铝熔体吹气发泡过程的水模拟研究
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摘要
采用水模拟方法结合泡沫铝的实际发泡实验对铝熔体的吹气发泡过程进行了研究。应用高速摄影技术记录气泡在聚乙烯醇水溶液中的形成与上升过程,分析气泡形状、体积和运动速度的变化规律;探讨气体流速、孔径、出气口运动速度等工艺参数对气泡上升运动与分布的影响。结合铝熔体发泡实验,预测并验证了气流量、压强、流速、出气口距没入液面的深度、出气口的运动速度等工艺参数对气泡尺寸的影响。研究出气管内压力降对出气管首尾两端生成的气泡升至液面后尺寸差别的影响。通过对气泡进行受力分析,推导气泡在充气膨胀阶段结束时的尺寸预测模型。
研究结果表明:气泡的生成分为膨胀和脱离两个阶段,在充气膨胀阶段其形状为椭球体,当气泡完全脱离出气口后,其形状变为扁球体。气泡在水溶液中的极限上升速度为382 mm/s。静态流场中,单个气泡的上升运动轨迹为周期和振幅逐渐增大的螺旋形曲线,气流量(0.025~0.075 L/min)与出气口距没入液面的深度(150~330 mm)越大、出气口直径(0.2~0.3 mm)越小时,气泡的摆动振幅越大。动态流场中,气泡群在出气管横截平面内呈正弦规律分布,提高出气管运动速度能使气泡群在发泡室中的分布更加均匀。
当出气口的运动速度由0增加至366 mm/s时,铝熔体表面气泡直径由10.44减小到2.59 mm,水溶液表面气泡直径由3.38减至2.65 mm,当出气口运动速度为366 mm/s时,水模拟预测值和泡沫铝胞直径的相对误差为10.17%。当气流量由0.025增至0.075 L/min时,预测气泡直径由2.48增至2.93 mm(增加了18.14%),泡沫铝胞直径由2.62增至3.61 mm(增加了34.79%)。当水溶液的粘度由2.27变为16 mPa?s时,气泡的直径由2.33增大至2.48 mm。随着出气口距没入液面深度的逐渐增加(150~330 mm),水溶液表面气泡直径逐渐变大(2.25~2.57 mm),考虑静压力差异并修正后,胞直径与预测值的相对误差由15.45%减小至3.22%。出气管首端出气口生成的气泡比尾端出气口生成的气泡尺寸大(2.72~6.24%),且气流量越大、气道长度越长、管道内径越小,出气管首尾两端出气口生成的气泡尺寸差别越大。
Through water simulation experiment combine with aluminum foaming experiment, the foaming process of aluminum melt was studied. Using high speed photography technology recorded the bubble formation and ascension in the PVA solution. Analyze bubble shape, size and velocity variation. Study the bubble trajectory distribution with different gas flow rate, orifice diameter and stir speed. Combining with aluminum foaming experiment, the influence of bubble size on different processing parameter was studied. The influence of pressure decrease on surface bubble diameter was studied. Through force analysis on the bubble, the bubble size prediction model was derived.
The experiment results indicate that the bubble is the ellipse spheroid during the process of expanding. When the bubbles completely out of orifice, their shape change into flat sphere. The limit speed of bubble during ascent in the PVA is 382 mm/s. In the static flow field, the rising trajectory of a single bubble is a spiral curve with increasing period and amplitude. when the single hole incidence airflow discharge(0.025~075 L/min), the immersion depth increase from 160 to 330 mm and the orifice diameter changing from 0.3 to 0.2 mm, the bubble oscillation amplitude increased. In the dynamic flow field, the bubbles were sinusoidal distribution in the foaming room, and increase the velocity of air tube can improve the uniformity of bubbles.
When the biggest linear velocity of air tube is increase from 0 to 366 mm/s, the bubble diameter of water simulation is reduced from 3.38 to 2.65 mm and the bubble diameter of aluminum reduced from 10.44 to 2.95 mm. The relative error of simulation and experiment is 10.17% with the velocity of air tube is 366 mm/s. When the air flow is increase from 0.025 to 0.075 L/min, the bubble diameter of water simulation is increased from 2.48 to 2.93 mm and the bubble diameter of aluminum increased from 2.62 to 3.61 mm. The water experiment results indicate that when the liquid viscosity changing from 2.27 to 16 mPa.s, the bubble diameter increases from 2.33 to 2.48 mm. When the immersion depth of the orifice increase from 150 to 330 mm, the bubble diameter of water simulation is increase from 2.25 to 2.57 mm, and the bubble diameter of aluminum is 2.732 mm, Consider the static pressure, The relative error of experiment and simulation reduced from 15.45 to 3.22%. The bubble generated from the first size of air tube is bigger than the other side (2.72~6.24%). Increase the air flow and the length of air tube or reduce the pipe diameter, the inconsistent of bubble size is greater.
研究结果表明:气泡的生成分为膨胀和脱离两个阶段,在充气膨胀阶段其形状为椭球体,当气泡完全脱离出气口后,其形状变为扁球体。气泡在水溶液中的极限上升速度为382 mm/s。静态流场中,单个气泡的上升运动轨迹为周期和振幅逐渐增大的螺旋形曲线,气流量(0.025~0.075 L/min)与出气口距没入液面的深度(150~330 mm)越大、出气口直径(0.2~0.3 mm)越小时,气泡的摆动振幅越大。动态流场中,气泡群在出气管横截平面内呈正弦规律分布,提高出气管运动速度能使气泡群在发泡室中的分布更加均匀。
当出气口的运动速度由0增加至366 mm/s时,铝熔体表面气泡直径由10.44减小到2.59 mm,水溶液表面气泡直径由3.38减至2.65 mm,当出气口运动速度为366 mm/s时,水模拟预测值和泡沫铝胞直径的相对误差为10.17%。当气流量由0.025增至0.075 L/min时,预测气泡直径由2.48增至2.93 mm(增加了18.14%),泡沫铝胞直径由2.62增至3.61 mm(增加了34.79%)。当水溶液的粘度由2.27变为16 mPa?s时,气泡的直径由2.33增大至2.48 mm。随着出气口距没入液面深度的逐渐增加(150~330 mm),水溶液表面气泡直径逐渐变大(2.25~2.57 mm),考虑静压力差异并修正后,胞直径与预测值的相对误差由15.45%减小至3.22%。出气管首端出气口生成的气泡比尾端出气口生成的气泡尺寸大(2.72~6.24%),且气流量越大、气道长度越长、管道内径越小,出气管首尾两端出气口生成的气泡尺寸差别越大。
Through water simulation experiment combine with aluminum foaming experiment, the foaming process of aluminum melt was studied. Using high speed photography technology recorded the bubble formation and ascension in the PVA solution. Analyze bubble shape, size and velocity variation. Study the bubble trajectory distribution with different gas flow rate, orifice diameter and stir speed. Combining with aluminum foaming experiment, the influence of bubble size on different processing parameter was studied. The influence of pressure decrease on surface bubble diameter was studied. Through force analysis on the bubble, the bubble size prediction model was derived.
The experiment results indicate that the bubble is the ellipse spheroid during the process of expanding. When the bubbles completely out of orifice, their shape change into flat sphere. The limit speed of bubble during ascent in the PVA is 382 mm/s. In the static flow field, the rising trajectory of a single bubble is a spiral curve with increasing period and amplitude. when the single hole incidence airflow discharge(0.025~075 L/min), the immersion depth increase from 160 to 330 mm and the orifice diameter changing from 0.3 to 0.2 mm, the bubble oscillation amplitude increased. In the dynamic flow field, the bubbles were sinusoidal distribution in the foaming room, and increase the velocity of air tube can improve the uniformity of bubbles.
When the biggest linear velocity of air tube is increase from 0 to 366 mm/s, the bubble diameter of water simulation is reduced from 3.38 to 2.65 mm and the bubble diameter of aluminum reduced from 10.44 to 2.95 mm. The relative error of simulation and experiment is 10.17% with the velocity of air tube is 366 mm/s. When the air flow is increase from 0.025 to 0.075 L/min, the bubble diameter of water simulation is increased from 2.48 to 2.93 mm and the bubble diameter of aluminum increased from 2.62 to 3.61 mm. The water experiment results indicate that when the liquid viscosity changing from 2.27 to 16 mPa.s, the bubble diameter increases from 2.33 to 2.48 mm. When the immersion depth of the orifice increase from 150 to 330 mm, the bubble diameter of water simulation is increase from 2.25 to 2.57 mm, and the bubble diameter of aluminum is 2.732 mm, Consider the static pressure, The relative error of experiment and simulation reduced from 15.45 to 3.22%. The bubble generated from the first size of air tube is bigger than the other side (2.72~6.24%). Increase the air flow and the length of air tube or reduce the pipe diameter, the inconsistent of bubble size is greater.
引文
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