目的 基于热压印制造技术,系统研究微沟槽形貌偏差与流速的耦合作用对减阻机制的影响。方法 本研究基于ANSYS构建含不同直线度与对称度偏差的微沟槽计算模型,重点考察102、136、170 m/s（对应雷诺数Re=1.04×104、1.38×104、1.73×104）等3种流速工况下的减阻行为,通过对2类形貌偏差条件下的减阻率、压力场、速度场、湍流特性、涡量结构和壁面剪切力等关键参数进行对比,揭示误差类型与流场响应之间的关系。结果 随着流速增大,形貌误差对减阻性能的影响逐渐增强。在102~ 170 m/s流速范围内,直线度偏差的减阻变化率（-0.004 4~-0.006 3%/μm）明显高于对称度偏差（-0.001 0~ -0.003 3%/μm）,表明直线度偏差在高流速条件下对减阻性能更敏感。随着流速增加,微沟槽的形貌精度呈非线性显著提升。为维持微沟槽的减阻效果,在102、136、170 m/s流速下,直线度允许误差分别严控至±16、±10和±2 μm,而对称度允许误差则分别控制在±70、±20和±10 μm。2种形貌偏差对减阻特性的影响机制存在明显差异,直线度偏差会同时增大沟槽内的压差阻力和摩擦阻力,并显著加剧速度梯度,诱发局部回流和流向涡的产生,而对称度偏差则主要破坏流动对称性,导致局部湍流增强和流动失稳。结论 采用热压印技术制备的微沟槽减阻结构时,需满足阵列直线度误差≤±2 μm、对称度误差≤±10 μm的严格精度要求,方能在雷诺数Re=1.04×104~1.73×104维持减阻效果,超出该精度阈值时,微沟槽会因流动失稳导致功能退化甚至产生增阻效应。该研究揭示了形貌精度与减阻性能的定量关系,并提出了相应的工艺优化方案,为其在微沟槽制造的精度控制提供理论支撑。
Abstract
Through the application of thermal imprint manufacturing technology, the work aims to systematically investigate the impact of the coupling effect between micro-groove morphological deviations and flow velocity on drag-reduction mechanisms. The software ANSYS was employed to construct a computational model of micro-grooves with different straightness and symmetry deviations, focusing on the drag-reduction behavior under three flow velocity conditions of 102, 136, and 170 m/s (corresponding to Reynolds numbers Re=1.04×104, 1.38×104 and 1.73×104). Furthermore, by comparing key parameters such as drag reduction, pressure field, velocity field, turbulence characteristics, vortex structure, and wall shear stress under two types of morphological deviation conditions, the relationship between error types and flow field responses was revealed. The results of the study showed that: (1) The effect of morphology error on drag-reduction performance increased significantly with the increasing flow velocity. The variation rates of drag reduction for straightness deviation were -0.004 4%/μm, -0.005 5%/μm and -0.006 3 %/μm at flow rates range of 102-170 m/s, whereas the variation rates of drag reduction for symmetry deviation for the same Mach number operating conditions were -0.001 0%/μm, -0.001 8%/μm and -0.002 5%/μm. From the above, this showed that straightness deviation was more sensitive to drag-reduction performance under high flow velocity conditions. (2) With the increase of the flow rate, the morphological accuracy of the micro-grooves showed a significant increase in nonlinearity. To maintain the drag-reduction effect of the micro-grooves, at flow velocities of 102, 136, and 170 m/s, the allowable error in straightness was strictly controlled to within ±16, ±10 and ±2 μm respectively, while the allowable error in symmetry was controlled within ±70, ±20, and ±10 μm respectively. (3) There was a significant difference in the effect mechanism of the two morphological deviations on the drag-reduction characteristics: the straightness deviation increased both differential pressure resistance and friction resistance in the groove, and significantly intensified the velocity gradient, inducing localized reflux and flow vortices, whereas the symmetry deviation mainly destroyed the symmetry of the flow, leading to localized turbulence enhancement and flow instability. Therefore, when the hot embossing technology is used to fabricate the micro-groove drag-reduction structure, it is necessary to meet the strict precision requirements of array straightness error ≤±2 μm and symmetry error ≤±10 μm. Only then can the drag-reduction effect be maintained within the Reynolds number range of Re=1.04×104-1.73×104. Exceeding these precision thresholds may cause micro-grooves to degrade in functionality or even induce drag-increasing effects due to flow instability. This study reveals the quantitative relationship between morphological accuracy and drag-reduction performance, and proposes corresponding process optimization schemes, providing theoretical support for precision control in micro-groove manufacturing. In the future, the accuracy and consistency of morphology control can be further improved through technical measures such as optimizing mould processing and improving hot stamping process parameters. Looking ahead, advances in micro-nano manufacturing technologies (such as ultra-precision machining and nanoimprinting) are expected to break through existing precision limitations, thereby expanding the applicability of micro-groove drag-reduction technology across a wider range of Reynolds numbers. At the same time, it can also promote the large-scale application of this technology in fields such as aerospace, providing innovative solutions for energy conservation and emission reduction.
关键词
热压印技术 /
展向微沟槽 /
减阻性能 /
直线度偏差 /
对称度偏差 /
流场特性 /
允许误差
Key words
thermal embossing technology /
spreading micro-groove /
drag-reduction performance /
straightness deviation /
asymmetry deviation /
flow field characteristics /
allowable error
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基金
北方工业大学有组织科研（110051360024XN148-38）
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