形态/材料二元耦合仿生功能表面增效节能机理及应用研究
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摘要
水泵是人类应用最广泛的通用机械之一，与人类工农业生产及日常生活息息相关，但其效率低，耗电量大等问题仍然比较突出。传统的提高水泵效率的方法有抽级改造法，改造或更换叶轮法，仿鲨鱼皮riblet表皮法，叶轮流道中加陶瓷法，叶轮表面图憎水涂料法，但都有其局限性。
研究表明，水生生物在流体介质运动中，皮肤弹性可根据流体载荷发生动态变化，并与皮下组织特有的非光滑结构形成动态耦合表面，并具有特定的减阻功能。这种通过体表与流体介质互动而实现形态/表面弹性二因素动态耦合称为形态/材料二元动态耦合。本文受上述现象启发，在仿生耦合理论的指导下，依据仿生学相似原理，构建形态/材料二元动态耦合仿生功能表面；该功能表面由不同属性的双层材料构成，利用表面膜材料的弹性变形以及表面膜材料与基底材料表面上仿生非光滑结构的动态耦合，对流体介质进行主动控制，从而实现减阻功能；并以典型流体介质中工作的机械部件-泵为研究载体，以增效、减阻为研究目标，采用试验优化设计方法优化二元动态耦合仿生功能表面结构参数；通过流固耦合模拟技术探索动态耦合仿生功能表面增效节能机理，为获取“低能耗、高效率”的耦合仿生功能表面设计制造理论体系奠定基础，为实现流体机械部件在较为宽泛的工况下的减阻、增效问题提供新方法。为此，本文主要从以下几个方面进行了研究并得到以下结论：
1．完善了耦合仿生功能表面的设计与制造工艺
利用中间介质，采用一次铸造成型法，完成了形态因素在基底材料也就是水泵叶轮复杂流道表面上的加工工艺研究，实现了基底材料仿生非光滑结构的加工。一次铸造成型法尤其适用于复杂不规则曲面加工非光滑表面。
采用旋转涂覆工艺方法，将聚氨酯材料涂覆于加工有非光滑结构的基底材料上，形成具有一定弹性的形态/材料二元耦合仿生功能表面。
2．形态/材料二元耦合仿生功能表面流固耦合模拟及机理分析
以水泵为载体，以提高水泵效率为目标，对设计的形态/材料二元动态耦合仿生功能表面进行了优化设计试验。试验表明，动态耦合仿生功能表面在水泵叶轮上的布置位置对水泵的效率影响显著；仿生耦合水泵效率提高显著，其效率曲线变得丰满平顺，也就是说，即使仿生耦合水泵运行偏离最大效率点，仍然可以在较高的效率范围内运行；优化后的仿生耦合水泵效率提高可达5%及以上，与单因素仿生非光滑水泵相比，仿生耦合水泵在整个流量段内的增效节能性能稳定、显著。
3．形态/材料二元耦合仿生功能表面减阻机理研究
从流固耦合数值模拟的角度，进行耦合仿生功能表面-流体介质作用机理的初探研究。得出其增效节能机理为：流体在较低的流速下，由于聚氨酯弹性涂层的存在，在负高压时产生弹性变形，吸收了部分能量，并在负高压峰值后又释放这部分能量，称为缓释效应，这种效应可以有效的减小能量损失，从而提高水泵效率；在流速较高，流量较大的情况下，水流强烈冲击耦合叶片时，变形后的耦合水泵叶轮表面处于完全耦合状态，其叶片表面表现为非光滑结构而吸收部分叶轮流道内部的紊流能量，对横向和纵向的湍流猝发都有抑制，起到稳定紊流、推迟转捩的作用，达到增效节能的目的。
The pump is one of the most widely used general machinery to the human. It isclosely bounded up with human industrial and agricultural production, but it still hassome problems, such as low efficiency, large power consumption. The traditionalmethods of improving the efficiency of water pump are pumping level transformation,modification or replacement of the impeller, riblet method of imitation shark skinepidermis, impeller passage with ceramics and other methods, the surface of theimpeller of hydrophobic coating method and so on, but each of them has its ownlimitations.
Using the surface membrane materials elastic deformation, using surfacemembrane material and on the surface of the base material of bionic non-smoothstructure dynamics the coupling actively control of the fluid medium, to reduce dragfunction; and the pump that is a typical fluid medium of the work of the mechanicalcomponents is taken as the carrier, with synergistic, drag reduction as the researchobject, using experimental design optimization of Binary of dynamic coupling bionicfunctional surface structure parameters; explores the dynamic coupling bionic functionsurface drag reduction mechanism by fluid-solid coupling technique, in order to obtainthe “low consumption, high efficiency” coupling bionic functional surface design andmanufacture system lays a foundation for the realization of this theory, to provide newmethods for machinery components in more general condition of drag reduction,synergism problem. Therefore, this article were mainly studied from the followingaspects and obtained the corresponding conclusions:
First, perfected the design and manufacturing process of coupling bionicfunctional surface. The use of intermediate medium by using a casting molding method,completed the processing technology research of Shape factors in the substratematerial which is complicated by flow channel on the surface of the pump impeller,realized the processing of the basal material of bionic non-smooth structure. A castingmolding method is especially suitable for the complex and irregular surface machiningnon-smooth surface.
Using spin coating process, the polyurethane material was coated on the substratematerial with non-smooth structures, forming morphology/material coupling bionicfunctional surface with certain elasticity.
Second, morphological/material two element coupling bionic functional surfacefluid solid coupling simulation and mechanism analysis. Using water as the carrier, inorder to improve the pump efficiency as the goal, to design the shape of two Binary ofmorphological/material dynamic coupling bionic functional surface were optimized bydesigning experiments. Experiments show that, the dynamic coupling bionic functionalsurface in water pump impeller arrangement significantly influenced and improved thepump efficiency; the efficiency curves of plump was smoothed, that is to say, even ifthe bionic coupling pump running deviation from the point of maximum efficiency, itstill can be in the high efficiency range operation; optimized bionic coupling pumpefficiency can reach5%and above, compared with the single factor of bionicnon-smooth water pump, bionic coupling pump can enhance the efficiencyperformance and save energy more significantly and stable in the whole flow period.
Third, morphological/material two elements coupling bionic functional surfacedrag reduction mechanism research.
From the aspect of fluid-solid coupling numerical simulation, coupling bionicfunctional surface fluid medium action mechanism was studied. The energy savingmechanism for: fluid at low flow rates, due to the existence of polyurethane elasticcoatings, in the negative pressure generated elastic deformation, absorb a portion ofenergy, and release this energy in the negative pressure peak, which is called therelease effect can effectively reduce the energy loss, thereby improving the waterpump efficiency; in the higher flow velocity, the larger flow volume conditions, waterflow strongly impact coupled blades, deformed coupling pump impeller surface is in afully coupled state, the blade surface ceased to be smooth structure and absorbing aportion of the flow passage of impeller internal turbulent energy, inhibited thehorizontal and vertical turbulent burst, stabilized turbulence and delayed transition,which raised the production efficiency.
研究表明，水生生物在流体介质运动中，皮肤弹性可根据流体载荷发生动态变化，并与皮下组织特有的非光滑结构形成动态耦合表面，并具有特定的减阻功能。这种通过体表与流体介质互动而实现形态/表面弹性二因素动态耦合称为形态/材料二元动态耦合。本文受上述现象启发，在仿生耦合理论的指导下，依据仿生学相似原理，构建形态/材料二元动态耦合仿生功能表面；该功能表面由不同属性的双层材料构成，利用表面膜材料的弹性变形以及表面膜材料与基底材料表面上仿生非光滑结构的动态耦合，对流体介质进行主动控制，从而实现减阻功能；并以典型流体介质中工作的机械部件-泵为研究载体，以增效、减阻为研究目标，采用试验优化设计方法优化二元动态耦合仿生功能表面结构参数；通过流固耦合模拟技术探索动态耦合仿生功能表面增效节能机理，为获取“低能耗、高效率”的耦合仿生功能表面设计制造理论体系奠定基础，为实现流体机械部件在较为宽泛的工况下的减阻、增效问题提供新方法。为此，本文主要从以下几个方面进行了研究并得到以下结论：
1．完善了耦合仿生功能表面的设计与制造工艺
利用中间介质，采用一次铸造成型法，完成了形态因素在基底材料也就是水泵叶轮复杂流道表面上的加工工艺研究，实现了基底材料仿生非光滑结构的加工。一次铸造成型法尤其适用于复杂不规则曲面加工非光滑表面。
采用旋转涂覆工艺方法，将聚氨酯材料涂覆于加工有非光滑结构的基底材料上，形成具有一定弹性的形态/材料二元耦合仿生功能表面。
2．形态/材料二元耦合仿生功能表面流固耦合模拟及机理分析
以水泵为载体，以提高水泵效率为目标，对设计的形态/材料二元动态耦合仿生功能表面进行了优化设计试验。试验表明，动态耦合仿生功能表面在水泵叶轮上的布置位置对水泵的效率影响显著；仿生耦合水泵效率提高显著，其效率曲线变得丰满平顺，也就是说，即使仿生耦合水泵运行偏离最大效率点，仍然可以在较高的效率范围内运行；优化后的仿生耦合水泵效率提高可达5%及以上，与单因素仿生非光滑水泵相比，仿生耦合水泵在整个流量段内的增效节能性能稳定、显著。
3．形态/材料二元耦合仿生功能表面减阻机理研究
从流固耦合数值模拟的角度，进行耦合仿生功能表面-流体介质作用机理的初探研究。得出其增效节能机理为：流体在较低的流速下，由于聚氨酯弹性涂层的存在，在负高压时产生弹性变形，吸收了部分能量，并在负高压峰值后又释放这部分能量，称为缓释效应，这种效应可以有效的减小能量损失，从而提高水泵效率；在流速较高，流量较大的情况下，水流强烈冲击耦合叶片时，变形后的耦合水泵叶轮表面处于完全耦合状态，其叶片表面表现为非光滑结构而吸收部分叶轮流道内部的紊流能量，对横向和纵向的湍流猝发都有抑制，起到稳定紊流、推迟转捩的作用，达到增效节能的目的。
The pump is one of the most widely used general machinery to the human. It isclosely bounded up with human industrial and agricultural production, but it still hassome problems, such as low efficiency, large power consumption. The traditionalmethods of improving the efficiency of water pump are pumping level transformation,modification or replacement of the impeller, riblet method of imitation shark skinepidermis, impeller passage with ceramics and other methods, the surface of theimpeller of hydrophobic coating method and so on, but each of them has its ownlimitations.
Using the surface membrane materials elastic deformation, using surfacemembrane material and on the surface of the base material of bionic non-smoothstructure dynamics the coupling actively control of the fluid medium, to reduce dragfunction; and the pump that is a typical fluid medium of the work of the mechanicalcomponents is taken as the carrier, with synergistic, drag reduction as the researchobject, using experimental design optimization of Binary of dynamic coupling bionicfunctional surface structure parameters; explores the dynamic coupling bionic functionsurface drag reduction mechanism by fluid-solid coupling technique, in order to obtainthe “low consumption, high efficiency” coupling bionic functional surface design andmanufacture system lays a foundation for the realization of this theory, to provide newmethods for machinery components in more general condition of drag reduction,synergism problem. Therefore, this article were mainly studied from the followingaspects and obtained the corresponding conclusions:
First, perfected the design and manufacturing process of coupling bionicfunctional surface. The use of intermediate medium by using a casting molding method,completed the processing technology research of Shape factors in the substratematerial which is complicated by flow channel on the surface of the pump impeller,realized the processing of the basal material of bionic non-smooth structure. A castingmolding method is especially suitable for the complex and irregular surface machiningnon-smooth surface.
Using spin coating process, the polyurethane material was coated on the substratematerial with non-smooth structures, forming morphology/material coupling bionicfunctional surface with certain elasticity.
Second, morphological/material two element coupling bionic functional surfacefluid solid coupling simulation and mechanism analysis. Using water as the carrier, inorder to improve the pump efficiency as the goal, to design the shape of two Binary ofmorphological/material dynamic coupling bionic functional surface were optimized bydesigning experiments. Experiments show that, the dynamic coupling bionic functionalsurface in water pump impeller arrangement significantly influenced and improved thepump efficiency; the efficiency curves of plump was smoothed, that is to say, even ifthe bionic coupling pump running deviation from the point of maximum efficiency, itstill can be in the high efficiency range operation; optimized bionic coupling pumpefficiency can reach5%and above, compared with the single factor of bionicnon-smooth water pump, bionic coupling pump can enhance the efficiencyperformance and save energy more significantly and stable in the whole flow period.
Third, morphological/material two elements coupling bionic functional surfacedrag reduction mechanism research.
From the aspect of fluid-solid coupling numerical simulation, coupling bionicfunctional surface fluid medium action mechanism was studied. The energy savingmechanism for: fluid at low flow rates, due to the existence of polyurethane elasticcoatings, in the negative pressure generated elastic deformation, absorb a portion ofenergy, and release this energy in the negative pressure peak, which is called therelease effect can effectively reduce the energy loss, thereby improving the waterpump efficiency; in the higher flow velocity, the larger flow volume conditions, waterflow strongly impact coupled blades, deformed coupling pump impeller surface is in afully coupled state, the blade surface ceased to be smooth structure and absorbing aportion of the flow passage of impeller internal turbulent energy, inhibited thehorizontal and vertical turbulent burst, stabilized turbulence and delayed transition,which raised the production efficiency.
引文
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