目的 为探究亚毫米级凹槽阵列结构的尺寸参数对叶片材料抗水蚀性能的影响,优化表面结构参数,以实现汽轮机叶片材料抗水蚀性能的提升。方法 本文基于ANSYS/LS-DYNA非线性显式动力学软件,采用光滑粒子流体动力学（SPH）和有限元（FEM）耦合算法,建立了17-4PH叶片材料（含光滑表面及不同尺寸亚毫米级凹槽阵列结构）的水射流冲击数值模型,系统分析了不同槽宽（L）与槽间距（W）对材料水蚀累积质量损失及冲击压力的影响规律。结果 研究表明,与光滑表面相比,亚毫米级凹槽阵列结构可有效抑制叶片材料的水蚀损伤。当L/W比值为4或2且W≤200 μm时,凹槽结构抗水蚀效果显著;其中,L=400 μm、W=100 μm的凹槽结构经2.3 μs水射流冲击后,其累积质量损失（31.7 μg）和平均冲击压力（1.2 GPa）均为最低,表明该结构具备最优的抗水蚀特性。结论 在汽轮机叶片表面设计参数合理的亚毫米级凹槽阵列结构,可有效降低水射流冲击压力,减少材料累积质量损失,从而提升抗水蚀性能。本研究揭示了凹槽尺寸参数对叶片材料水蚀损伤行为的影响规律,为叶片抗蚀表面结构的优化设计提供了理论指导与基础数据,有助于保障设备的长期稳定运行。
Abstract
In order to explore the influence of size parameters of the submillimeter groove array structure on the water droplet erosion resistance of the blade material, the structural parameters were optimized to improve the water droplet erosion resistance of the steam turbine blade material. The coupling algorithm of smoothed particle hydrodynamics (SPH) and the finite element method (FEM) was adopted to overcome the large mesh deformation. The simulation was carried out based on ANSYS/LS-DYNA nonlinear explicit dynamics software. Models of 17-4PH martensitic substrate were established, including a smooth surface and a series of groove array structures with different widths (L) and spacings (W). The reliability of the model was verified by simulating the water jet impact on a rigid plane. The initial impact pressure was 1.907 GPa, and the error was only 2.77% compared with the theoretical value of water hammer pressure 1.854 GPa, which showed that the numerical model had high accuracy and reliability. The results show that under a fixed groove spacing (W), the cumulative mass loss of materials decreases monotonously with the increase of the groove width (L). Under a fixed groove width (L), the cumulative mass loss increases first and then decreases with the increase of the groove spacing (W). Compared with the smooth surface, the reasonably designed groove array structure shows a significant anti-water droplet erosion effect. When the width-to-spacing ratio L/W is 4 or 2 and the groove spacing W does not exceed 200 μm, the anti-water droplet erosion effect of the groove structure is significant, and the cumulative mass loss of the blade material is reduced by about 13.1% on average compared with the smooth sample. In addition, the average impact pressure of the three representative groove structures (L=400 μm, W=100 μm; L=800 μm, W=200 μm; L=200 μm, W=100 μm) is about 10.5% lower than that of the smooth structure, and the cumulative mass loss of water droplet erosion is lower than that of the smooth surface. Among them, the sample with L=400 μm and W=100 μm has the lowest average impact pressure (about 1.2 GPa) and the smallest cumulative mass loss (31.7 μg) after 2.3 μs of water jet impact, thus exhibiting the optimal water droplet erosion resistance. Conversely, the protective effect is significantly weakened for samples with L/W = 0.25, 0.5, and 1, for which the mass loss approaches or even exceeds that of the smooth sample. The design of a submillimeter groove array structure with reasonable parameters on the surface of the turbine blade can effectively reduce the impact pressure of the water jet and the cumulative mass loss of the material, thereby improving the water droplet erosion resistance. The findings provide theoretical guidance and basic data for revealing the influence of groove size parameters on water droplet erosion damage and optimizing material surface structure design to improve the erosion resistance of blade materials, which is helpful to ensure the long-term stable operation of equipment.
关键词
汽轮机叶片 /
SPH-FEM /
凹槽阵列结构 /
数值模拟 /
累积质量损失
Key words
steam turbine blade /
SPH-FEM /
groove array structure /
numerical simulation /
cumulative mass loss
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基金
国家自然科学基金青年科学基金项目（52205212）
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