加力燃油泵隔舌空化机理及抑制方法研究
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摘要
加力燃油泵是军用航空发动机燃油控制系统的主要部件，其性能及可靠性对提高战斗机的生存能力及作战性能十分关键。现役某型发动机加力燃油泵为高速离心泵，长期运行于非设计工况，出现了罕见的隔舌空蚀破坏及小流量工作不稳定等问题。针对上述问题，探索加力燃油泵非设计工况内流场特征及隔舌空化原因、机理与有效抑制方法，所得结论对完善高速离心泵设计理论、提高水力性能及可靠性、促进高推比航空发动机的发展具有重要意义。
首先，针对径向直叶片开式叶轮与环形蜗壳间流道复杂的几何结构，构建了全流道分块拓扑及块结构化网格模型。采用雷诺平均方法（RANS）及相变空化模型，对泵内复杂湍流场进行了系统的数值模拟。非定常计算能得到与试验外特性相符的流量扬程特性，可以较为准确地模拟内流场特征：大流量工况，叶片前缘及轮盘底部存在小范围旋转空化，会导致当地空蚀破坏，环形腔室隔舌处流动存在轻微分离；小流量工况，叶轮表面未发生空化，而隔舌处存在严重的高速分离流，可由此诱发剪切湍流漩涡空化。
进而，针对某简单结构的单孔燃油喷嘴内高速分离流空化，分别采用RANS湍流/转捩模式和大涡模拟（LES）动态亚格子应力模型，揭示出分离转捩对燃油分离流空化初生的主导作用。分离转捩区Kelvin-Helmholtz（K-H）涡翻滚扭曲伴随的瞬时负压脉动会促发空化初生，瞬时空泡随K-H涡运动形成可观测空泡群，同时分离线处也伴随有空化初生。基于LES单相瞬态流场的时间统计平均，得出了高速分离流空化初生的判据，计算发现网格尺度变大将无法正确捕捉分离转捩特征，而分离线空化仍可用于判定分离转捩区空化初生。喷嘴入口倒圆采用较小的半径即可明显抑制分离转捩过程，并降低大尺度脉动负压。
最后，采用动态亚格子应力模型对加力燃油泵非设计工况隔舌分离流进行模拟，计算捕捉到隔舌分离剪切层失稳及涡脱落变形的非定常过程：小流量工况，隔舌处会产生分离转捩空化，导致壁面空蚀破坏，倒圆半径较大时可抑制隔舌分离流并避免空化。兼顾结构强度及设计尺寸限制，研究了环形腔室径向宽度缩小以及矩形截面腔室设计对改善泵水力性能及抑制空化的效果，并发展了主回流性能分析法，为加力燃油泵的优化设计提供了理论支持和工程指导。
After-burningfuel pump is one of the important parts of fuel control system inaero-engine, its performance and reliability is critical to the viability andcombatperformance improvement of fighters. Recently, infrequent casing tonguecavitation damage and low flow-rate instability phenomena were found in anafter-burningfuel pump, which is a high-speed centrifugal pump, of a certainaero-engine after a long term operation ofoff-design conditions. A series of numericalinvestigation was conducted to explore the internal flow characteristic underoff-design conditions and consequentcasing tongue cavitation mechanism,which hasgreat meaning to develop optimization design theory and improve the hydraulicperformance and reliability of high-speed centrifugal pump, as well as the promotionof high performance aero-engine development.
The block topology and multi-block structured grid have thus been constructed,due to complex geometric structure of the flow passage between the annular casingand straight radial blades of the open impeller. Utilizing Reynolds-AveragedNavier-Stokes equations (RANS)and a phase change cavitation model，the turbulentfield inside the pump was simulated. The flow-rate headcharacteristics predicted byunsteady resultsare consistent with the experimental measurement, then the internalflow were explored by the unsteady calculation. Under large flow-rate condition,there is limited rotational cavitation on the front edge of the blades as well as thebottom of the hub，which will lead to locally cavitation damage. The annular chamberflow near the casing tongue separates mildly. Under small flow-rate condition, nocavitation happens on the impeller surface, while high-speed fuel near the casingtongue comes into serious flow separation, which will probably bring about vortexcavitation in shear turbulence there.
Then, in respect of high-speed separation flow cavitation mechanism, RANSturbulence/transition model and Large-Eddy Simulation (LES) dynamic subgrid scalemodel have been adoptedrespectively to simulate the high-speed separated flow in asimple geometric structure, an experimental single-hole fuel nozzle,separation transition was found to play a dominant role in the cavitation inception of fuelseparated flow. In the separation transitional zone, Kelvin-Helmholtz(K-H)vortexbillow and distortion motions lead to transient negative pressure fluctuation whichtriggers cavitation inception. Transient cavitation bubbles moving within the K-Hvortex form an observable cavitation area, while there is also cavitation at theseparation line. Based on the time statistical average of the LES single-phase results,a cavitation inception criterion for high-speed separated flow has been deduced. It canbe considered as a judging method of cavitation inception in the downstreamseparation transitional zonewhether the separation line cavitates. The nozzle inletfilleting with just a small radius obviously suppresses the transition process anddecrease the large-scale fluctuated negative pressure.
Finally, with the dynamic subgrid scale model, the separated flow near theafter-burning fuel pump casing tongue under off-design conditions was investigated.The results identify the unsteady process of separation shear layer destabilization aswell as vortex shedding and distortion. It is found that: under small flow-ratecondition, separation transitional cavitation comes into being near the casing tonguewhich induces wall damage hole there. Also, filleted only with a large radius, the flowseparation and cavitation at the casing tongue can be fully avoided. In considerationof structure strength and external dimension restraint, the effect of narrow radialwidth and rectangular cross-section chamber designs on improving pumphydraulicperformance and preventing casing tongue cavitation have been studied andevaluated. The above results provide a good theory basis and engineering guidancefor optimal design of the after-burning fuel pump.
首先，针对径向直叶片开式叶轮与环形蜗壳间流道复杂的几何结构，构建了全流道分块拓扑及块结构化网格模型。采用雷诺平均方法（RANS）及相变空化模型，对泵内复杂湍流场进行了系统的数值模拟。非定常计算能得到与试验外特性相符的流量扬程特性，可以较为准确地模拟内流场特征：大流量工况，叶片前缘及轮盘底部存在小范围旋转空化，会导致当地空蚀破坏，环形腔室隔舌处流动存在轻微分离；小流量工况，叶轮表面未发生空化，而隔舌处存在严重的高速分离流，可由此诱发剪切湍流漩涡空化。
进而，针对某简单结构的单孔燃油喷嘴内高速分离流空化，分别采用RANS湍流/转捩模式和大涡模拟（LES）动态亚格子应力模型，揭示出分离转捩对燃油分离流空化初生的主导作用。分离转捩区Kelvin-Helmholtz（K-H）涡翻滚扭曲伴随的瞬时负压脉动会促发空化初生，瞬时空泡随K-H涡运动形成可观测空泡群，同时分离线处也伴随有空化初生。基于LES单相瞬态流场的时间统计平均，得出了高速分离流空化初生的判据，计算发现网格尺度变大将无法正确捕捉分离转捩特征，而分离线空化仍可用于判定分离转捩区空化初生。喷嘴入口倒圆采用较小的半径即可明显抑制分离转捩过程，并降低大尺度脉动负压。
最后，采用动态亚格子应力模型对加力燃油泵非设计工况隔舌分离流进行模拟，计算捕捉到隔舌分离剪切层失稳及涡脱落变形的非定常过程：小流量工况，隔舌处会产生分离转捩空化，导致壁面空蚀破坏，倒圆半径较大时可抑制隔舌分离流并避免空化。兼顾结构强度及设计尺寸限制，研究了环形腔室径向宽度缩小以及矩形截面腔室设计对改善泵水力性能及抑制空化的效果，并发展了主回流性能分析法，为加力燃油泵的优化设计提供了理论支持和工程指导。
After-burningfuel pump is one of the important parts of fuel control system inaero-engine, its performance and reliability is critical to the viability andcombatperformance improvement of fighters. Recently, infrequent casing tonguecavitation damage and low flow-rate instability phenomena were found in anafter-burningfuel pump, which is a high-speed centrifugal pump, of a certainaero-engine after a long term operation ofoff-design conditions. A series of numericalinvestigation was conducted to explore the internal flow characteristic underoff-design conditions and consequentcasing tongue cavitation mechanism,which hasgreat meaning to develop optimization design theory and improve the hydraulicperformance and reliability of high-speed centrifugal pump, as well as the promotionof high performance aero-engine development.
The block topology and multi-block structured grid have thus been constructed,due to complex geometric structure of the flow passage between the annular casingand straight radial blades of the open impeller. Utilizing Reynolds-AveragedNavier-Stokes equations (RANS)and a phase change cavitation model，the turbulentfield inside the pump was simulated. The flow-rate headcharacteristics predicted byunsteady resultsare consistent with the experimental measurement, then the internalflow were explored by the unsteady calculation. Under large flow-rate condition,there is limited rotational cavitation on the front edge of the blades as well as thebottom of the hub，which will lead to locally cavitation damage. The annular chamberflow near the casing tongue separates mildly. Under small flow-rate condition, nocavitation happens on the impeller surface, while high-speed fuel near the casingtongue comes into serious flow separation, which will probably bring about vortexcavitation in shear turbulence there.
Then, in respect of high-speed separation flow cavitation mechanism, RANSturbulence/transition model and Large-Eddy Simulation (LES) dynamic subgrid scalemodel have been adoptedrespectively to simulate the high-speed separated flow in asimple geometric structure, an experimental single-hole fuel nozzle,separation transition was found to play a dominant role in the cavitation inception of fuelseparated flow. In the separation transitional zone, Kelvin-Helmholtz(K-H)vortexbillow and distortion motions lead to transient negative pressure fluctuation whichtriggers cavitation inception. Transient cavitation bubbles moving within the K-Hvortex form an observable cavitation area, while there is also cavitation at theseparation line. Based on the time statistical average of the LES single-phase results,a cavitation inception criterion for high-speed separated flow has been deduced. It canbe considered as a judging method of cavitation inception in the downstreamseparation transitional zonewhether the separation line cavitates. The nozzle inletfilleting with just a small radius obviously suppresses the transition process anddecrease the large-scale fluctuated negative pressure.
Finally, with the dynamic subgrid scale model, the separated flow near theafter-burning fuel pump casing tongue under off-design conditions was investigated.The results identify the unsteady process of separation shear layer destabilization aswell as vortex shedding and distortion. It is found that: under small flow-ratecondition, separation transitional cavitation comes into being near the casing tonguewhich induces wall damage hole there. Also, filleted only with a large radius, the flowseparation and cavitation at the casing tongue can be fully avoided. In considerationof structure strength and external dimension restraint, the effect of narrow radialwidth and rectangular cross-section chamber designs on improving pumphydraulicperformance and preventing casing tongue cavitation have been studied andevaluated. The above results provide a good theory basis and engineering guidancefor optimal design of the after-burning fuel pump.
引文
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