双螺杆压缩机转子型线的设计制造新方法研究

The compressors are so widely used in industrial sectors, such as mining industry, chemical industry, power industry, metallurgical industry, construction industry, machinery industry and refrigeration industry, which account for 25% of overall power consumption of plants and cost more than 80% of their own operating electricity. And then the compressors are bound to affect the manufacturing industry that occupied 80% of all industrial added value. However, in our country, there are neither core technologies, nor independent intellectual property rights about the high-performance screw compressors that can do 24 hours work in one day under low-temperature environment.In fact,it is a pair of screw rotors and the corresponding rotor profiles that influence the harsh demanding performance of high efficient and low noise for twin screw compressors that occupy more than 80% total sales volume of all positive displacement compressors. On the groundwork of collection and analysis of existing rotor profiles, error feedback propagation neural network theory is used to adaptively interpret the number of segments composed of rotor profiles, weight and feature of each segment. Based on moving frame of sculptured curve of the differential geometry,the best connection mode between rotor profiles of is studied. Simultaneously, the traditional method of directly generating rotor profiles of screw compressors and the way of designing rotor profiles based on sealing line are integrated to achieve the forward，reverse and close-loop design of screw rotors. So the optimal model of screw compressor rotors is established gradually. Furthermore,this plan focuses on the numerical simulation method to describe the status of multiphase fluid by the means of fluid and thermodynamics numerical simulation techology. Simulation results are simultaneously compared to physical measurements data recorded by making use of micro-type sensors that embedded on the root of rotors.The screw rotos are uniformly ground by jet stream under super high pressure and jet blades which are distributed in reasonable way.The proposed plan is enough powerful to adaptively develop the green environmental protection and efficient twin-screw compressors with independent intellectual property rights.

占工厂整体电耗25%和自身运行电费成本80%以上的压缩机左右着广泛使用它的矿山、化工、动力、冶金、建筑、机械、制冷等工业部门，也必然影响着全部工业增加值80%的制造业。可24小时低温运转的高效高性能螺杆压缩机在我国既无关键核心技术，又无自主知识产权。决定所有容积式压缩机80%以上销售量的双螺杆压缩机高效低噪苛刻性能的是一对螺杆转子及其型线。本项目拟在收集、分析现有型线的基础上，利用误差反馈传播神经网络理论自适应推演转子型线组成及其权重和各段型线的特性；基于微分几何的曲线活动标架研究型线间最佳连接方式，综合传统的转子型线架建压缩机和密封线逆向设计转子型线的方法，集成螺杆转子的正反全闭环设计，逐步建立最优的螺杆压缩机转子模型；再流体动力学数值模拟多相流状况，与根部植入的压力传感器记录比对，以喷射研磨完善螺杆转子的均匀磨削加工和合理射流分布，自适应开发具有自主知识产权绿色环保高效的双螺杆压缩机。

目前国内企业掌握的螺杆压缩机技术有限，自主研发的螺杆压缩机性能与国外优秀螺杆压缩机存在一定差距，深入研究其中的关键技术，开发高技术含量的压缩机产品，拥有双螺杆压缩机领域自主知识产权具有重大战略意义。. 在现有典型优秀螺杆转子型线基础上，总结出了用于转子型线设计的基本曲线类型、啮合方式对螺杆压缩机几何参数、性能参数的影响，借助啮合原理中齿廓法线法为包络条件的求解方法，演绎推导由阴转子到阳转子的正向设计方法和由啮合线到转子型线的反向设计方法。正向中实现了由一条样条曲线架构整条转子型线的方法，增加了型线设计的灵活性；反向中研究了啮合线对转子齿形的影响规律，将其划分成8个功能段，实现了通过局部调整啮合线的方法优化转子齿形的目的。基于Visual C++平台，结合MFC模块和Open GL的图形显示功能，开发了一套双螺杆压缩机转子型线设计系统（TwinScrew Profile Design，简称TSPD），TSPD主要包含正向设计、反向设计以及典型型线生成模块，并可评价转子性能优劣，有效指导双螺杆压缩机转子型线的开发设计。. 针对以往Fluent动网格计算易出现负体积网格以及计算不稳定和计算时间过长的不足点，探索出了一种用于双螺杆压缩机CFD分析的新方法，其采用ANSA划分流体域面网格和STAR CCM+划分体网格的混合处理方式，有效提升了仿真精度与分析结果的可靠性，并且计算时间缩减为原先的50%。搭建了压缩机工作性能测试平台，对其在不同工况下的性能进行试验研究，有效验证了CFD仿真结果的正确性与可靠性。运用流体动力学理论研究了磨料粒子冲蚀过程中材料去除机理及控制方法，结合螺杆转子加工现状，开展了水射流铣削加工实验，提出了应用多轴磨料水射流螺杆转子复杂曲面精加工新方法。基于螺杆转子复杂曲面成形原理和刀片全生命周期算法提出了增加磨损部位铣刀刀片的粗铣刀设计方法，并运用实验证明了该方法的合理性。. 综上所述，本项目实现了双螺杆压缩机转子型线从理论设计到性能仿真与测试、再到转子加工制造新方法的研究计划，完成了项目研究目标。