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风扇/轴流压气机最大负荷设计技术探索
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摘要
无论是国防、民用领域的巨大需求驱动,还是遵循叶轮机气动理论和技术的内在发展逻辑,高负荷叶轮机始终是重要发展趋势,力求最大负荷设计是叶轮机气动理论和设计技术研究的永恒主题。
     基于对风扇/轴流压气机流动机理及设计流程的认识,本文首次尝试对“什么是最大负荷设计”、“怎样实现最大负荷设计”进行全面地阐释,从基元叶型、叶片基元展向匹配、叶片排排间匹配三个层面分别展示了可使风扇/轴流压气机负荷最大化的技术方向和技术内涵。
     一、基元叶型方面,大折转角(亚音)、有限分离(超音)设计是最大负荷设计的努力方向。本文发展了适用于以大折转角为特征的低损失亚音叶型设计方法并编制了相应程序。该方法包含叶片造型及准三维流场分析两部分,论文工作侧重于发展一种特定的叶片造型方法,它基于一种专利叶型厚度分布,依靠调整叶型中弧线弯度分布规律实现负荷最大化的目标。
     二、叶片基元展向匹配方面,本研究从影响负荷最大化的叶身展向积迭(注:原指掠弯是裕度定制的一部分,为方便论述,本文将此统一论述为裕度定制)、叶尖间隙、叶片与端壁角区这三个最重要因素出发,探讨了各因素影响负荷最大化的机理,并由此给出了最大负荷设计过程中的技术措施和努力方向。
     1)从掌控风扇/轴流压气机裕度方法回顾入手,探析了美国和俄罗斯裕度控制方法及相应特点,结合对“掠/弯”因素的认识提出了裕度定制技术:并开发了能够体现裕度定制思想的二维特性预估方法,可在二维层面下方便快捷地考虑以掠/弯为代表的叶片基元展向积迭以及叶片排间轴向间距带来的影响;
     2)借鉴Denton关于不可压叶尖泄漏损失的理论分析,推导出适用于可压缩流动的叶尖泄漏掺混损失计算的基本关系式。在仅考虑泄漏掺混损失情况下,对叶尖基元负荷、间隙、泄漏流量系数整体水平及这些参数的弦向分布等因素的影响进行了理论和数值分析。并基于此对风扇/轴流压气机中叶尖流动控制技术进行了阐述和分析,从叶尖泄漏流控制方面为最大负荷设计提供技术指导:
     3)基于角区流动为叶表与端壁附面层交汇流动的物理认识,假设忽略附面层内二次流影响,并且将角区内三维附面层流动等效为二维附面层,建立了角区流动分离预测模型,提出了角区流动控制技术。依据该模型对目前风扇/轴流压气机设计中采用的各种角区分离控制技术进行了分析。
     三、叶片排排间匹配方面,除了裕度定制中所涉及的正在日渐成熟的二维、三维定常方法外,缘线匹配是全方位考虑排间匹配的设计自由度。文中以关注不同缘线匹配对压气机的气动、振动影响为出发点,采用数值方法,利用进口边界尾迹和真实叶片两种模型考察了上游叶片尾迹撞击下游叶表的展向轨迹及其在气动和振动方面的影响。研究指出,尽管目前数值模拟研究仍未发现单组缘线匹配存在显著气动影响,但缘线匹配却在控制叶片振动、气动噪声方面显现潜力。
Whether driven by great demands from national defense and civilian fields, or following internal evolution logic of aerodynamic theory and techniques of turbomachinery, high-loaded turbomachinery is always an important development trend, and then, striving hard to maximum loading design is permanent topic in researches on aerodynamic theory and design techniques of turbomachinery.
     Based on knowledge of flow mechanisms and design process for fan and axial-flow compressor, this dissertation firstly attempted to explain roundly what "maximum loading design" is and how to develop "maximum loading design". Preliminary explorations on maximum loading design techniques were developed through three aspects such as blade airfoil shape, radial matching between blade sections, and stage matching between blade rows. Main research work would be listed as follows:
     1. As to blade airfoil shape design, large turning angle blade (subsonic) and restricted separated blade (supersonic) are the two effort aspects. In the dissertation, a design method of large turning angle subsonic airfoil for use in stator hub section was developed. The method includes quasi-three-dimensional flow analysis, and blade contouring method which the dissertation focused on. Firstly, blade airfoil shape was contoured by adjusting metal angle distribution combined with special thickness distribution from a U.S. patent, and then the blade-to-blade flow was computed by solving the two-dimensional steady Navier-Stokes equations, finally, overall performance and internal flowfield characterization were obtained and analyzed.
     2. As to radial matching between blade sections, preliminary investigations were developed from three aspects such as stall margin customizing technique, control technology of tip clearance flow, prediction model and control technology of corner separate.
     a) On basis of reviewing on methods of achieving the goal of stall margin in design process of fan and axial-flow compressor, in conjunction of understandings on "Sweep/Dihedral", stall margin customizing technique was put forward; two-dimensional performance prediction method for stall margin customizing was developed, it can consider influences of radial stacking patterns of blade sections and axial distances between blade rows conveniently and rapidly.
     b) A simple model for tip leakage mixing loss of unshrouded blades for compressible flow was presented. The work drew ideas, was based on the theoretical analysis of the loss by Denton. Relationship for computing the loss is derived, in terms of blade surface static pressure, chordwise distribution of tip clearance, discharge coefficient and total pressure loss coefficient in the tip region. Parameter studies reveal average level and chordwise distribution of the above factors' contribution to the loss. Finally, combined with conclusions obtained above, explanations were given to various control technology of tip clearance flow.
     c) Based on the physical intuition of that the three-dimensional corner boundary layer is the conflux of both blade and end wall boundary layer, with assumptions of ignoring the cross flow effect and three-dimensionality of the nearby main flow, an equivalent two-dimensional corner boundary layer was put forward to predict the behavior of corner boundary layer. And then, a corner separate criterion was established using the boundary layer separate criteria. Finally, combined with conclusions obtained above, explanations were given to various control technology of comer separate.
     3. As to stage matching between blade rows, besides growing steady two-dimensional and three-dimensional methods which can could be dealt with by stall margin customizing technique, edge matching is a proper choice for guiding design to consider stage matching. Numerical investigations were presented in order to better understand the influences of edge matching on unsteady flow and performance of fan and axial-flow compressors, moreover, influences of edge matching on vibration and rotor/stator interaction noise were investigated preliminarily.
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