Effect of rotor-mounted protrusion on sealing performance and flow structure in rotor-stator cavity

This paper presents an experimental investigation on the effect of protrusion radial position and height on the sealing performance and flow structure in the rotor-stator cavity. The rotor-mounted protrusions are assembled at three radial positions and are set to three heights. The cavity is equipped with three rim seals: a radial seal, an axial seal and a seal with double fins on the stator. The annulus Reynolds number is set at $4.39\times {10}^5$ and the rotational Reynolds number ranges from $7.51\times {10}^5$ to $1.20\times {10}^6$. Heat and mass transfer analogy is applied. Pressure and ${\mathrm{C}\mathrm{O}}_2$ concentration are measured. The experimental results show that in cavities with different rim seals, radial distributions of the sealing efficiency, pressure and swirl ratio are basically the same. The sealing performance is improved by protrusions compared with the cavity without protrusion and improves with the increase of protrusion radial position and height. The effect of protrusion increases with the increase of the rotational Reynolds number. The windage loss and the flow resistance introduced by protrusions are investigated. It is found that induced windage loss and flow resistance decrease with the increase of protrusion radial position but increase with the protrusion height.     

Validation of the RANS-simulation of laminar separation bubbles on airfoils

This paper presents RANS simulations of the low-Reynolds-number flow past an SD7003 airfoil at $\mathit{Re}=6\times {10}^4$, where transition takes place across a laminar separation bubble. The transition prediction procedure using an approximate envelope method as well as a linear stability solver is discussed. The numerical results are validated against PIV- and force measurements obtained in several wind- and watertunnels and are also compared to XFOIL results. Good agreement is found within the operational range of the airfoil.     

Intrinsic component filtering for fault diagnosis of rotating machinery

Fault diagnosis of rotating machinery has always drawn wide attention. In this paper, Intrinsic Component Filtering (ICF), which achieves population sparsity and lifetime consistency using two constraints: $l_{1/2}$ norm of column features and $l_{3/2}$ -norm of row features, is proposed for the machinery fault diagnosis. ICF can be used as a feature learning algorithm, and the learned features can be fed into the classification to achieve the automatic fault classification. ICF can also be used as a filter training method to extract and separate weak fault components from the noise signals without any prior experience. Simulated and experimental signals of bearing fault are used to validate the performance of ICF. The results confirm that ICF performs superior in three fault diagnosis fields including intelligent fault diagnosis, weak signature detection and compound fault separation.     

Influences of milling and grinding on machined surface roughness and fatigue behavior of GH4169 superalloy workpieces

Surface topography of superalloy GH4169 workpieces machined by milling and grinding is different significantly. Meanwhile, surface roughness, as one of the main indicators of machined surface integrity, has a great influence on the fatigue behavior of workpieces. Based on analyzing the formation mechanism and characteristics of surface roughness utilizing different machining processes and parameters, the machined surface roughness curve can be decoupled into two parts utilizing frequency spectrum analysis, which are kinematic surface roughness curve and stochastic surface roughness curve. The kinematic surface roughness curve is influenced by machining process,parameters, geometry of the cutting tool or wheel, the maximum height of which is expressed as R'_z.By subtracting the kinematic part from the measurement curve, the stochastic surface roughness curve and its maximum height R'_zcan be obtained, which is influenced by the defects of cutting tool edge or abrasive grains, built-up edges(BUE), cracks, high frequency vibration and so on. On the other hand, the results of decoupling analysis of surface roughness curves indicate that Raand Rz values of milling GH4169 are 2–5 times and 1–3 times as high as those of grinding, while R'_zvalue of milling is 13.85%–37.7% as high as that of grinding. According to the results of fatigue life tests of specimens machined by milling and grinding, it can be concluded that fatigue behavior of GH4169 decreases with the increase of R'_zmonotonically, even utilizing different machining processes.     

Frictional behavior during cold ring compression process of aluminum alloy 5052

The friction is the considerable boundary condition in bulk metal forming. In this paper, the ring compression test was used to evaluate the friction coefficient and factor in Coulomb friction model and Tresca friction model for the plastic deformation of aluminum alloy AA5052. The micro-macro analysis method combining surface morphology and micro-texture was used to explore the friction behaviors in AA5052 cold forming process. In general, the magnitude (μ or m) of friction changes before and after a deformation threshold during ring compression. The maximum change rate of the magnitude (μ or m) before and after the deformation threshold is close to 18.5% under the present experimental conditions, and the change rate decreases with increasing loading speed. The lubrication using MoS₂ is better than that using oil at lower speeds (0.15 mm/s, 1.5 mm/s), but the lubrications for MoS₂ and oil are similar at higher speeds (15 mm/s). The surface roughness, three-dimensional topography, and surface texture of compressed ring have a sudden change around the deformation threshold, which deviate from the previous evolution trend. The increased friction after deformation threshold also promotes the formation of sufficient shear strain layer in the subsurface plane of the compressed ring, and then it hinders the formation of the typical deformation textures with β-oriented line and promotes the appearance of shear textures such as $\left\{\text{001}\right\}〈\text{110}〉$, $\left\{\text{111}\right\}〈\mathit{uvw}〉$ and $\left\{\mathit{hkl}\right\}〈110〉$ textures.