基于3D分形端面表征的机械密封启停阶段摩擦磨损特性研究

doi:10.11949/0438-1157.20250737

摘要/Abstract

摘要：

针对非接触式机械密封在启停阶段因工况不稳定发生碰磨引起密封失效的问题，基于密封端面摩擦副微凸体3D分形表征原理，采用Archard黏着磨损理论方法建立了非接触式机械密封在启停阶段的流-固-热-磨耦合模型，计算出摩擦副的磨损率和磨损量并通过试验验证了模型的准确性，分析了非接触式机械密封在启停阶段的操作压力、操作温度、操作转速以及螺旋槽结构参数对摩擦副接触特性、温升特性和摩擦磨损特性的影响规律。结果表明：启停阶段操作转速和操作压力对密封磨损率和磨损量影响显著，操作温度通过密封环的热变形间接影响磨损程度；降低启停阶段的操作压力、操作温度并以大于1500 r·min^-1转速启停、以转速增量大于1000 r·min^-1调节均有利于减少摩擦副启停过程中的摩擦磨损；综合考虑密封启停阶段和稳定工作阶段的性能得到螺旋槽结构参数的优选取值为：槽坝比0.7~0.8，槽堰比0.4~0.6，螺旋角16°~18°，槽数10~12个，槽深6~8 μm。

关键词: 机械密封, 启停特性, 磨损, 分形, 流体力学

Abstract:

To address seal failure caused by face contact during start-stop phases of non-contact mechanical seals under unstable operating conditions, a fluid-solid-thermal-wear coupled model was established based on the 3D fractal characterization of micro-asperities and Archard's adhesive wear theory. The model calculates wear rate and volume of the seal faces, and its accuracy was validated experimentally. A systematic analysis was conducted on how operating pressure, temperature, rotational speed, and spiral groove structural parameters during the start-stop phase influence the contact characteristics, thermal behavior, and frictional wear of the seal faces. The results show that rotational speed and pressure significantly affect wear, while temperature influences it indirectly via thermal deformation of the seal rings. Lowering the operating pressure and temperature during the start-stop phase, starting and stopping at speeds greater than 1500 r·min^-1, and adjusting the speed in increments greater than 1000 r·min^-1 all help reduce friction and wear during the start-stop phase of the friction pair. Considering both start-stop and steady-state performance, the optimal spiral groove parameters are: dam ratio 0.7—0.8, weir ratio 0.4—0.6, spiral angle 16°—18°, 10—12 grooves, and groove depth of 6—8 μm.

Key words: mechanical seal, start-stop characteristics, attrition, fractals, fluid mechanics

中图分类号:

TH 117

陈凯放, 李双喜, 毕恩哲, 孙宇辉, 田举鹏, 王磊. 基于3D分形端面表征的机械密封启停阶段摩擦磨损特性研究[J]. 化工学报, 2025, 76(12): 6508-6526.

Kaifang CHEN, Shuangxi LI, Enzhe BI, Yuhui SUN, Jupeng TIAN, Lei WANG. Research on friction and wear characteristics of mechanical seals in start-stop phases based on 3D fractal end-face characterization[J]. CIESC Journal, 2025, 76(12): 6508-6526.

图/表 45

图1 非接触式机械密封结构简图

Fig.1 Schematic diagram of non-contact mechanical seal structure

图2 静环端面螺旋槽

Fig.2 Helical groove on stationary ring end face

表1 密封结构参数和工况参数

Table 1 Sealing structure parameters and working condition parameters

参数	数值	参数	数值
密封端面外径r_o/mm	62.8	螺旋槽槽数N_g/个	12(6~14)
密封端面内径r_i/mm	48.8	进口压力p_in/MPa	0.6(0.1~1.0)
螺旋槽螺旋角α/(°)	15(12~20)	出口压力p_out/MPa	0.1
螺旋槽槽坝比γ₁	0.7(0.5~0.9)	介质温度T_in/℃	500(100~900)
螺旋槽槽堰比γ₂	0.5(0.1~0.9)	转速n/(r·min)	0~4000
螺旋槽槽深h_g/ μm	6(4~12)	平衡半径r_s/mm	52.0

图3 槽数对密封特性的影响

Fig.3 Effect of groove number on sealing performance

表2 粗糙轮廓测量值与计算值

Table 2 Measured and calculated values of rough contours

粗糙轮廓特征	密封环材料	计算值	测量值
算术平均差R_a/μm	GH4169	0.009	0.009
算术平均差R_a/μm	SiC	0.003	0.003
最大轮廓峰高R_p/μm	GH4169	0.201	0.200
最大轮廓峰高R_p/μm	SiC	0.110	0.109
最大轮廓谷深R_v/μm	GH4169	0.185	0.188
最大轮廓谷深R_v/μm	SiC	0.131	0.128
轮廓单元平均宽度R_sm/μm	GH4169	1.083	1.067
轮廓单元平均宽度R_sm/μm	SiC	0.483	0.533

图4 边界条件示意图

Fig.4 Schematic diagram of boundary conditions

图5 几何模型

Fig.5 Geometrical model

图6 流体域计算网格无关性验证

Fig.6 Grid independence verification of fluid domain

图7 固体域计算网格无关性验证

Fig.7 Grid independence verification of solid domain

图8 耦合流程示意图

Fig.8 Schematic diagram of coupling process

图9 操作压力对摩擦副接触特性的影响

Fig.9 Effect of operating pressure on contact characteristics of friction pair

图10 操作压力对摩擦副温升的影响

Fig.10 Effect of operating pressure on temperature rise of friction pair

图11 操作压力对摩擦副磨损特性的影响

Fig.11 Effect of operating pressure on wear characteristics of friction pair

图12 操作压力对磨损量的影响

Fig.12 Effect of operating pressure on wear volume

图13 操作温度对摩擦副接触特性的影响

Fig.13 Effect of operating temperature on contact characteristics of friction pair

图14 操作温度对摩擦副温升的影响

Fig.14 Effect of operating temperature on temperature rise of friction pair

图15 操作温度对摩擦副磨损特性的影响

Fig.15 Effect of operating temperature on wear characteristics of friction pair

图16 操作温度对磨损量的影响

Fig.16 Effect of operating temperature on wear volume

图17 操作转速对摩擦副接触特性的影响

Fig.17 Effect of operating speed on contact characteristics of friction pair

图18 操作转速对摩擦副温升的影响

Fig.18 Effect of operating speed on temperature rise of friction pair

图19 转速增量对摩擦副磨损的影响

Fig.19 Effect of speed increment on friction pair wear

图20 转速增量对磨损量的影响

Fig.20 Effect of speed increment on wear volume

图21 槽坝比对摩擦副接触特性的影响

Fig.21 Effect of groove-to-dam ratio on contact characteristics of friction pair

图22 槽坝比对摩擦副温升的影响

Fig.22 Effect of groove-to-dam ratio on temperature rise of friction pair

图23 槽坝比对摩擦副磨损的影响

Fig.23 Effect of groove-to-dam ratio on friction pair wear

图24 槽坝比对磨损量的影响

Fig.24 Effect of groove-to-dam ratio on wear volume

图25 槽堰比对摩擦副接触特性的影响

Fig.25 Effect of groove-to-weir ratio on contact characteristics of friction pair

图26 槽堰比对摩擦副温升的影响

Fig.26 Effect of groove-to-weir ratio on temperature rise of friction pair

图27 槽堰比对摩擦副磨损特性的影响

Fig.27 Effect of groove-to-weir ratio on wear characteristics of friction pair

图28 槽堰比对磨损量的影响

Fig.28 Effect of groove-to-weir ratio on wear volume

图29 螺旋角对摩擦副接触特性的影响

Fig.29 Effect of helix angle on contact characteristics of friction pair

图30 螺旋角对摩擦副温升的影响

Fig.30 Effect of helix angle on temperature rise of friction pair

图31 螺旋角对摩擦副磨损特性的影响

Fig.31 Effect of helix angle on wear characteristics of friction pair

图32 螺旋角对磨损量的影响

Fig.32 Effect of helix angle on wear volume

图33 槽数对摩擦副接触特性的影响

Fig.33 Effect of groove number on contact characteristics of friction pair

图34 槽数对摩擦副温升的影响

Fig.34 Effect of groove number on temperature rise of friction pair

图35 槽数对摩擦副磨损特性的影响

Fig.35 Effect of groove number on wear characteristics of friction pair

图36 槽数对磨损量的影响

Fig.36 Effect of groove number on wear volume

图37 槽深对摩擦副接触特性的影响

Fig.37 Effect of groove depth on contact characteristics of friction pair

图38 槽深对摩擦副温升的影响

Fig.38 Effect of groove depth on temperature rise of friction pair

图39 槽深对摩擦副磨损特性的影响

Fig.39 Effect of groove depth on wear characteristics of friction pair

图40 槽深对磨损量的影响

Fig.40 Effect of groove depth on wear volume

图41 高温非接触式机械密封试验台

Fig.41 High-temperature non-contact mechanical seal test rig

图42 操作压力对摩擦副磨损特性的影响

Fig.42 Effect of operating pressure on wear characteristics of friction pair

图43 试验前后密封动环和静环端面形貌对比

Fig.43 Comparison of seal dynamic ring and static ring end face morphology before and after testing

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