Liquid Metal Bearing Performance in Laminar and Turbulent Regimes

The design and development of a high speed journal bearing test rig is described. Test results are presented for water and high temperature liquid potassium lubricated journal bearings.

The test program included investigations of bearing torque, lubricant flow rate and stability limits for bearings operating in the laminar regime, through the transition to turbulent flow and in the turbulent flow regime. Torque vs. speed curves were obtained over a range of loads and bearing-journal clearance ratios. The test results are compared with predicted laminar bearing performance. Good correlation with theory was obtained in the laminar regime as indicated by plots of friction parameter vs. Reynolds number at zero load. The transition from laminar flow occurred at higher speeds than predicted by Taylor's criterion under all conditions of load. Recorded bearing torques in the nonlaminar regimes were four to forty times as great as predicted by laminar theory. The results of the materials compatibility study which supplemented the bearing study are summarized.     

湍流效应对干气密封性能影响的研究进展

在干气密封的理论研究与设计计算过程中,一般都是基于层流流动假设下进行的,但随着密封运行工况渐趋于高参数化、工艺介质多相化,在高参数、极端复杂工况下时流体会处于湍流流动状态,传统的层流流动理论就变得不再适用,因此在干气密封的理论设计与研究中就需要考虑润滑气体的湍流效应。总结现今应用较为广泛的3种湍流润滑模型,即Constantinescu模型、Ng-Pan-Elrod模型和Hirs模型,并介绍各模型的理论基础与适用范围。对湍流润滑方程及其在不同模型下的湍流系数表达式进行说明,综述考虑湍流效应对干气密封稳、动态性能影响的国内外研究进展。     

随钻测井用井下发电机系统的涡轮设计

对随钻测井系统中井下涡轮发电机的关键部件进行了研究.首先,建立了一种水力性能较高的涡轮模型;然后,基于计算流体力学(CFD)理论,采用Fluent软件对不同叶片参数的涡轮模型进行了紊流流场研究,并分析了流量、转速对涡轮流场的影响;最后,通过涡轮发电机地面单向水利实验验证了流量、转速、负载与涡轮发电机输出电压的关系.仿真结果表明:15叶片、叶片进口角30°以上、出口角45°以下、中弧线圆弧半径40mm以内对应的涡轮模型水力性能较好,但水力效率过高也会降低涡轮的工作寿命,因此,在一定范围内增大流量、转速对提高涡轮水力效率具有积极影响.所建立的涡轮模型能够提高涡轮的输出功率并保证其工作寿命.     

机械搅拌槽内非牛顿流体内流特性研究

在工业生产中获得广泛应用的机械搅拌混合,其流体大都是非牛顿流体,具有与牛顿流体不同的流变性质（弹性效应,剪切稀化以及剪切变稠）,所以急需对非牛顿流体情况下搅拌槽内的内流特性开展研究。基于Lin-A315桨型的粒子图像测速技术（Particle Image velocimetry,PIV）试验结果对搅拌槽内非牛顿流体的流场特性进行定常/非定常数值模拟,研究不同质量分数的黄原胶溶液在不同搅拌速度下的轴面流速分布、湍动能分布、径向截线的流速剖面、所需要的搅拌混合时间以及搅拌能耗。结果表明,数值模拟可以很好地模拟分析机械搅拌槽内非牛顿流体的流场特性;提高搅拌速度可以增加槽内主循环流的范围和强度,搅拌槽内涡的分布和湍动能分布范围也相应变大,与100 r/min相比,300 r/min和500 r/min工况下的轴向速度最大值增加3.6倍和5.9倍,所需要的混合时间缩短0.46倍和0.36倍;增加黄原胶溶液的浓度会减小流场的主循环流范围,增加速度梯度,降低槽底区域循环速度,所以与非牛顿流体溶液浓度的变化相比,所需要混合时间对转速变化更为敏感;另外提高搅拌速度会增加搅拌能耗,因此对低浓度非牛顿流体宜选择中等转速、高浓度非牛顿流体宜选择高转速以有利于溶液混合和能源节约。     

高功率密度液力变矩器空化特性研究

高功率密度液力变矩器由于其内部流速高、局部压力低而易出现空化现象，导致其液力性能恶化。针对液力变矩器内空化现象进行试验及数值研究，通过对不同转速、不同速比及不同补偿油压力下液力变矩器性能测试，获得空化随工况及供油条件变化规律。构建基于Rayleigh-Plesset的全流道瞬态空化仿真模型对不同工况下液力变矩器内部两相空化流动进行预测，利用应力混合涡模拟湍流模型精确捕捉涡流状态，实现对有/无空化下液力变矩器内部流场及液力特性的计算。结果表明，液力变矩器在高泵轮转速、低速比及低补偿压力下容易发生空化，空化程度随着速比的下降而升高，在起动工况时达到最大。在空化工况下，液力变矩器导轮流道内产生大量空泡，空泡阻碍油液流动，导致循环流量降低，进而使液力变矩器传递功率的能力下降，起动工况下能容系数降低高达31%。全流道瞬态空化模型能够实现液力变矩器空化特性的精确预测，对变矩比、能容系数及效率的最大预测误差由无空化的30%降低至5%。     

地震及多风况下风力机塔架动力响应

为分析不同风速的湍流风与地震联合作用下大型风力机塔架动力学响应,以美国可再生能源实验室(NREL) 5 MW风力机为研究对象,基于考虑土-构耦合效应的Wolf理论,利用动态入流理论及Prandtl理论修正的叶素动量理论计算气动力,基于FAST软件预留数据接口开发了地震载荷计算模块,建立了湍流风与地震联合作用下的风力机仿真模型;计算了5组风速与30种强度地震耦合共150种工况下的风力机塔架动力学响应。结果显示：额定风速下,塔顶位移响应受地震激励影响明显;低风速下地震作用对塔架加速度响应影响较大,高风速的湍流风会加剧塔架剪切力和弯矩响应;湍流风与地震联合作用时,塔顶位移及剪切力和塔基剪切力及弯矩的临界地面加速度峰值随风速的增大先增大再减小,塔顶加速度的临界地面加速度峰值在高风速下随风速增大而增大。     

轴流式通风机非设计工况下流场的数值研究及性能预测

利用Fluent软件,以OB-84型轴流通风机为对象,采用SIMPLE方法求解了N-S方程和Realizablek-ε湍流模型,对轴流式通风机的内部三维粘性流场进行了数值模拟研究,获得了设计工况下风机内部许多流动细节、规律及性能参数,并得出了结论。     

中等及大迎角下的翼型气动弹性性质研究

采用不同湍流模型的雷诺平均Navier-Stokes方程计算中等及大迎角条件下的非定常气动力,在全湍流流场假设情况下,耦合翼型振动方程,在时间域内数值模拟了中等雷诺数下翼型在不同迎角、尤其是失速迎角附近的气动弹性动态过程。通过算例分析,得出了研究结果。     

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。     

Comparison of Lubrication Models for Plane Slider Bearings

Accurate models of lubricant films are necessary to predict the performance of bearings under complex operating conditions. This investigation compares load predictions of the Reynolds equation and bulk flow model to that predicted by a three dimensional pseudo-spectral technique which incorporates thermal and inertial effects. Four different operating regimes along with their associated dimensionless parameters are identified. Three of these regimes are discussed, namely: laminar isothermal, turbulent isothermal, and turbulent thermal. The results provide insight into the conditions under which the Reynolds equation and bulk flow model are in good correlation with the pseudo-spectral technique.     

软性磨粒流精密加工工艺参数优化方法

针对固-液两相软性磨粒流加工中随着磨粒流温度的升高而导致流体黏度下降,进而导致湍动能和动压力分布不均匀的问题,提出一种新型的加工方法,即通过改变流速来补偿温度变化对湍动能和动压力的影响。基于对加工机理的研究,认为湍动能和动压力分别影响加工表面的加工纹理和材料去除率,确定了一种评价湍流形态的标准。对同一速度下不同温度时的湍动能和动压力的大小分布进行对比,研究了温度对湍动能和动压力大小和分布的影响;对同一温度下不同速度时的湍动能和动压力的大小分布进行对比,研究了速度对湍动能和动压力大小和分布的影响。通过大量仿真求得了9个不同温度下的最优温度,并作出了温度-速度曲线,为以后的湍流调控和自动控制系统的设计提供参考。实验结果表明,调速后工件表面的加工均匀度有明显的提升。     

Numerical analysis of turbulent flow over a backward-facing step using reynolds stress closure model

Reynolds stress turbulence models are adopted and applied for calculating turbulent flow over a backward-facing step. For the diffusion term in the transport equations for the Reynolds stresses, two gradient-type models are employed and compared. In addition, investigations on the modified ∈ equations are carried out. The results of the computations are compared with the extant experimental data. As a consequence, it is concluded that the Reynolds stress models predict the flow field better than the standardk-∈ model in the recirculating region. However, after the reattachment the return to the ordinary turbulent boundary layer is shown to be too slow to predict the flow field irrespective of turbulence models.     

A comparative study of the tool–chip contact length in turning of two engineering alloys for a wide range of cutting speeds

Tool chip contact length is an important parameter in machining, as it provides an indication of the size of area of interaction between the hot chip and the tool surface and hence the interface heat transfer zone. Heat transfer and thermally activated wear modes usually dominate tool wear in the high speed machining of steels and machining of titanium alloys at most cutting speeds. In this study, existing models for the prediction of tool–chip contact length are reviewed and examined for their suitability in high speed machining of two widely used engineering alloys. Orthogonal turning tests for AISI 1045 steel and Ti6Al4V titanium alloy are conducted for a range of cutting speeds from conventional to high speeds. New contact length models are presented for both materials covering a wide range of cutting speeds. More significantly, these contact length models are appropriate for high speed machining where thermal loads significantly influence process performance. Additionally, the work discusses how the machinability of engineering materials influences the ability to predict contact length.     

Do convective inertia forces affect turbulent bearing characteristics?

Ever increasing rotational shaft speeds and the use of unconventional lubricants such as water and liquid metals has prompted growing interest in turbulent lubrication theory¹. High surface velocities, large bearing dimensions, and low kinetic viscosities of lubricants give high values of Reynolds number and, eventually, super-laminar flow.An analytical study has been carried out at the University of Cairo on the effect of convective inertia on film pressure and load capacity of full infinitely long journal bearings. A computer program, based on the analysis outlined in Appendix 1, was developed to yield analytical results for fluid film pressure and bearing load capacity under widely varying conditions. Results were obtained for laminar and turbulent regimes.     

FLUID MECHANICS APPROACH TO MACHINING AT HIGH SPEEDS: PART II: A POTENTIAL FLOW MODEL

Finite element models of machining at high speeds usually assume that there is a stagnation point at the tool tip as is the norm in the machining community. However, at ultra-high speeds the yield strength of the workpiece is easily exceeded in the material around the tool tip, allowing that material to “flow” and possibly allowing the stagnation point to migrate away from the tool tip. A potential flow solution is used to model the behavior of the material around a sharp tool tip during machining at high speeds. Interestingly, the flow solution predicts that there is a stagnation point on the rake face, not at the tool tip as is usually assumed. Because the stagnation point is not at the tool tip, the flow solution predicts a significant amount of deformation in the workpiece resulting in large residual strains and a possible related temperature rise on the finished surface.     

Compressor performance of two-stage turbocharging system

To study the performance of high and low stage compressors and that of the system as a whole, a two-stage turbocharging system was matched, and a special two-stage turbocharging system test bench was built. For each test curve, the speeds of the two stage turbochargers were adjusted to the fixed data, and a compressor performance experiment was performed. The results showed many differences between the corrected mass flow and the actual mass flow of the high pressure (HP) stage compressor. To find out the actual supercharging effect of the two-stage turbocharging system, it is better to adopt the actual mass flow. The two-stage turbocharging system in this paper has much higher efficiency under most operating conditions if the pressure ratio assignment is 1:1. The system can get very high supercharging pressure when the speeds of the two stage turbochargers are rather low, which ensures the system’s security and reliability.     

一种气体流量的软测量系统研究

流量信号是生产过程中一个重要参数。虚拟仪器技术是仪器仪表领域一个充满活力的发展方向。从光滑圆管的3种紊流流速分布模型出发，应用虚拟仪器技术，实现了使用管道截面上的最大流速来测量气体流量的软测量方法。详细阐述了该方法的测量原理、系统构成及特点，体现了在流量测量领域的先进技术和最新方法。实验数据表明了这种方法是准确、可靠的，能够实现在线、自动测量并具有节能的效果，具有较好的应用前景。     

Viscoseal—Pressure Generation and Friction Loss under Turbulent Conditions

A new theory is developed that predicts the sealing coefficient and the friction factor of a viscoseal under turbulent flow conditions. This theory, being a synthesis of Boon and Tal's laminar viscoseal theory and Ng, Pan, and Elrod's turbulent lubrication theory, shows very satisfactory correlation with available experimental data. The results have been given in simplified formulas such that they are readily usable for design purposes. At high Reynolds numbers the seal geometry has been optimized, although performance near the optimum is rather constant for rather different values of the geometrical parameters. Existing theories on the turbulent behavior of the viscoseal are briefly discussed.     

Taylor Vortices–Induced Instability (Transition Flow) versus “Turbulence” in Concentric Cylinders Separated by Microscale Clearances

This paper is concerned with the relationship between the onset and the development of the Taylor instabilities and their treatment as turbulent flows in the most accepted turbulence models (Constantinescu (1); Ng-Pan (2); Hirs (3)) used with the Reynolds equation, in the range of 41.3√R/C < Re < 2000. The authors show that in between these limits there is a transition regime where the velocity and pressure profiles are fundamentally different from either a Couette flow or a fully developed turbulent flow. Thus the issue under consideration is whether the flow formations observed during Taylor instability regimes should be simulated using the widely accepted turbulence models as they presently are modeled in microscale clearance flows. We are considering the flow of light silicone oil in gaps varying from 3.302 mm (0.13 in.) to 0.127 mm (0.005 in.) between two concentric cylinders, with the inner cylinder rotating. The computational engine used in this study is a well-established and a tried software package: CFD-ACE+. It was found that the Taylor vortices (cells) begin to form at certain, but different, “critical” speeds, function of clearance size, and as the speed grows, the vortices become fully developed and evolve further into wavy vortices. Calculations show that both the 1st and 2nd critical Taylor numbers and Reynolds numbers are functions of the clearance size. The Taylor numbers decrease, while the Reynolds numbers increase with the decrease in clearance size. The onset of both instabilities is clearly characterized by the discontinuities in the Torque-√Ta (or Torque – Re) curve slope. The calculations presented here show that the slope changes in the above-mentioned graphs are due to the changes in the average velocity gradient on the outer cylinder and not to a change in the actual viscosity as it is implemented by the turbulence models mentioned above. Finally a comparison is made between present calculations and the data of Roberts (4), Cole (5), Walowit et al. (6), Weinstein (7), Koschmieder (8), and DiPrima (9).     

蜗壳形状对高速部分流泵性能的影响

利用FLUENT6.3.21软件,选择了S-A湍流模型,对同一叶轮配两种蜗壳的高速部分流泵进行了内部流场数值模拟和性能预测,通过比较分析,提出采用矩形螺旋蜗壳能提高关死点扬程,得到较为平坦的扬程曲线,且能提高泵的效率.并通过内部流场分析,解释了引起外特性差异的原因.