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Assessment of fatigue life of remanufactured impeller based on FEA

Lei XU,Huajun CAO,Hailong LIU,Yubo ZHANG

《机械工程前沿（英文）》 2016年第11卷第3期页码 219-226 doi: 10.1007/s11465-016-0394-x

摘要：

Predicting the fatigue life of remanufactured centrifugal compressor impellers is a critical problem. In this paper, the S-N curve data were obtained by combining experimentation and theory deduction. The load spectrum was compiled by the rain-flow counting method based on the comprehensive consideration of the centrifugal force, residual stress, and aerodynamic loads in the repair region. A fatigue life simulation model was built, and fatigue life was analyzed based on the fatigue cumulative damage rule. Although incapable of providing a high-precision prediction, the simulation results were useful for the analysis of fatigue life impact factors and fatigue fracture areas. Results showed that the load amplitude greatly affected fatigue life, the impeller was protected from running at over-speed, and the predicted fatigue life was satisfied within the next service cycle safely at the rated speed.

关键词： remanufactured impeller fatigue life impeller failures finite element analysis (FEA)

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Mesoscale fabrication of a complex surface for integral impeller blades

Xibin WANG,Tianfeng ZHOU,Lijing XIE,Li JIAO,Zhibing LIU,Zhiqiang LIANG,Pei YAN

《机械工程前沿（英文）》 2017年第12卷第1期页码 116-131 doi: 10.1007/s11465-017-0426-1

摘要：

Integral impeller is the most important component of a mini-engine. However, the machining of a mesoscale impeller with a complex integral surface is difficult because of its compact size and high accuracy requirement. A mesoscale component is usually manufactured by milling. However, a conventional milling tool cannot meet the machining requirements because of its size and stiffness. For the fabrication of a complex integral impeller, a micro-ball-end mill is designed in accordance with the non-instantaneous-pole envelope principle and manufactured by grinding based on the profile model of the helical groove and the mathematical model of the cutting edge curve. Subsequently, fractal theory is applied to characterize the surface quality of the integral impeller. The fractal theory-based characterization shows that the completed mesoscale integral impeller exhibits a favorable performance in terms of mechanical properties and morphological accuracy.

关键词： mesoscale fabrication micro-milling tool mesoscale milling impeller blade

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Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review

Haiyang LU, Yanle LI, Fangyi LI, Xingyi ZHANG, Chuanwei ZHANG, Jiyu DU, Zhen LI, Xueju RAN, Jianfeng LI, Weiqiang WANG

《机械工程前沿（英文）》 2019年第14卷第4期页码 402-411 doi: 10.1007/s11465-019-0548-8

摘要： The theoretical and technological achievements in the damage mechanism and evaluation model obtained through the national basic research program “Key Fundamental Scientific Problems on Mechanical Equipment Remanufacturing” are reviewed in this work. Large centrifugal compressor impeller blanks were used as the study object. The materials of the blanks were FV520B and KMN. The mechanism and evaluation model of ultra-high cycle fatigue, erosion wear, and corrosion damage were studied via theoretical calculation, finite element simulation, and experimentation. For ultra-high cycle fatigue damage, the characteristics of ultra-high cycle fatigue of the impeller material were clarified, and prediction models of ultra-high cycle fatigue strength were established. A residual life evaluation technique based on the “ - - ” (where was the nonlinear parameter, was the Vickers hardness, and was the fatigue life) double criterion method was proposed. For erosion wear, the flow field of gas-solid two-phase flow inside the impeller was simulated, and the erosion wear law was clarified. Two models for erosion rate and erosion depth calculation were established. For corrosion damage, the electrochemical and stress corrosion behaviors of the impeller material and welded joints in H S/CO environment were investigated. (critical stress intensity factor) and d /d (crack growth rate, where is the total crack length and is time) varied with H S concentration and temperature, and their variation laws were revealed. Through this research, the key scientific problems of the damage behavior and mechanism of remanufacturing objects in the multi-strength field and cross-scale were solved. The findings provide theoretical and evaluation model support for the analysis and evaluation of large centrifugal compressor impellers before remanufacturing.

关键词： remanufacturing centrifugal compressor impeller remanufacturing blank damage mechanism evaluation model

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Optimal ratio of bend channel in centrifugal compressor

WEN Suping, HU Xiaowen, LI Tingbin, ZHANG Yong, WANG Jun

《能源前沿（英文）》 2008年第2卷第4期页码 381-385 doi: 10.1007/s11708-008-0084-4

摘要： A numerical investigation on the flow in a bend channel by coupling the impeller with the vaneless diffuser in a centrifugal compressor with different ratios (bend radius to bend channel width ) is presented. The jet-wake effect of the impeller outlet is considered and flow pattern in the bend channel and the performance of the centrifugal compressor stage are investigated. The results indicate that there is an optimal ratio for increasing the stage efficiency to the highest for a specific compressor stage. The change in ratio significantly affects the flow angle of the bend channel outlet. The prime reason for the total pressure loss in the bend channel is the wall friction in the bend channel.

关键词： specific compressor different centrifugal compressor pressure impeller

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Five-axis rough machining for impellers

Ruolong QI, Weijun LIU, Hongyou BIAN, Lun LI

《机械工程前沿（英文）》 2009年第4卷第1期页码 71-76 doi: 10.1007/s11465-009-0010-4

摘要： The most important components used in aerospace, ships, and automobiles are designed with free form surfaces. An impeller is one of the most important components that is difficult to machine because of its twisted blades. Rough machining is recognized as the most crucial procedure influencing machining efficiency and is critical for the finishing process. An integrated rough machining course with detailed algorithms is presented in this paper. An algorithm for determining the minimum distance between two surfaces is applied to estimate the tool size. The space between two blades that will be cleared from the roughcast is divided to generate CC points. The tool axis vector is confirmed based on flank milling using a simple method that could eliminate global interference between the tool and the blades. The result proves that the machining methodology presented in this paper is useful and successful.

关键词： five-axis impeller tool-path planning flank milling ruled surface

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Noise reduction for centrifugal fan with non-isometric forward-swept blade impeller

MA Jianfeng, QI Datong, MAO Yijun

《能源前沿（英文）》 2008年第2卷第4期页码 433-437 doi: 10.1007/s11708-008-0082-6

摘要： To reduce the noise of the T9-19No.4A centrifugal fan, whose impeller has equidistant forward-swept blades, two new impellers with different blade spacing were designed and an experimental study was conducted. Both the fan’s aerodynamic performance and noise were measured when the two redesigned impellers were compared with the original ones. The test results are discussed in detail and the effect of the noise reduction method for a centrifugal fan using impellers with non-isometric forward-swept blades was analyzed, which can serve as a reference for researches on reduction of fan noise.

关键词： different reference aerodynamic performance centrifugal impeller

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Cavitation in semi-open centrifugal impellers for a miniature pump

LUO Xianwu, LIU Shuhong, ZHANG Yao, XU Hongyuan

《能源前沿（英文）》 2008年第2卷第1期页码 31-35 doi: 10.1007/s11708-008-0011-8

摘要： Cavitation in miniature pumps was investigated experimentally for two semi-open centrifugal impellers. Although both impellers had the same blade cross-section, one impeller had a two-dimensional blade, while the other had a leaned blade. The flows were also analyzed using a numerical model of the three-dimensional turbulent flow in the pumps near the peak efficiency point using the -? turbulence model and the VOF cavitation model. The average cavitation performance of each impeller was satisfactorily predicted by the numerical simulations. The results show that the miniature pumps have similar cavitation performances as an ordinary-size pump, with the cavitation performance of the semi-open impeller reduced by increased axial tip clearances. Also, both the hydraulic and cavitation performance of the semi-open impeller were improved by the leaned blade. The results also show that uniform flow upstream of the impeller inlet will improve the cavitation performance of a miniature pump.

关键词： cavitation performance semi-open impeller increased two-dimensional efficiency