The Flow Simulation and Experimental Study of Low-Specific-Speed High-Speed Complex Centrifugal Impellers＊

Based on the Navier-Stokes equations and the Spalart-Allmaras turbulence model, three-dimensional turbulent flow in four low-specific-speed centrifugal impellers are simulated numerically and analyzed. The relative velocity distribution, pressure distribution and static pressure rise at the design point are obtained for the regular impeller with only long blades and three complex impellers with long, mid or short blades. It is found that the back flow region between long-blade pressure side and mid-blade suction side is diminished and is pushed to pressure side of short blades near the outlet of impeller at suction side by the introduction of mid, short blades, and the size of back flow becomes smaller in a multi-blade complex impeller. And the pressure rises uniformly from inlet to outlet in all the impellers. The simulated results show that the complex impeller with long, mid and short blades can improve the velocity distribution and reduce the back flow in the impeller channel. The experimental results show that the back flow in the impeller has an important influence on the performance of pump and a more-blade complex impeller with long, mid and short blades can effectively solve low flow rate instability of the low-specific-speed centrifugal pump.

EXPERIMENTAL STUDY ON HIGH-SPEED CENTRIFUGAL PUMPS WITH DIFFERENT IMPELLERS

The experimental study is carried out on high-speed centrifugal pumps withthree different impellers. The experimental results and analysis show that high-speed centrifugalpumps with a closed complex impeller can achieve the highest efficiency and the lowest headcoefficient followed by those with half-open impeller and open-impeller, and can obtain much easilystable head-capacity characrastic curve, while those with a half-open complex impeller can't. Thecharacteristic curve with a open impeller is almost constant horizontal line before droppingsharply. The results also show that the axial clearance between pump casing and impeller caninfluence greatly on the performance of centrifugal pumps.

EFFECT OF TIP CLEARANCE ON PERFORMANCE AND FLOW FIELD OF SMALL SIZED HIGH SPEED CENTRIFUGAL FAN

A centrifugal fan with the high speed and compact dimensions is studied numerically and experimentally. The centrifugal fan consists of a shrouded impeller rotating at 34 000 r/min with a small tip clearance 0.7 mm to the fixed outer casing. Computational models with/without the tip clearance are built and the κ-ω shear stress transport （SST） turbulence model and the unstructured mesh are applied to the numerical simulation for unsteady solutions. The overall performance is measured on a standard experimental bench and the major flow feature of each component inside the centrifugal fan is numerically investigated. In the presence of the tip clearance due to the difference of static pressure between leading and trailing edges of the clearance, i. e. , leading and trailing edges of the impeller, a strong return flow exists inside the clearance passage and re-circulates the main stream inside the impeller passage, and produces the strong flow interaction, thus changing the flow field and influencing the overall performance.

A study on centrifugal casting of high speed steel roll

High speed steel (HSS) rolls can replace traditional rolls such as alloyed cast iron rolls and powder metallurgical (PM) hard alloy rolls. The main reasons for the replacement are that the wear resistance of low-cost alloyed cast iron rolls is poor and the cost of high-quality PM hard alloy rolls is very high. By means of centrifugal casting, HSS rolls having excellent wear resistance have been manufactured. The hardness of the HSS roll is 6.5~67 HRC, the range of variation is smaller than 2 HRC and its impact toughness is 15 J/cm^2. The wear rate of HSS rolls used in the pre-finishing stands of high-speed hot wire-rod rolling mill reaches 2.5×10^(-4)mm per ton steel. Furthermore, the manufacturing cost of HSS rolls is significantly lower than that of PM hard alloy rolls; it is only 30 percent of that of PM hard alloy rolls.

Statistical analysis of pressure fluctuations during unsteady flow for low-specific-speed centrifugal pumps

A three-dimensional transient numerical simulation was conducted to study the pressure fluctuations in low-specific-speed centrifugal pumps. The characteristics of the inner flow were investigated using the SST k-ω turbulence model. The distributions of pressure fluctuations in the impeller and the volute were recorded, and the pressure fluctuation intensity was analyzed comprehensively, at the design condition, using statistical methods. The results show that the pressure fluctuation intensity increases along the impeller streamline from the leading edge to the trailing edge. In the impeller passage, the intensity near the shroud is much higher than that near the hub at thc inlet. However, the intensity at the middle passage is almost equal to the intensity at the outlet. The pressure fluctuation intensity is the highest at the trailing edge on the pressure side and near the tongue because of the rotor-stator interaction. The distribution of pressure fluctuation intensity is symmetrical in the axial cross sections of the volute channel. However, this intensity decreases with increasing radial distance. Hence, the pressure fluctuation intensity can be reduced by modifying the geometry of the leading edge in the impeller and the tongue in the volute.

Optimization on the Impeller of a Low-specific-speed Centrifugal Pump for Hydraulic Performance Improvement

In order to widen the high-efficiency operating range of a low-specific-speed centrifugal pump, an optimization process for considering efficiencies under 1.0Qd and 1.4Qd is proposed. Three parameters, namely, the blade outlet width b2, blade outlet angle β2, and blade wrap angle φ, are selected as design variables. Impellers are generated using the optimal Latin hypercube sampling method. The pump efficiencies are calculated using the software CFX 14.5 at two operating points selected as objectives. Surrogate models are also constructed to analyze the relationship between the objectives and the design variables. Finally, the particle swarm optimization algorithm is applied to calculate the surrogate model to determine the best combination of the impeller parameters. The results show that the performance curve predicted by numerical simulation has a good agreement with the experimental results. Compared with the efficiencies of the original impeller, the hydraulic efficiencies of the optimized impeller are increased by 4.18% and 0.62% under 1.0Qd and 1.4Qd, respectively. The comparison of inner flow between the original pump and optimized one illustrates the improvement of performance. The optimization process can provide a useful reference on performance improvement of other pumps, even on reduction of pressure fluctuations.

Centrifugal Casting of High Speed Steel/Nodular Cast Iron Compound Roll Collar

The centrifugal casting of compound HSS/nodular cast iron roll collar was studied,and the factors affecting transition zone quality were analyzed.The pouring temperature and interval in pouring are the main factors affecting transition zone quality.By controlling process parameter and flux adding during casting,high quality roll collar was obtained.The cause,why in the casting of HSS part,segregation appears easily,was analyzed and the countermeasure eliminating segregation was put forward,the measure eliminating heat treatment crackling was also put forward.

Development of centrifugal casting high speed steel rolls

The present study aims at developing the high speed steel (HSS) as rollmaterials to replace the traditional roll materials such as the alloy cast iron and powdermetallurgical (PM) hard alloy. The HSS roll billet was formed by centrifugal casting, and the billetwas rough machined alter soften annealing heat treatment, then it was quenched and tempered to getsuitable hardness and toughness. After that the HSS roll was finish machined to the final dimensionof phi 285 mm in the outer diameter, phi 160 mm in the inner diameter and 120 mm in width and itssurface hardness was tested. Finally the HSS roll was used in high speed wire rod mill. The testresults show that a high and homogeneous hardness can obtain on the work surface of HSS rolls, thesurface hardness is 63-65HRC and its variation is smaller than 2HRC. The impact toughness of thiskind of HSS is about 16 J/cm^2. The results of on-line service investigation in high speed wire rodmill indicate that the HSS rolls have excellent wear resistance, the steel rolling quantity per mmof HSS rolls is 3120 t, the service life-span of HSS rolls is 4 times longer than that of highchromium cast iron rolls and it is close to that of the PM hard alloy rolls. The manufacturingburden of HSS rolls is obviously lower than that of the PM hard alloy rolls, it is only 25 percentof that of the PM hard alloy rolls.

Microstructures in Centrifugal Casting of SiC_p/AlSi9Mg Composites with Different Mould Rotation Speeds

Two ingots were produced by centrifugal casting at mould rotational speeds of 600 rpm and 800 rpm using 20 vol%SiC p /AlSi9Mg composite melt,respectively.The microstructure along the radial direction of cross-sectional sample of ingots was presented.SiC particles migrated towards the external circumference of the tube,and the distribution of SiC particles became uniform under centrifugal force.Voids in 20 vol%SiC p /AlSi9Mg composite melt migrated towards the inner circumference of the tube.The quantitative analysis results indicated that not only SiC particles but also primaryαphases segregated greatly in centrifugal casting resulting from the transportation behavior of constitutions with different densities in the SiC p /AlSi9Mg composite melt.In addition,the eutectic Si was broken owing to the motion of SiC p /AlSi9Mg composite melt during centrifugal casting.

Development of Centrifugal Cast High Speed Steel Roll with High Wear Resistance for Pre-Finishing Stands of a Hot Rod-Wire Mill

The present study aims at developing high speed steel (HSS) as roll materialsto replace traditional roll materials such as the alloy cast iron and powder metallurgical (PM)hard alloy, because low-cost alloy cast iron rolls have poor wear resistance and the cost ofhigh-quality PM hard alloy rolls is too high to be accepted by some users. By means of a centrifugalcasting method, HSS rolls with excellent wear resistance have been developed. Its hardness is 65-67 HRC, and its variation is smaller than 2HRC; its impact toughness excels 15J/cm^2. Usingpre-finishing stands of a high-speed hot wire-rod rolling mill, the wear rate of HSS rolls per onethousand ton of steel is 0. 25mm. However, the manufacturing burden of HSS rolls is obviously lowerthan that of PM hard alloy rolls; it is only 30% of that of PM hard alloy rolls.

Effect of the Density of Molten Metal on the Raining Phenomenon in Horizontal Centrifugal Casting

In this work the influence of the density of the molten metal on the emergence of the raining phenomenon in the horizontal centrifugal casting process is numerically studied. Transient 2D numerical simulations were carried out using Computational Fluid Dynamics software. Three molten metals with different density, namely aluminum, iron and lead, and three angular frequencies, namely 50, 66 and 77 rad/s were considered. It is found that the density of the molten metal significantly affects the emergence, transient or permanent, of the rain phenomenon. However, the magnitude and duration of the rain phenomenon depend on the angular frequency of the rotating mold. Likewise, since gravitational forces affect the metal according to its density, the value of the critical rotation speed of the mold is also affected.

Experimental Study of Cavitation Phenomenon in a Centrifugal Blood Pump Induced by the Failure of Inlet Cannula

Cavitation of centrifugal blood pump is a serious problem accompany with the blocking failure of short inlet cannula. However, hardly any work has been seen in published literature on this complex cavitation phenomenon caused by the coupling effect of inlet cannula blocking and pumps suction. Even for cavitation studies on ordinary centrifugal pumps, similar researches on this issue are rare. In this paper, the roles of throttling, rotation speed and fluid viscosity on bubble inception and intensity in a centrifugal blood pump are studied, on the basis of experimental observations. An adjustable throttle valve installed just upstream blood pump inlet is used to simulate the throttling effect of the narrowed inlet cannula. The rotation speed is adjusted from 2 600 r/rain to 3 200 r/min. Glycerin water solutions are used to investigate the influences of kinetic viscosity. Bubbles are recorded with a high-speed video camera. Direct observation shows that different from cavitation in industrial centrifugal pumps, gas nuclei appears at the nearby of vane leading edges while throttling is light, then moves upstream to the joint position of inlet pipe and pump with the closing of the valve. It＇s found that the critical inlet pressure, obtained when bubbles are first observed, decreases linearly with viscosity and the slope is independent with rotation speeds; the critical inlet pressure and the inlet extreme pressure which is obtained when the throttle valve is nearly closed, fall linearly with rotation speed respectively and the relative pressure between them is independent with rotation speed and fluid viscosity. This paper studies experimentally on cavitation in centrifugal blood pump that caused by the failure of assembled short inlet cannula, which mav beneficial the desima of centrifugal blood Dumo with inlet cannula.

Breaking and Characteristics of Ganoderma Lucidum Spores by High Speed Entrifugai Shearing Pulverizer

The spores of Ganoderma lucidum were ground and broken to ultrafine particles by high speed centrifugal shearing（HSCS） pulverizer. The characteristics of Ganoderma lucidum spores were analyzed by scanning electron microscope （SEM）, Fourier transform infrared spectrophotometry （FTIR）. Ultraviolet-visible pectrophotometer was used to determine the extraction ratio of aqueous solubility polysaccharide between the raw and broken spores. The immunological function on the mice before and after the breaking of spores wan investigated. The experimental results show that after being ground, the sporoderm-broken ratio reachs 100%, the original active ingredients of ganoderma lucidum spores do not change, and the extraction ratio of aqueous solubility polysaccharide is greatly increased by 40.08%. The broken spores show much higher immunological activity comparing with original spores of Ganoderma lucidum.

Effect of centrifugal counter-gravity casting on solidification microstructure and mechanical properties of A357 aluminum alloy

To investigate the influence of Centrifugal Counter-gravity Casting(C3) process on the solidification microstructure and mechanical properties of the casting, A357 aluminum alloy samples were produced by different process conditions under C3. The results show that C3 has better feeding capacity compared with the vacuum suction casting; and that the mechanical vibration and the convection of melts formed at the centrifugal rotation stage suppress the growth of dendrites, subsequently resulting in the refinement of grains and the improvement of mechanical properties, density and hardness. A finer grain and higher strength can be obtained in the A357 alloy by increasing centrifugal radius and rotational speed. However, casting defects will appear near the rotational axis and the mechanical properties will decrease once the rotational speed exceeds 150 r·min-1.

Cavitation Detection in Variable Speed Pump by Analyzing the Acoustic and Vibration Spectrums

Cavitation in pumps must be detected and prevented. The present work is an attempt to use the simultaneous measurements of vibration and sound for variable speed pump to detect cavitation. It is an attempt to declare the relationship between the vibration and sound for the same discharge of 780 L/h and NPSHA of 0.754 at variable speeds of 1476 rpm, 1644 rpm, 1932 rpm, 2190 rpm, 2466 rpm, and 2682 rpm. Results showed that: the occurrence of cavitation depends on the rotational speed, and the sound signals in both no cavitation and cavitation conditions appear in random manner. While, surveying the vibration and sound spectrums at the second, third, and fourth blade passing frequencies reveals no indications or phenomenon associated with the cavitation at variable speeds. It is recommended to survey the vibration spectra at the rotational and blade passing frequencies simultaneously as a detection unique method of cavitation.

A NEW CENTRIFUGAL ATOMIZATION TECHNIQUE OF SPRAY ROTATION FOR POWDER PREPARATION

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Effect of casting technology on microstructure and phases of high carbon high speed steel

The as-cast microstructures of high carbon high speed steels （HC-HSS） made by sand casting, centrifugal casting and electromagnetic centrifugal casting, respectively, were studied by using of optical microscopy （OM） and D/max2200pc X-ray diffraction. The results show that the microstructure of as-cast HC- HSS is dominated by alloy carbides （W2C, VC, Cr7C3）, martensite and austenite. The centrifugal casting and electromagnetic centrifugal casting apparently improve the solidification structure of HCoHSS. With the increase of magnetic intensity （B）, the volume fraction of austenite in the HC-HSS solidification structure increases significantly while the eutectic ledeburite decreases. Moreover, the secondary carbides precipitated from the austenite are finer with more homogeneous distribution in the electromagnetic centrifugal castings. It has also been found that the lath of eutectic carbide in ledeburite becomes finer and carbide phase spacing in eutectic ledeburite increases along with the higher magnetic field strength.

Design and Key Technology of Oil-Free Centrifugal Air Compressor for Hydrogen Fuel Cell

For a 120 kW hydrogen fuel cell system,a centrifugal air compressor with fixed power of 22 kW fuel cell is designed.Firstly,the theoretical calculation is carried out for the aerodynamic characteristics of a ultra-high-speed permanent magnet synchronous motor,an air compressor,and an aerodynamic foil bearing.Then,a prototype is trial-produced and a related test bench is built for test verification.Finally,both the simulation and test results indicate that the designed centrifugal air compressor meets the overall requirements of the hydrogen fuel cell system,and the relevant conclusions provide both theoretical and experimental references for the subsequent series development and design of the centrifugal air compressor.

Effect of impeller reflux balance holes on pressure and axial force of centrifugal pump

The size of impeller reflux holes for centrifugal pump has influence on the pressure distribution of front and rear shrouds and rear pump chamber, as well as energy characteristics of whole pump and axial force. Low specific-speed centrifugal pump with Q=12.5 m3/h, H=60 m, n=2950 r/min was selected to be designed with eight axial reflux balance holes with 4.5 mm in diameter. The simulated Q-H curve and net positive suction head(NPSH) were in good agreement with experimental results, which illustrated that centrifugal pump with axial reflux balance holes was superior in the cavitation characteristic; however, it showed to little superiority in head and efficiency. The pressure in rear pump chamber at 0.6 times rate flow is 29.36% of pressure difference between outlet and inlet, which reduces to 29.10% at rate flow and 28.33% at 1.4 times rate flow. As the whole, the pressure distribution on front and rear shrouds from simulation results is not a standard parabola, and axial force decreases as flow rate increases. Radical reflux balance holes chosen to be 5.2 mm and 5.9 mm in diameter were further designed with other hydraulic parts unchanged. With structural grids adopted for total flow field, contrast numerical simulation on internal flow characteristics was conducted based on momentum equations and standard turbulence model(κ-ε). It is found that axial force of pump with radical reflux balance holes of5.2 mm and 5.9 mm in diameter is significantly less than that with radical reflux balance holes of 4.5 mm in diameter. Better axial force balance is obtained as the ratio of area of reflux balance holes and area of sealing ring exceeds 6.