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n
P(t) = Qi Li,n (t) (3)
i=0
Vi Bi,n (t)
Li,n (t) = n i = 1, 2, . . . , nm − 1 (4)
j=0 Vj B j,n (t)
1 Coordinate system
Bi,n (t) represent rational basis functions, Qi are the
φ1 , φ2 is rotation angles; ω2 , ω1 is rotation velocities; control points, m is the number of power, Vi are weight
θ1 , θ2 is radians of point C and point H centred on O2. factors of the parametric equation. NURBS curves
could be modified through changing either control
points or weight factors. Twin-screw compressor rotor
Meshing principle profile is mostly constructed by the multiple curves, and
Here is a predefined segment of the female rotor profile, many modifications are needed before a good perform-
and the parametric equations is as follows ance screw rotor profile to be acquired. For these
reasons, NURBS curves are applied to establish rotor
profile so as to shortening profile design time.
x2 = x2 (t)
tb ≤ t ≤ t e (1)
y2 = y2 (t)
2 a The rotor profile of unilateral asymmetric combined cycloid with pin gear arc. b The new designed rotor profile
Freeform curves such as NURBS curves are introduced, curves. The equations are expressed as follows
and the newly designed rotor profile is shown in Fig. 2b.
h
Comparing Fig. 2a with Fig. 2b, it is easy to see the fol- Bi,3 (t)Wi Vi
lowing: (1) the straight lines are replaced by circular arcs C(t) = i=1
n (7)
i=1 Bi,3 (t)Wi
in segments B2C2, H2I2. A smooth mesh between the
male and female profiles is achieved; moreover, the Vi are the control points of the NURBS curves, Wi are
effects of working stress concentration are suppressed the weight factors, Bi,3 (t) are the basis functions of three
on screw rotors through this design. (2) The combination B-spline equations which are defined by the vectors of
of the NURBS curves and their envelopes are used control points Vi , h is the number of control points.
instead of the combination of a point and cycloid in seg- Point H2 is a fixed point in the female rotor tooth
ments E1H1, E2H2. As a result, the seal volume of the profile. Since Point H1 is coincided with point H2, the
original profile is eliminated, and the diffusion of gas is parametric equations of cycloid H1I1 could be written
reduced. (3) Points H1,2 are moved some distance as equation (8): λ is the distance between a point of the
towards the upper left of their original position to cycloid H1I1 and the male rotor axis O1. e = 0.625%; A0 .
prevent the starting point H1 of cycloid H1I1 from being
worn heavily. But the height of the highest point is ⎧
⎪ x1 = A0 cos φ1 − (R2 − e) cos (θ2 − kφ1 )
brought down on meshing line, which makes the relative ⎪
⎪
⎨ y2 = A0 sin φ1 + (R2 − e) sin (θ2 − kφ1 )
leakage triangle expanded. (4) The interdental volume is
(8)
amplified by expanding the radius of arcs C1E1, C2E2. ⎪
⎪ 1 (R2 − e)2 + A2 − λ2
⎪
⎩ φ1 = u θ2 − arccos
All the new designs are listed in Table 1. 2A0 (R2 − e)
numerical model could be given as follows corresponding screw rotor three-dimensional model
could be obtained. The flow models are exported to
r2 Gambit in STP file format, and the contact surfaces of
μt = ρCμ (9) these models are defined as interfaces. Finally, they are
ε
classified into unstructured tetrahedral meshes by
where μt is turbulent viscosity; ρ is gas density; Cμ is dynamic mesh method, which is shown in Fig. 3b. The
empirical constant; r, ε is turbulent kinetic energy; turbu- grid quantity of the air flow models is listed in Table 2.
lent dissipate rate.
The air flow could be written as follows
Dynamic simulation results
∂(ρui r) ∂(ρr) ∂ The distribution of pressure and velocity
+ = Gr + Gb − ρε − YM + Sr (10) The twin-screw compressor flow numerical simulation is
∂xi ∂t ∂xj
analysed by the professional fluid analysis software
FLUENT after setting the operating speed
∂(ρui ε) ∂(ρε) ∂ μt ∂ε ε 3000 rev min−1 and other relevant parameters. The
+ = μ+ + C1ε (Gr dynamic pressure simulation results of the original and
∂xi ∂t ∂xj σ ε ∂xj r
new air flow fields are shown in Fig. 4. The pressure of
ε2 the twin-screw compressor flow is gradually increased
+ C3ε Gb ) − C2ε ρ + Sε (11)
r from the intake port to exhaust port, which is obvious
to be noted in Fig. 4. The pressure is low in intake port,
where but the pressure of the exhaust port is high. The downside
⎧ pressure of the meshing line is higher than the upside
⎪
⎪ ∂ui ∂uj ∂ui pressure significantly, which matches the practical distri-
⎪
⎪ Gr = μt +
⎪
⎨ ∂xj ∂xi ∂xj bution of the compressor flow pressure. According to
μ ∂T 1 ∂ρ . (12) Fig. 4, the pressure of the intake port is −0.0922 MPa
⎪
⎪ Gb = βgi t , β=−
⎪
⎪ Prt ∂xi ρ ∂T on the original air flow field, whereas the new flow
⎪
⎩ √ field’s pressure is −0.0907 MPa; the highest pressure of
YM = 2ρεMt2 , Mt = r/a2 , a = λRT
original exhaust port is 0.707 MPa on original air flow,
the pressure of new flow field is 0.767 MPa. The
Gr is turbulent kinetic energy related to the gradient of
maximum differential pressure of the original flow is
mean speed; Gb is turbulent kinetic energy related to the
0.7992 MPa, the maximum differential pressure of the
buoyancy of air; YM is influence coefficient of the total
new flow field is 0.8577 MPa. As described above, the
dissipation rate related to the pulsation of compressible
pressure distribution of the novel profile air flow field is
turbulence; C1ε , C2ε , C3ε is empirical constants. Prt is
optimised: the intake pressure improved by 1.6%, the
turbulent Prandtl number; σ ε , σ r are Prandtl numbers
highest exhaust pressure improved by 8.5% and the
of turbulent dissipation rate and turbulent kinetic
maximum differential pressure improved by 7.3%.
energy; gi is component of gravity acceleration in the
As shown in Fig. 5, the location of high velocity is the
direction of i; Mt , β, a is turbulent Mach number,
leakage triangle where the air is leaked from the high-
thermal expansion coefficient, sound speed.
pressure area to the low-pressure area. It is obvious to
The physical parameters of air in a standard atmos-
see that the maximum leaking velocity of the original
pheric pressure at 20°C are as follows: the density of air
flow is 725 m s−1, whereas the velocity of new flow field
is ρ = 1.29 kg m−3; kinetic viscosity is 17.9 × 10−6 Pa s−1;
is 768 m s−1. Compared with the original flow field, the
thermal conductivity is 2547 W m K; specific heat capacity
is 1005 J (kg−1 K−1). Since the flow is assumed isothermal,
the energy equations are not given. Table 2 Grid quantity of the air flow models
5 a Velocity vector of the original flow field. b Velocity vector of the new flow field
leaking velocity is increased by 5.6%. For the phenom- basis of the simulation results. Ultimately, a prototype
enon of backflow is exhibited in the exhaust port,10 the of the twin-screw compressor rotor profile would be pro-
displacement of intake flow field is put as the displace- duced and a confirmatory experiment is to be made to
ment of the compressor. The displacement of the original verify performance of the rotor profile. Apart from all
compressor flow field is 15.5 m−3 min−1, and the new the above, it could be seen that this new design method
one’s is 16.1 m−3 min−1, which is increased by 3.9%. could overcome the inconvenience in traditional rotor
profile design or optimisation process such as the compli-
Further optimisation cated modification in rotor profile, shortage of funds and
The maximum differential pressure of newly designed flow time in the compressor performance experiments, pro-
is increased obviously based on the dynamic simulation blems in data collection and analysis.
analysis results. It forebodes a certain rationality of the
novel rotor profile compared with the original profile.
However, the slight increase of the compressor displace-
Conclusion
ment is mainly because points H1,2 are moved some dis- In this paper, the rotor profiles are established by free-
tance towards the upper left of their original position. As form curves (non-uniform rational B-spline curves) to
a result, the leakage triangle is expanded. And the obtain a smooth mesh of the rotors, and the optimisations
further growth of compressor displacement is affected. of rotor profiles could be made by motions of the control
Further improvement of the newly designed twin-screw points or changes of weight factors of the curves easily.
compressor rotor profile is still needed. Freeform curves When compared the simulation results of the new
such as NURBS curves could be applied to replace the profile with the original profile, it is easy to be noted
cycloid and the arcs in segment H1I1. Segments E1H1, that the maximum differential pressure of the new com-
E2H2 would be extended outward some distance to pressor flow field is increased significantly, which indi-
achieve a smooth mesh of female and male tooth profiles. cates a certain rationality of the redesigned profile.
The radius of arc H2I2 would be increased and points H1,2 In the twin-screw rotor profile design process,
are extended towards the upper right of their original pos- Computational Fluid Dynamics theories and freeform
ition. The above optimisations could be achieved by mod- curves are applied. On the basis of the numerical simu-
ifying control points of curves or weight factors of the lation results, freeform curves are applied to optimise
parametric equations. Then, a new numerical model the rotor profile until a novel good performance profile
would be built to simulate the compression process of is obtained. With this method, physical experiments are
compressor. The rotor profile would be adjusted until a decreased as few as possible to realise the advantages of
good performance rotor profile to be obtained on the cost, reliability and agility.
Acknowledgements 4. Y.-R. Wu and Z.-H. Fong: ‘Improved rotor profiling based on the
arbitrary sealing line for twin-screw compressors’, Mech. Mach.
This project is funded by National Science Foundation of Theory, 2008, 43, (6), 695–711.
China (51275210), (51105175); Industry-University- 5. J. Wen, X. Sun, W. Sun and G. Zhang: ‘Rotor profiles design method
and numerical simulation for twin-screw kneader’, Chinese J. Mech.
Research Foundation of Jiangsu Province (BY2013015- Eng., 2013, 49, (3), 63–73 (in Chinese).
30); and Six-Major-Talent-Summit Project of Jiangsu 6. W. Shi, X. Yu and J. Li: ‘Finite element modal analysis of double
Province, China (2013-ZBZZ-016). screw compressor rotor’, Compressor Technol., 2012, 4, 7–9 (in
Chinese).
7. J. Chen and H. Cui: ‘Shape modification of NURBS curves based on
weight’, J. Naval Univ. Eng., 2012, 24, (4), 108–112 (in Chinese).
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