飞秒激光表面织构对压裂泵动密封组件摩擦磨损性能的影响研究

Fracturing is one of the main measures to increase production of oil and gas at present, while fracturing pump is one of the key equipment of fracturing. Fracturing pump plunger seal system carries out reciprocating linear motion under ultra-high impact load. The wear failure of plunger surface leads to seal leakage, which is the key factor limiting fracturing pump performance and reliability. Therefore, how to improve the wear resistance of plunger dynamic seal assembly has become a serious problem. Micro /nano surface textures, which have optimum lubrication and wear resistance in bionics field, were introduced to the interface of plunger and seals in order to improve the lubricating and anti-wear performance. The unit experimental study based on infinitesimal method and similarity theory will be carried out in this project, and the theoretical models for surface texture on the lubricating and anti-friction performance of plunger seal assembly are established based on nonlinear deformation of elastomers and Reynolds equation. Through the combination of theoretical and experimental methods, the mechanism of micro/nano-textured parameters on the tribological properties of plunger dynamic seal assembly of fracturing pump is intensively studied. Femtosecond laser processing and testing techniques of optimal textures arranged on the plunger surface is studied, forming a new theory and new technology to improve wear-resistance performance of plunge seal assembly.

压裂是目前油气增产的主要措施之一，而压裂泵是压裂施工中的关键装备之一。压裂泵柱塞密封系统在超高压冲击下作往复运动，柱塞表面的磨损失效导致密封刺漏是限制压裂泵工作性能和可靠性的关键因素。因此，如何提高柱塞动密封组件的抗磨、减摩性能是目前亟待解决的问题。本项目创新性的提出，将仿生学领域润滑、减磨性能较优的表面微/纳米织构，引入到柱塞（刚性材料）与密封盘根（柔性材料）摩擦副的润滑、减磨性能改善研究中。项目通过开展基于微元法和相似理论的表面织构柱塞密封摩擦副单元试验研究，建立并修正基于弹性体非线性变形与雷诺方程模型相耦合的柱塞密封组件表面织构润滑、减磨分析模型，在此基础上采用理论和实验相结合的方法，深入研究压裂泵工况下微/纳米织构参数对压裂泵柱塞动密封组件摩擦学性能的影响机理，优选织构布置于柱塞配对副表面的飞秒激光加工工艺及测试技术，形成一套柱塞密封组件减摩性能提升的表面织构设计新理论和新技术。

压裂是目前油气增产的主要措施之一，而压裂泵是压裂施工中的关键装备之一。压裂泵柱塞密封系统在超高压冲击下作往复运动，柱塞表面的磨损失效导致密封刺漏是限制压裂泵工作性能和可靠性的关键因素，亟需新的工艺技术及方法来提高柱塞（刚性材料）及密封组件（弹性材料）的抗磨、减摩性能。.本项目首先基于微元法和相似理论设计了模拟柱塞动密封组件在冲击动载荷工况下的单元试验方案，创新性地将仿生学领域润滑、减磨性能较优的表面微/纳米织构引入到压裂泵柱塞-密封盘根摩擦副中，开展了布置于柱塞摩擦副表面织构的激光加工工艺和织构类型、几何参数、布置方式等参数对压裂泵柱塞动密封组件摩擦磨损性能的影响规律的实验研究，初步获得了激光加工工艺参数与织构几何参数之间的映射关系，以及织构类型、几何参数、布置方式对平均摩擦系数和温升的影响规律。.其次，开展了压裂泵柱塞密封组件工况下表面织构润滑计算仿真模型的建立与求解工作，并结合单元实验数据对模型进行了修正，在修正模型的基础上，开展了织构参数及布置方式等对油膜厚度和油膜压力等影响规律的数值分析，获得了在无外界条件造成最小油膜厚度（2μm）的条件下，织构深度、织构截面形状、织构分布角度、织构长宽比和织构类型对油膜压力影响程度依次降低。.最后，在单元试验和数值分析结果相互验证的基础上开展了优选压裂泵柱塞表面织构参数的全尺寸实验研究，搭建了具有表面织构的压裂泵柱塞动密封组件全尺寸摩擦学性能试验台架，完成了布置于全尺寸柱塞动密封组件的优选织构的加工工艺设计，并通过温升指标参数初步论证了优选的柱塞表面织构可以显著提升柱塞-密封盘根摩擦副的润滑、减磨性能。.本项目将表面微/纳米织构引入到压裂泵柱塞-密封盘根摩擦副的润滑、减磨性能改善研究中，显著降低了压裂泵柱塞的磨损速率、提高了压裂泵整体的工作性能及可靠性。本研究结果可推广至油气装备的润滑减磨及结构优化设计中，对改善摩擦副的润滑性能及延长设备的工作寿命具有重要意义及工业价值。