前混合磨料水射流除鳞喷嘴混合腔内部流场

基于计算流体动力学多相流混合物模型,应用FLUENT软件对前混合磨料水射流除鳞喷嘴高压水与磨料混合腔内部流场进行数值模拟.比较了不同进料方式对流场均匀性的影响.分析了两侧为高压水入口条件下,磨料入口直径、高压水入口直径、高压水入口位置和角度以及收缩段锥角对流场混合均匀性的影响,得到了影响混合腔内部流场混合均匀性的合理结构参数.数值计算结果表明:入口速度一定的条件下,磨料中进式喷嘴混合腔的混合均匀性优于磨料侧进式喷嘴混合腔.随磨料入口和高压水入口直径增加,混合腔出口的射流速度均增加,但随高压水入口直径增加导致出口磨料浓度呈先增后减的趋势,磨料入口与高压水入口合理的质量流量比值约为3∶4,两侧高压水入口位置对流场混合均匀性影响较小,高压水入口角度和收缩段锥角均为30°时流场性能更佳.      

钢板控冷设备中几种管路结构的喷嘴管出口流量均匀性研究

利用有限元耦合场数值模拟计算方法对某钢厂4200mm轧机的雾化控冷设备中用过的几种管路结构的流场进行了三维稳态数值模拟,得到了不同管路结构下各喷嘴管出口流量的情况。并对这几种结构的喷嘴管出口流量均匀性进行了比较分析。为雾化控冷设备管路结构的设计提供了参考。     

钢板控冷设备中几种管路结构的喷嘴管出口流量均匀性研究

利用有限元耦合场数值模拟计算方法对某钢厂4200mm轧机的雾化控冷设备中使用过的几种管路结构的流场进行了三维稳态数值模拟,得到了不同管路结构下各喷嘴管出口流量的情况。并对这几种结构的喷嘴管出口流量均匀性进行了比较分析。为雾化控冷设备管路结构的设计提供了参考。     

热轧带钢层流冷却过程温度场研究

 建立了热轧带钢层流冷却过程中温度场的三维有限元模型,对3 mm厚带钢轧后冷却过程带钢温度场进行模拟计算,得出卷取温度比现场测量值低9.5 ℃,相对误差为1.42%,验证了模型和假设的合理性。研究了上喷嘴直径对带钢温度的影响,带钢上表面宽度方向上存在2种不同的冷却区域：位于喷嘴正下方层流冷却过程中交替经过冲击区和平流区的区域和位于两喷嘴之间层流冷却过程中只经过平流区的区域,这造成带钢宽度方向上温度分布不均匀。计算结果表明,喷水量保持不变的情况下,存在一个最佳喷嘴直径,使带钢宽度方向上温度分布更均匀。喷水速度保持不变,增加喷嘴的直径有利于带钢宽度上方温度均匀,但增加了喷水量,降低了带钢的卷取温度。     

喷嘴喷淋距离对连铸小方坯二冷均匀性的影响

研究了不同喷淋距离下连铸小方坯二冷喷嘴的水量分布,建立了凝固传热模型分析了82B钢连铸坯的热行为。该模型特别考虑了二冷区铸坯表面宽度方向的水流密度分布,并根据铸坯表面测温结果进行了模型校正。采用凝固传热模型研究了喷嘴喷淋距离对连铸二冷均匀性的影响。结果表明:喷嘴喷淋距离的增加有助于提高二冷水横向分布的均匀性,导致铸坯表面温度横向均匀性降低、纵向均匀性提高。这些效果有助于改善铸坯内部裂纹,但是会对角部裂纹产生不利影响。在二冷区前段喷嘴采用低喷淋距离,二冷区末段采用高喷淋距离,既可以提高铸坯角部温度,又能降低表面最大回温速率,有助于同时改善连铸坯角部和内部裂纹。在此基础上,提出了一种连铸小方坯二冷喷嘴布置方式,即二冷区每段喷嘴喷淋距离沿拉坯方向逐渐增加,该方法有助于提高连铸坯“纵?横”冷却均匀性。      

喷嘴射流特征对连铸二冷区蒸汽膜穿透行为的影响

 连铸二冷区铸坯表面温度通常高于900 ℃,此时喷淋液滴接触高温铸坯时不会湿润铸坯表面,仅在其上形成一层蒸汽膜,阻碍了液滴与铸坯表面接触传热。针对以上问题,以国内某钢厂连铸二冷区的扁平型水喷嘴为原型,建立了喷嘴射流仿真计算模型,并对所建模型进行了理论和实验室验证;采用数值模拟的方法研究了喷嘴自由射流区的流场分布,运用连铸喷嘴冷却检测系统测量获得了射流液滴粒径演变规律;结合数值模拟和实验室测定结果,定量分析了喷嘴在不同水流量下射流液滴冲击铸坯表面蒸汽膜深度的变化规律。结果表明,该喷嘴的最大射流速度在喷嘴出口处,射流在喷嘴出口附近出能维持较大的射流速度,且随着水量的增加,射流保持高射流速度的距离也增长;整体射流的轴向速度占比均在80%以上。当喷淋水量越大时,射流液滴粒径变得越小;随着距喷嘴出口距离的增加,射流中心处的液滴粒径逐渐增大并达到最大值;当水流量为9和12 L/min时,液滴粒径基本相同,这表明当水流量增加到一定值时,冷却水量的增加不影响液滴粒径分布。在不同水流量下,随着喷淋距离的增加,液滴穿透铸坯表面蒸汽膜深度呈先增大后略微减小的变化规律,在喷射距离为100~200 mm范围内时,液滴穿透深度最大,这表明喷射高度在该范围时,喷淋冷却效果最好。     

高炉小模块非金属冷却壁设计参数

小模块冷却壁是将性能优异的耐火材料直接浇铸在平行排列的冷却水管上而形成的一种新型冷却设备。采用ANSYS软件建立了小模块冷却壁温度场计算模型,利用该模型计算了炉气温度为1200~1600℃、冷却水流速为0.5~2.5m/s条件下壁体材质导热系数、水管材质、水管直径、水管间距、冷却水流速及工作环境温度等条件变化时小模块冷却壁的温度分布状况。结果表明,小模块冷却壁对炉气温度变化的适应能力较强,壁体材质导热系数、水管间距、壁体厚度对小模块冷却壁传热性能影响较大,而水管直径、水管材质及水流速的影响较小。     

基于固液两相流模拟的选矿循环水深度澄清装置优化

部分选矿循环水中含一定量的高分散性悬浮颗粒,仅依靠简单浓缩沉降难以澄清,无法达到回用要求。针对这一难题,提出了一种选矿循环水固体悬浮物澄清装置。为优化装置的结构参数与运行参数,建立了选矿循环水深度澄清装置的二维物理模型,基于计算流体力学（CFD）的方法,选用Mixture和RNG k?ε 模型对装置主要的结构参数与运行参数展开了数值模拟研究。研究发现适当降低水力循环区喷嘴长度,增加喉管与喷嘴管径比、颗粒沉降区开口尺寸、装置直径等结构,能够降低颗粒沉降区平均湍动能,由于湍动能为单位质量流体由于紊流脉动所具有的动能,故降低了颗粒沉降区流场的紊流程度,增加了水流的稳定性,提高了装置对悬浮颗粒的去除效果;同时发现降低入口流速、增加悬浮颗粒粒径有助于提高悬浮物的去除率,当进水流速为0.1 m·s?1、经过混凝的悬浮颗粒形成粒径大于100 μm时,装置对选矿循环水中的悬浮颗粒去除效果显著。      

结晶器内冷却器-U形管内流场温度场耦合数值模拟

采用ANSYS有限元通用软件,对设计开发的圆环主半径54 mm、圆柱高180 mm、横向圆柱长45 mm、冷却水初始温度320 K、冷却器内壁温度525 K的内冷却器-U形管内冷却水速度为6～14 m/s时,对流场温度场耦合作用下冷却水流动状况进行数值模拟。结果表明,进口速度太小,易在弯曲区形成涡流,速度太大,易在弯曲区产生更大的流速,对管壁冲击较大,影响其使用寿命;所以内冷却器进口速度在10 m/s时冷却效果最佳。     

攀钢板坯连铸机二冷区喷嘴特性测试

对连铸二冷区喷嘴的冷态特性进行了研究。测定了不同喷水条件下喷嘴的压力一流量关系,喷水密度分布以及喷射角和喷雾粒度分布。分析了国内外喷嘴的特性曲线,为国内厂家生产喷嘴提供了更为合理的参数。     

除尘系统双流量喷嘴的性能试验研究

通过试验研究了除尘系统双流量喷嘴，在喷嘴不同结构参数下气压和水流量变化的特性，分析了喷嘴结构参数、气压、水流量对水压、气耗率、雾化角、颗粒度以及水滴喷出速度的影响规律，优化后的喷嘴有效地改善了烟气冷却不充分的状况。为喷嘴雾化冷却性能的分析研究和优化设计提供了技术途径。     

Water atomisation of metal powders: effect of water spray configuration

ABSTRACT

We consider the effect of water spray configuration on the fineness and uniformity of a metal powder produced by water atomization of a melt stream. The effects of water spray travel distance, nozzle design, water pressure, melt superheat, and apex angle on the particle size distribution of a metal powder is studied via a laboratory-scale water atomizer; the main focus is on the first two, which are usually fixed parameters of the atomizer. Correlations are proposed relating the mass median size and standard deviation of the powder to the parameters cited. Similar correlations for water pressure, melt superheat, and apex angle have been reported elsewhere; we present data on these effects to confirm the validity of our results, especially as Bi-42%Sn powder has not been studied before. What is new are results on the effect of water spray travel distance and nozzle design on the mass median size and standard deviation of powder.     

环缝气流冲击雾化制粉喷嘴流场特性的仿真研究

分析了一种环缝气流冲击雾化制粉喷嘴的结构和工作原理, 并对该雾化喷嘴模型进行了流场分布数值仿真, 研究了不同进气压力和窄缝倾角对流场速度分布的影响。研究结果表明, 从进气管入口到气流冲击雾化喷嘴出口, 加速气流速度保持最大值不变, 在距进气管入口中心线上80 mm位置之后逐渐减小; 随着进气压力的增加, 气流冲击雾化喷嘴出口速度表现出明显的增加趋势, 且仿真结果与理论计算结果误差在10%范围以内。随着窄缝倾角的增加, 负压涡流逐步向进粉管靠近, 回流区、分离区和混合区的最大速度值表现出单调增加的变化规律; 综合考虑气流冲击效果和喷射速度, 确定最优的窄缝倾角50°~60°。     

A numerical study of high-velocity oxygen fuel thermal spraying process. Part I: Gas phase dynamics

A mathematical model is formulated to simulate the effect of operational parameters on the gas dynamics that occur during high-velocity oxygen fuel (HVOF) thermal spraying. Computational fluid dynamic techniques are implemented to solve the Favre-averaged mass, momentum, and energy conservation equations. The renormalization group (RNG) κ-ɛ turbulence model is used to account for the effect of turbulence, and high-order interpolation schemes are employed to resolve compressibility effects in the supersonic jets. The calculated results show that the most sensitive parameters affecting the process are propylene flow rate, total flow rate of oxygen and propylene (oxyfuel flow rate), total inlet gas flow rate, and barrel length. The results show that increasing the total inlet gas flow rate has limited effect on the gas velocity and temperature inside the nozzle for the parameter range investigated in the present study. However, increasing the total inlet gas flow rate increases the total thermal inertia and momentum inertia; moreover, under these conditions the flame gas is retained at a high velocity and temperature for a longer distance. Increasing the oxyfuel flow rate significantly increases flame velocity and temperature, particularly after exiting the nozzle. The effect of propylene flow rate is significant and complex. In order to minimize the extent of the oxidation of the sprayed powder particles and to achieve a high flame temperature and velocity, the overall injected stream should be adjusted to be propylene-rich. The nitrogen flow rate significantly affects the gas flow inside the gun. On the basis of the calculated results, it is evident that, in order to obtain maximum gas velocity and temperature, the nitrogen flow rate should be kept to a minimum, provided that particles can be delivered to the gun in a smooth manner. By minimizing the entrainment of the surrounding air, a nozzle with a longer barrel length achieves a relatively high gas velocity and temperature for a longer distance than does a nozzle with a shorter barrel length. The calculated results are in good agreement with available experimental results.     

A Physical Model Study of Swirl Phenomena in a Top Blown Bath

The present study is focused on swirl motion in a top blown water model, where a deep water swirl motion is observed. During the experiments, the top lance, with cylindrical nozzles, was placed above the water surface and thereby produced an external force on the bath. The effect on how different parameters, such as nozzle diameter and the distance between the bath surface and nozzle exit, i.e. the lance height, affect the swirl motion were studied. More specifically, the amplitude and period of the swirl as well as the starting and damping time of the swirl were determined. The amplitude was found to increase with an increased nozzle diameter and gas flow, while the period had a constant value of about 0.5 s for all nozzle diameters, gas flows and lance heights. The starting time for the swirl motion was found to decrease with an increased gas flow, while the damping time was found to be independent of gas flow rate, nozzle diameter, lance height and ratio of depth to diameter.     

CAS-OB钢包内钢水流场和均匀混合时间

采用水模拟方法研究了有、无浸渍罩情况下CAS-OB钢包内钢水的流场,同时研究了底吹气体流量、底吹位置和浸渍罩插入深度对钢水均匀混合时间的影响.研究结果表明:底吹位置、底吹气体流量、浸渍罩插入深度对均匀混合时间有一定影响,并得到了均匀混合时间与底吹气体流量、底吹位置和浸渍罩插入深度之间的关系.     

旋风风冷冷渣器的结构优化研究

采用Fluent软件,以CFD方法对旋风风冷冷渣器主冷却段内部气固两相流动在不同的实验参数下进行数值模拟,进而得到最优的圆筒长度、圆筒直径以及入口风速,从而提高了冷渣器的性能和冷却效果。     

常化炉后钢板控制冷却均匀性研究

针对炉后空冷区造成的钢板头尾温差问题,提出利用逐渐改变冷却装置水量和调节辊道速度的方法解决钢板长度方向冷却不均匀问题,建立了常化炉后钢板控制冷却温度场模型,通过计算得出,采用上述两种方法后,钢板的头尾温差显著减小。并且利用ANSYS有限元软件优化模块对两种方法的冷却工艺参数进行了优化。为实际生产中常化炉后ACC控冷系统提高钢板冷却均匀性和钢板性能质量提供了理论依据。     

Determining Operating Inlet Pressure Head Incorporating Uniformity Parameters for Multioutlet Plastic Pipelines

An important objective of a microirrigation system is to determine the proper operating inlet pressure head, ensuring the desired level of water application uniformity as well as the allowable pressure head variation along the multioutlet pipeline. This paper offers, simple, direct, but sufficiently accurate, relationships incorporating different microirrigation uniformity parameters, such as Christiansen uniformity coefficient, coefficient of variation of emitter discharge, and allowable pressure head variation, to determine the operating inlet pressure head (i.e., pressure head and outflow profiles) for multioutlet plastic pipelines. In this analysis some mathematical expressions were deduced to relate three uniformity parameters; then the operating inlet pressure head is simply reformulated by taking into account a multiplying factor α to the required average outlet pressure head, in terms of three uniformity parameters. Resulting, the influence of different uniform pipe slopes on the water application uniformity and the operating inlet pressure head for various emitter discharge exponents, was evaluated. In addition, to cover various design combinations an extensive comparison between the proposed equations and those of the previous studies was also presented. Examination of the results from this research indicated that, the performance of the proposed technique is sufficient in comparison to those of the recent analytical and numerical procedures.     

Study of transient flow and particle transport in continuous steel caster molds: Part I. Fluid flow

Unsteady three-dimensional flow in the mold region of the liquid pool during continuous casting of steel slabs has been computed using realistic geometries starting from the submerged inlet nozzle. Three large-eddy simulations (LES) have been validated with measurements and used to compare results between full-pool and symmetric half-pool domains and between a full-scale water model and actual behavior in a thin-slab steel caster. First, time-dependent turbulent flow in the submerged nozzle is computed. The time-dependent velocities exiting the nozzle ports are then used as inlet conditions for the flow in the liquid pool. Complex time-varying flow structures are observed in the simulation results, in spite of the nominally steady casting conditions. Flow in the mold region is seen to switch between a “double-roll” recirculation zone and a complex flow pattern with multiple vortices. The computed time-averaged flow pattern agrees well with measurements obtained by hot-wire anemometry and dye injection in full-scale water models. Full-pool simulations show asymmetries between the left and right sides of the flow, especially in the lower recirculation zone. These asymmetries, caused by interactions between two halves of the liquid pool, are not present in the half-pool simulation. This work also quantifies differences between flow in the water model and the corresponding steel caster. The top-surface liquid profile and fluctuations are predicted in both systems and agree favorably with measurements. The flow field in the water model is predicted to differ from that in the steel caster in having higher upward velocities in the lower-mold region and a more uniform top-surface liquid profile. A spectral analysis of the computed velocities shows characteristics similar to previous measurements. The flow results presented here are later used (in Part II of this article) to investigate the transport of inclusion particles.