步增大到1 mm时,泄漏流和主流之间发生了更为严重的卷吸效应。     

轴流泵端壁间隙流动特性的数值研究

基于N-S方程,标准k-ε模型和SIMPLEC算法,在三种叶端间隙、三种工况条件下,对轴流泵端壁间隙流动进行了数值模拟。重点考察了叶端间隙流动对叶轮出口流场及性能的影响。数值结果表明,间隙增加,扬程下降,特别是越在小流量工况下越明显。