基于微造型阀芯与异形阀腔结构的煤矿水压三用阀基础研究

Comparing with emulsion, using water as the working medium to coal mine supporting equipment has advantages of security, environmental protection and low price. However, it also has problems such as the sealing, lubrication and cavitation etc. Therefore, the coal mine water hydraulic three-function valve is proposed as research carrier, which is based on the structure of textured valve core and special-shaped valve chamber. In order to improve the lubrication and sealing performance of the chamber friction pairs, the texture of the valve core is applied. To reveal the best matching materials of the friction and the mechanism of the textured core lubrication, sealing and antipollution under complex working conditions, the textured valve chamber model of friction pairs under the environment of random vibration and variable pressure difference is established, which includes hydrodynamic lubrication model, variable scale dynamic sealing model and the fluid-solid coupling model of introducing micro abrasive disturbance. To improve the cavitation resistive performance of the chamber, a special-shaped valve chamber macrostructure is optimized. For analyzing coupling characteristics between the micro cavitation mechanism of the textured core and the macro cavitation mechanism of the special-shaped valve chamber, the multiphase flow field model of textured special-shaped valve chamber is established. A new method of using texture micro cavitation bearing and restraining the damage of the chamber macro cavitation is proposed. Moreover, the prototype of the water hydraulic three-function valve is developed and the prototype test is made. Finally, the perfect design theory and evaluation method of water hydraulic three-function valve about textured valve core and special-shaped valve chamber structure is formed. The research can provide theoretical support for the popularization and application of water hydraulic technology in coal mine supporting equipment.

与乳化液相比，煤矿支护装备使用水作为工作介质，具有安全环保、节约资源、价格低廉等诸多优点，同时也存在密封、润滑和气蚀等难题。本项目提出一种基于微造型阀芯及异形阀腔结构的煤矿水压三用阀，并以此为研究载体。借助微造型阀芯微观结构，改善阀芯摩擦副的润滑与密封性能，并建立随机振动及变压差条件下的摩擦副动压润滑模型、变尺度动密封模型和引入微磨粒扰动的流固耦合模型，揭示摩擦副材料最佳配对及复杂工况下微造型阀芯的润滑、密封及抗污染机理。设计并优化异形阀腔宏观结构，改善其抗气蚀性能，建立微造型异形阀腔流场多相流模型，分析微造型阀芯微观空化机理与异形阀腔宏观气蚀机理间的耦合特性，提出对微造型微观空化承载加以利用，且对阀腔宏观气蚀破坏进行抑制的新方法。研制水压三用阀样机并进行试验研究，形成完善的微造型阀芯与异形阀腔结构的水压三用阀设计理论与评价方法，为水液压技术在煤矿支护装备中的应用和推广提供理论支撑。

与乳化液相比，煤矿三用阀以水作为工作介质，具有安全环保、节约资源、价格低廉等诸多优点，但同时其也存在密封、润滑和气蚀等问题。水液压三用阀的压力和流量变化大导致节流口的气蚀严重，同时井下环境恶劣，微磨粒污染严重，严重影响了其使用性能。针对上述问题，提出了一种基于微造型阀芯和异形阀腔的煤矿水液压三用阀新结构，借助微造型阀芯微观结构，提高了阀芯摩擦副的润滑与密封性能，通过异形阀腔宏观结构，改善了其抗气蚀性能。项目研究了水压三用阀阀芯微造型的润滑和减磨机理，建立了阀芯摩擦副动压润滑模型，研究了微造型阀芯的动压承载及润滑特性，分析了复合微造型及多参数交互作用对润滑性能的影响，并开展了其变织构润滑与承载特性研究。研究了水压三用阀阀芯微造型与微磨粒间的流固耦合作用，建立了微造型阀芯与微磨粒间的流固耦合模型，探究了微造型对颗粒的容纳、输送和外排机理，分析了磨粒与微造型间的挤压和磨损特性，并开展了阀芯磨损量的多因素交互作用分析。研究了水压三用阀异形阀腔结构设计理论及其抗气蚀机理，建立了其流场仿真流模型，揭示了煤矿水压三用阀异形阀腔结构的抗气蚀机理，探究了水压三用阀异形阀腔结构的气蚀消减及转移方法，并优化了异形阀腔宏观结构。搭建了基于柔性铰链的多功能专用往复摩擦磨损试验机，完善了微造型复合加工平台，优选了水液压三用阀关键摩擦副材料，开展了微造型试样的端面和往复摩擦磨损试验研究。研究表明：在阀芯表面设计合理的微造型结构可改善阀芯的润滑性能，并在一定程度上减轻阀芯摩擦副的摩擦和磨损；此外将二级节流及高压引流结构引入煤矿水液压三用阀的异形阀腔结构设计中，在理论上可有效降低阀腔的气蚀破坏，从而提高煤矿水液压三用阀的抗气蚀性能。项目研究丰富了煤矿水液压三用阀阀芯摩擦副的润滑与减磨理论，为微造型在煤矿水液压元件关键摩擦副中的工程设计奠定了基础，也为水液压技术在煤矿井下的应用和推广提供了重要理论支撑。