基于雷诺平均Navier-Stokes方程的表面传热系数计算

采用有限体积法数值求解控制二维绕流的雷诺平均Navier-Stokes(RANS)方程组,计算了光滑和粗糙NACA0012翼型以及圆柱表面的局部表面传热系数.分析了近壁面网格间距、湍流模式和表面粗糙度模型对数值计算结果的影响.结果表明:切应力输运(SST)湍流模型能够区分层流和湍流边界层的对流传热特性,并能预测转捩的发生;采用Spalart-Allmaras(S-A) 扩展模型能够计算粗糙壁面的对流传热系数,但采用忽略转捩函数的S-A模型不能有效计算层流边界层的传热系数.当近壁面网格间距接近10-5量级的黏性子层时,在光滑和粗糙壁面都能得到准确的传热系数分布.结合合适的近壁面网格间距,湍流模式和表面粗糙度模型可以得到与实验数据十分接近的表面传热系数曲线.通过与求解不可压缩RANS方程得到的结果比较后发现,不可压缩RANS方程主要忽略了压缩和黏性耗散效应,这种效应可以通过绝热升温项的形式并入总体热分析.      

Vortex dynamics and entropy generation in separated transitional flow over a compressor blade at various incidence angles

The transition process within a Laminar Separation Bubble（LSB） that formed on a compressor blade surface was investigated using Large Eddy Simulations（LESs） at a Reynolds number of 1.5×10⁵ and incidence angles of 0°,+3°,and+5°.The vortex dynamics in the separated shear layers were compared at various incidence angles and its effects on the loss generation were clarified through entropy analysis.Results showed that transition onset,which was accurately identified by the Linear Stabilit...     

Leading-edge flow separation control over an airfoil using a symmetrical dielectric barrier discharge plasma actuator

In order to promote an in-depth understanding of the mechanism of leading-edge flow separation control over an airfoil using a symmetrical Dielectric Barrier Discharge(DBD) plasma actuator excited by a steady-mode excitation, an experimental investigation of an SC(2)-0714 supercritical airfoil with a symmetrical DBD plasma actuator was performed in a closed chamber and a low-speed wind tunnel. The plasma actuator was mounted at the leading edge of the airfoil.Time-resolved Particle Image Velocimetry(PIV) results of the near-wall region in quiescent air suggested that the symmetrical DBD plasma actuator could induce some coherent structures in the separated shear layer, and these structures were linked to a dominant frequency of f0= 39 Hz when the peak-to-peak voltage of the plasma actuator was 9.8 kV. In addition, an analysis of flow structures without and with plasma actuation around the upper side of the airfoil at an angle of attack of18° for a wind speed of 3 m/s(Reynolds number Re = 20000) indicated that the dynamic process of leading-edge flow separation control over an airfoil could be divided into three stages. Initially, this plasma actuator could reinforce the shedding vortices in the separated shear layer. Then, these vortical structures could deflect the separated flow towards the wall by promoting the mixing between the outside flow with a high kinetic energy and the flow near the surface. After that, the plasma actuator induced a series of rolling vortices in the vicinity of the suction side of the airfoil, and these vortical structures could transfer momentum from the leading edge of the airfoil to the separated region, resulting in a reattachment of the separated flow around the airfoil.     

超临界翼型跨声速激波振荡数值模拟

应用DES(detached eddy simulation)方法研究了SC(2)-0714超临界翼型跨声速自维持激波振荡现象.使用的DES方法预测了激波在翼型上表面的周期性运动,分析了雷诺数对激波运动的减缩频率、平均激波位置、脉动压力系数等非定常特性的影响.结果表明:雷诺数对激波振荡运动特性的影响呈非线性关系;而雷诺数为6×106时的激波振荡运动特性与雷诺数分别为15×106及30×106时的特性存在明显差异.      

Investigation on surface integrity of electron beam melted Ti-6Al-4 V by precision grinding and electropolishing

Electron beam melting (EBM), as an excellent Additive Manufacturing (AM) technology, enables the printing of Ti-6Al-4 V alloy for a wide range of applications such as aerospace and biomechanical industries. It improves functionality and integrity of components and negates complexities in assembly processes. However, due to the poor surface and sub-surface integrity represented by the rough surface finish and low dimensional accuracy, achieving a favorable surface condition is quite challenging. Therefore, post processing becomes essential for these electron beam melted (EBM-ed) Ti-6Al-4 V alloys. Being the most common technique to improve such parts, milling of Ti-6Al-4 V alloy is very challenging and resulting tool wear issues, due to its unique material properties. Thus, this paper presents a comprehensive study on the surface integrity of EBM-ed Ti-6Al-4 V parts processed by precision grinding and electropolishing, aiming to qualitatively and quantitatively clarify the interrelation between process parameters and processed surface quality. The surface and subsurface characteristics such as profile accuracy, surface roughness, microstructure, defective layer and residual stress before and after post processing were compared and evaluated. The results show that by precision grinding, the profile accuracy was improved from over 300 µm PV to 7 µm PV, while surface roughness (R_a) was reduced from 30 µm to about 2 µm. The layer with partially melt particles was removed, but introduced a deformed subsurface layer with more residual stress. Then by applying electropolishing, the residual stress was released and the deformed layer was removed. In addition, R_a was further reduced to 0.65 µm. The research can serve as a reference for the integration of post machining processes with AM.     

Experimental and modeling study of surface topography generation considering tool-workpiece vibration in high-precision turning

High-precision turning(HPT) is a main processing method for manufacturing rotary high-precision components, especially for metallic parts. However, the generated vibration between tool tip and workpiece during turning may seriously deteriorate the surface integrity. Therefore,exploring the effect of vibration on turning surface morphology and quality of copper parts using3D surface topography regeneration model is crucial for predicting HPT performance. This developed model can update the machin...     

基于熵产理论的水翼空化特性研究

为了对空化流场中的能量损失做出定向、定量的评价,引入熵产理论对绕二维水翼流场进行了分析。以NACA0009翼型为计算模型,选用k-ω湍流模型以及ZGB空化模型对翼型的外特性进行了数值仿真并与实验结果进行了对比,发现计算结果与实验结果符合较好。仿真结果表明,熵产与翼型外特性之间有明显的相关性,在升力系数和阻力系数发生突变的时候,熵产和能量损失也发生剧烈变化;在流场中湍流耗散熵产始终占80%以上,大空化数下壁面熵产占比在10%左右,不可以忽略;能量损失总是集中分布在空穴的末端和翼型的尾端;空化数在0.6～0.4时,空穴会发生大尺度周期性脱落,造成流场的损失增大,但是当空化数0.4时,空穴变得比较稳定,使得流场比较稳定,损失减小。分析表明,熵产理论可以应用于空化流场分析中。     

粗糙壁面诱导的流动转捩数值模拟方法

为预测粗糙壁面诱导的流动转捩,对Langtry提出的γ-Re_θ转捩模型增加粗糙壁面的比耗散率和涡黏性的边界条件,并对模型中的经验关联函数——转捩动量厚度雷诺数进行修正,引入等效沙粒表面粗糙度作为变量,使模型具有一定的预测粗糙壁面诱导的流动转捩的能力.对粗糙平板自然转捩算例和变压力梯度平板绕流算例进行数值模拟,计算结果与风洞实验数据符合的较好.主要结论如下:表面粗糙度一般会增加边界层内的传热系数和阻力系数,同时使层流到湍流的转捩位置提前;自然转捩的转捩位置受表面粗糙度影响较大,与光滑壁面相比,平板算例中0.15mm的表面粗糙度使转捩位置提前40%;分离诱导转捩的转捩位置受表面粗糙度影响较弱,随着表面粗糙度逐渐增加,转捩位置和分离泡位置略有后移,且分离泡强度逐渐减弱,分离泡之后的阻力系数增加.      

Improving profile accuracy and surface quality of blisk by electrochemical machining with a micro inter-electrode gap

Electrochemical machining (ECM) has emerged as an important option for manufacturing the blisk. The inter-electrode gap (IEG) distribution is an essential parameter for the blisk precise shaping process in ECM, as it affects the process stability, profile accuracy and surface quality. Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk. To achieve micro-IEG (<50 μm) blisk finishing machining, this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration. The modelling and simulation of the blisk micro-IEG machining have been carried out. Exploratory experiments of variable-parameters blisk ECM were carried out. The results illustrated that the IEG width reduced with the progress of variable parameter process. The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 μm and 21 μm, respectively. The profile deviation for the blade’s concave surface and convex surface are 49 μm and 35 μm, while the surface roughness reaches R_a = 0.149 μm and R_a = 0.196 μm, respectively. The profile accuracy of the blisk leading/trailing edges was limited to within 91 μm. Compared with the currently-established process, the profile accuracy of the blade’s concave and convex profiles was improved by 50.5 % and 53.3 %, respectively. The surface quality was improved by 53.2 % and 50.9 %, respectively. Additionally, the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution. Some electrolytic products were dispersed on the machined surface, and their components were mainly composed of the carbide and oxide products of Ti and Nb elements. The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM, which can be used in engineering practice.     

翼型大攻角绕流的数值模拟

以求解二维N-S方程数值模拟NACA0012翼型大攻角状态的可压绕流特性;N-S方程是在贴体坐标系中给出的,以代数方法生成C型网格系统。采用LU-ADI格式计算,为提高格式的稳定性在隐式和显式部分分别添加了2阶和4阶人工粘性项。应用BaldwinLomax湍流二层代数模型模拟了大攻角时前缘分离涡的形成,旋涡对流及其非定常现象。在某些Mach数和攻角下NACA0012翼型的湍流解具有周期性。通过比较,本文数值计算结果同实验及国外相应的数值计算结果基本吻合。     

压气机叶片加工误差影响不确定分析

为了正确评估加工误差的影响,提出了一种考虑加工误差大小、分布随机性的数值研究方法以实现叶片性能不确定性分析。采用NURBS(非均匀有理B样条) 方法实现叶型参数化,通过检测及统计手段获取误差真实分布,运用蒙特卡洛模拟生成随机样本,并训练Kriging代理模型进行不确定性分析,得到了叶片加工误差对气动性能的影响。结果表明:加工误差对气动性能的影响与所处工况有关,最高使得损失增加0.853%;叶型性能对于吸力面表面型线更为敏感,在加工及检测过程应给予更高要求。      

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.     

可压缩紊流分离边界层的计算

本文介绍了一种求解二维可压缩紊流分离边界层的正反积分方法。该方法以边界层动量积分方程和平均流动能积分方程作为基本方程,采用适用于贴附和分离紊流的Swafford速度型解析式,对比计算了四种代数涡流粘性模型对沿流向各点的耗散积分及诸边界层特征参数的影响。计算结果和存在激波边界层较强干扰的跨音速翼型边界层的测量数据吻合。该方法可扩展用于计算翼型的尾迹特性。     

Assessment and improvement of k-ω-γ model for separation-induced transition prediction

The purpose of this work is to improve the k-ω-γ transition model for separationinduced transition prediction. The fundamental cause of the excessively small separation bubble predicted by k-ω-γ model is scrutinized from the perspective of model construction. On the basis,three rectifications are conducted to improve the k-ω-γ model for separation-induced transition.Firstly, a damping function is established via comparing the molecular diffusion timescale with the rapid pressure-strain timescale...     

Unsteady experimental and numerical investigation of aerodynamic performance in ultra-high-lift LPT

Detailed experimental and numerical investigations were performed for an ultra-high-lift front-loaded low-pressure turbine cascade (Zw = 1.58) with periodic wakes. The interaction mechanisms between the incoming wakes and endwall secondary flow were carefully examined. Wakes were produced by moving upstream rods, and flow field downstream of the cascade was measured using a seven-hole probe. Experimental results revealed that incoming wakes influenced not only the boundary layer development of the blade suction surface but also the complex endwall secondary vortex structures. On the suction surface: Incoming wakes clearly suppressed the suction side separation bubble at a low Reynolds number of 25000. Nevertheless, the effects of different wake passing frequencies were not significantly different at Re = 100000, and the profile losses under wake passing were even greater than in the absence of wakes. At the endwalls: Incoming wakes more strongly suppressed secondary flow at Re = 100000 than at Re = 25000, because the low-momentum fluid inside the incoming wakes clearly increased the endwall cross-passage pressure gradient at Re = 25000. The experimental results indicated that periodic wakes decreased the passage vortex and counter vortex core strength by 25% and 30%, respectively, at Re = 100000. Instantaneous results also demonstrated that endwall secondary vortices decreased significantly near the position of wakes passing.     

压气机叶片粗糙度对其性能衰退的影响研究

利用标准叶型数据进行压气机建模,对建立的模型进行了验证,证明模型是有效的。基于等价雷诺数修正原理,通过仿真方法定量研究了压气机叶片由于积垢沉淀等因素引起粗糙度增大,从而导致其性能的衰退情况。仿真结果表明,当压气机叶片表面粗糙度增大时,压气机主要特性参数都不同程度的减小,使压气机总体性能下降。     

基于局部拟合的压气机叶片加工坐标生成方法

建立了基于前缘局部拟合技术生成叶片加工坐标的方法。包括网格插值、造型逼近、局部拟合和叶型光顺等步骤。以某多级高效率高负荷轴流压气机第2级转子为例,通过几何分析与计算流体动力学分析检验了该方法。结果验证了所生成的加工坐标的几何准确性,且对叶片热转冷有限元分析,本文方法所需的网格数量比现有技术节省约75%,计算时间节省75%以上。本文方法相比现有技术可提高工作效率,更好满足工程需求。     

Aerodynamic characteristics of unsymmetrical aerofoil at various turbulence intensities

A series of wind tunnel tests were performed to investigate the effect of turbulent inflows on the aerodynamic characteristics of the unsymmetrical airfoil at various turbulence intensities and Reynolds number. To assess the aerodynamic characteristics, surface pressure measurements were made over the unsymmetrical airfoil surface by using a simultaneous pressure scanner MPS4264 of Scanivalve make. Self-generated passive grids made of parallel arrays of round bars were placed at four different locations to generate various Turbulence Intensities (TI) in the wind tunnel. The location of the passive grid has been normalized in terms of considering the distance between the entry of the test section and the leading edge of the model. Based on the wind tunnel results, by comparing the baseline without grid low turbulence case TI = 0.51% with other turbulence generated cases like TI = 4.68%, 4.73%, 6.04% and 8.46% at different Reynolds number, it is found that the coefficient of lift increases with the increase in the turbulence intensity. Results also reveal that the flow featuring turbulence can effectively delay the stall characteristics of an airfoil by attaching the flow over the airfoil for an extended region. Additionally, attempts were made to understand the influence of turbulence on the aerodynamic hysteresis.     

Surface integrity and fatigue behavior when turning γ-TiAl alloy with optimized PVD-coated carbide inserts

This paper presents a comprehensive investigation on the effects of tool and turning parameters on surface integrity and fatigue behavior in turning c-Ti Al alloy. The wear of inserts surface, cutting forces, and surface roughness were studied to optimize PVD-coated carbide inserts.Surface topography, residual stresses, microhardness, and microstructure were analyzed to characterize the surfaces layer under different turning parameters. Surface integrity and fatigue life tests of c-Ti Al alloy were conducted under turning and turning-polishing processes. The results show that compared to CNMG120412-MF4, CNMG120408-SM is more suitable because it obtained low cutting force, surface roughness, and tool wear. With increasing the cutting speed and depth, the depths of the compressive residual stress layer, hardening layer, and plastic deformation layer increased. For turning and turning-polishing specimens, the compressive residual stress was relaxed by less than 20%–30% after 10~7 cycles. The fatigue life of a turning-polishing specimen with R_a= 0.15 mm has increased 3 times from that of a turning specimen with R_a= 0.43 mm.     

吸附式压气机转子叶片气动优化设计

进行吸附式压气机转子叶片气动设计方法研究.提出通过迭代设计,应用三维流场计算结果提供S₂流面通流计算损失模型,提高了S₂流面流场计算精度;将最优化方法与数值模拟技术相结合,建立吸气与型面耦合的回转面二维叶型优化设计和三维叶片优化设计软件;应用所构建的设计软件,进行吸附式压气机转子设计,数值模拟结果表明:该转子在0.86的叶尖载荷下,设计点总压比为1.631、等熵效率为0.965,实现了高气动性能.