CN120384890B - Slurry pump impeller and manufacturing method thereof - Google Patents
Slurry pump impeller and manufacturing method thereofInfo
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- CN120384890B CN120384890B CN202510889581.7A CN202510889581A CN120384890B CN 120384890 B CN120384890 B CN 120384890B CN 202510889581 A CN202510889581 A CN 202510889581A CN 120384890 B CN120384890 B CN 120384890B
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- pump impeller
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Abstract
本申请涉及一种渣浆泵叶轮及其制造方法，属于泵用叶轮技术领域。渣浆泵叶轮包括金属芯骨和多个叶片，金属芯骨包括一对第一盖板和多个支撑片；一对第一盖板沿第一方向相对设置；支撑片位于一对第一盖板之间，且，支撑片与盖板固接；叶片沿其长度方向设置有根部和端部；其中，多个叶片以第一方向为轴线圆周阵列；根部相较于端部靠近多个叶片的轴线；支撑片穿过叶片，且，支撑片支撑叶片；支撑片被配置为在端部和根部之中更靠近端部；多个叶片与多个支撑片一一对应。本申请实施例提供的渣浆泵叶轮具有较长的使用寿命。
The present application relates to a slurry pump impeller and a manufacturing method thereof, belonging to the technical field of pump impellers. The slurry pump impeller includes a metal core and a plurality of blades, the metal core including a pair of first cover plates and a plurality of support plates; the pair of first cover plates are arranged relative to each other along a first direction; the support plates are located between the pair of first cover plates, and the support plates are fixed to the cover plates; the blades are provided with roots and ends along their lengths; wherein the plurality of blades are arranged in a circular array with the first direction as the axis; the roots are closer to the axes of the plurality of blades than the ends; the support plates pass through the blades, and the support plates support the blades; the support plates are arranged closer to the ends between the ends and the roots; and the plurality of blades correspond one-to-one to the plurality of support plates. The slurry pump impeller provided by the embodiment of the present application has a long service life.
Description
Technical Field
The application relates to the technical field of impellers for pumps, in particular to a slurry pump impeller and a manufacturing method thereof.
Background
The phosphogypsum is an industrial system for producing a phosphorus-containing product by taking phosphate ore as a raw material and through chemical processing, phosphogypsum tailings are produced in the production of the phosphate chemical, the phosphogypsum tailings are required to be treated in order to prevent the phosphogypsum tailings from polluting the environment, the phosphogypsum tailings are solid particles, and in order to facilitate transportation of the phosphogypsum tailings, the solid phosphogypsum tailings and phosphogypsum slurry mixing water are generally mixed to form slurry, and the phosphogypsum tailings are subjected to wet discharge through a conveying pump.
The centrifugal conveying pump is used for conveying phosphogypsum tailings by enabling the slurry pump shell to rotate at a high speed to generate centrifugal force by an impeller in the pump so as to push the slurry to flow at a high speed. Along with the annual increase of the production of the phosphorus chemical industry, the height of phosphogypsum yards is increased year by year, the distance between phosphogypsum tailings is further and further increased, and the requirement on the conveying lift of a phosphogypsum tailings conveying pump is also greater. In order to raise the conveying lift of the conveying pump, the diameter of the impeller of the conveying pump needs to be increased, phosphogypsum slurry mixing water mixed with phosphogypsum tailings (for environmental protection, certain factories can adopt tailings backwater with stronger acidity to replace phosphogypsum slurry mixing water) has stronger acidity and can cause corrosion to the impeller, so that the impeller adopted in the process of conveying the phosphogypsum tailings is generally made of materials (such as ceramics) with better corrosion resistance, the materials have brittleness, and the produced impeller edge is easy to break when the stress is larger, so that the diameter of the impeller made of the materials cannot be too large.
In order to meet the requirement of higher and higher lift of a conveying pump in the phosphogypsum tailing conveying process, a metal framework with higher strength can be arranged on the inner side of the impeller, and the cracking of the blades is restrained through the higher strength of the metal framework. However, in the use process of the delivery pump, the root parts of the blades of the impeller bear lower stress (centrifugal force and bending moment are smaller), but the cycle times are extremely high, and the metal frameworks of the root parts of the blades can accumulate fatigue damage quickly in the high-speed cyclic stress process and then damage, so that the whole service life of the blades is shorter.
Disclosure of Invention
The application aims to solve the problems and provide a slurry pump impeller which has long service life and improves the problems.
The application is realized by the following technical scheme:
In a first aspect, the application provides a slurry pump impeller, which comprises a metal core and a plurality of blades, wherein the metal core comprises a pair of first cover plates and a plurality of supporting pieces, the pair of first cover plates are oppositely arranged along a first direction, the supporting pieces are positioned between the pair of first cover plates and fixedly connected with the cover plates, the blades are provided with roots and end parts along the length direction, the plurality of blades are circumferentially arrayed with the first direction as an axis, the roots are close to the axes of the plurality of blades compared with the end parts, the supporting pieces penetrate through the blades, the supporting pieces support the blades, the supporting pieces are arranged closer to the end parts among the end parts and the roots, and the plurality of blades are in one-to-one correspondence with the plurality of supporting pieces.
In the technical scheme of the embodiment of the application, the stress circulation borne by the slurry pump impeller in the use process is mainly caused by rotation periodic load and vibration load, the rotation periodic load is that the impeller rotates once, all parts undergo complete stress circulation, the vibration load is high-frequency alternating stress caused by water flow disturbance, mechanical resonance or external excitation, the effect of the rotation load on the root and the end of the blade is that the number of times of the circulation of the root and the end is the same (once per revolution), but the stress amplitude increases gradually from the root to the end, and the effect of the vibration load on the root and the end of the blade is that the root possibly bears more frequent stress fluctuation due to the constraint effect of the blade decreases gradually from the root to the end. In summary, the stress (e.g., centrifugal force) borne by the end of the blade is large, but the cycle number is mainly from the rotational speed, the frequency is low, the stress (e.g., centrifugal force) borne by the root of the blade is small, but the cycle number is from both the rotational speed and the vibration, and the frequency is high.
In the traditional design, the root of the blade is subject to rapid fatigue failure of the metal framework due to the concentration of cyclic stress. According to the application, the support piece is close to the end part of the blade, so that the stress distribution is changed, the support piece with high fatigue limit metal supports the end part, the root part is supported by the material with fatigue resistance of the blade, so that the end part can bear more centrifugal force, the root part shares load due to the support piece close to the end part, the local stress amplitude is reduced, the stress born by the root part is smaller, and the fatigue resistance of the material (such as ceramic, carbon fiber composite material and the like) of the blade can resist the generation of fatigue damage in the process of high-speed cyclic stress, so that the whole service life of the blade is prolonged.
The metal core bar is formed by combining the cover plate and the supporting piece, so that the integral rigidity of the impeller is improved, particularly, the bending deformation of the blades due to centrifugal force is restrained under high-speed rotation, and for the blades made of brittle materials (such as ceramics), the supporting of the metal core bar can reduce the stress concentration at the end parts of the blades, avoid brittle fracture and allow the diameter of the impeller to be increased so as to meet the requirement of high lift.
The design of the blade circumferential array, the supporting sheets are in one-to-one correspondence with the blades, the evenly distributed supporting sheets ensure that the stress of each blade is balanced, the local overload risk is reduced, and the running stability of the impeller is improved.
In some embodiments, the support sheet and the first cover plate are each provided with a plurality of through holes.
In the technical scheme of the embodiment of the application, the supporting sheet and the first cover plate are provided with the through holes, and the through holes can obviously lighten the weight of the supporting sheet and the cover plate, so that the overall mass of the metal core bar is reduced, and the cyclic load of centrifugal force on the root of the blade during high-speed rotation is reduced. After the weight is lightened, the bending moment and the inertia force born by the root of the blade are reduced, the fatigue damage accumulation of the root is further delayed, and the service life of the slurry pump impeller provided by the application is prolonged. The through holes provide mechanical anchor points for the materials of the blades in the manufacturing process, slurry or adhesive infiltrates into the holes to form a locking structure, so that the interface bonding strength is improved, and the risk of separation of the metal core bars and the blades is reduced.
In some embodiments, the dimension from the end of the support sheet near the root to the end near the end is the length dimension of the support sheet, the axes of the blades penetrate through the axes of the first cover plates, the axes of one of the pair of first cover plates is connected with the driving piece, the axes of the other pair of first cover plates are provided with liquid inlets, the length dimension of one side of the support sheet near the driving piece is R1, the length dimension of one side of the support sheet near the liquid inlets is R2, and R1> R2 are satisfied.
In the technical scheme of the embodiment of the application, the first cover plate directly connected with the driving piece in the metal core is limited by the driving piece, the other first cover plate has a certain distance from the driving piece, the control effect of the driving piece is weaker, when R1> R2 is met, the length dimension of one end of the supporting piece close to the driving piece is larger than the dimension of one end of the supporting piece close to the liquid inlet, the dimension of one end of the supporting piece close to the liquid inlet is smaller, so that the weight of the part of the metal core far away from the driving piece is smaller, the inertia of the part is smaller, the weaker control effect of the driving piece can be adapted, the part of the metal core far away from the driving piece is prevented from vibrating relative to the driving piece, the normal rotation of the impeller is influenced, moreover, after the material enters the impeller, the impeller continues to flow inwards along the axial direction of the impeller under the action of the suction force of negative pressure, until the first cover plate connected with the driving piece is blocked, the material is contacted with the first cover plate connected with the driving piece, namely, the part of the impeller continues to contact with the impeller, the impact force of the part of the impeller is smaller, the part of the supporting piece is enabled, the part of the metal core is capable of adapting to the part of the impeller, and the weaker length of the part is longer than the part of the supporting piece, and the part is enabled to provide the longer than the supporting effect.
In some embodiments, an end of the support sheet near the end is flush with the outer circumferential surface of the first cover plate.
In the technical scheme of the embodiment of the application, one end of the supporting sheet close to the end part is flush with the peripheral surface of the first cover plate, so that the space size of the centers of the supporting sheets is gradually reduced from the suction inlet to the driving part, the shape of the supporting sheet is matched with the shape of the impeller, so that the size of the opening at the center of the impeller is gradually reduced from the suction inlet to the driving part, and the channel through which the material flows in the process of entering the impeller until being blocked and turned is gradually narrowed, so that water flow is concentrated and the energy loss is reduced.
In some embodiments, the device further comprises a pair of second cover plates, wherein the pair of second cover plates are oppositely arranged along the first direction, the first cover plate is positioned inside the second cover plates, the blades are positioned between the pair of second cover plates, and the blades are fixedly connected with the second cover plates.
In the technical scheme of the embodiment of the application, on one hand, the second cover plate is taken as an outer protective cover, the first cover plate is wrapped, slurry formed by mixing phosphogypsum tailings and phosphogypsum slurry mixing water (or tailing backwater) is prevented from directly flushing the first cover plate made of metal, and the risk of corrosion damage to the first cover plate is obviously reduced. On the other hand, the blade is fixedly connected with the second cover plate, so that part of centrifugal force is transmitted to the wheel shaft connected with the slurry pump blade through the second cover plate, the stress amplitude of the root is reduced, and the risk of root damage is reduced.
In some embodiments, two ends of the supporting piece extend into a pair of second cover plates to be respectively connected with a pair of first cover plates.
In the technical scheme of the embodiment of the application, two ends of the supporting sheet are fixedly connected with the first cover plate and the second cover plate respectively to form rigid connection penetrating through the inner layer and the outer layer, the metal core bars and the second cover plate are integrated into a three-dimensional supporting frame, the integral bending rigidity of the impeller is improved, and the radial deformation of the impeller under high centrifugal force is restrained. The second cover plate and the blades wrap the whole metal core, so that slurry formed by mixing phosphogypsum tailings and phosphogypsum slurry mixing water (or tailing backwater) is prevented from contacting the metal core. The supporting piece passes through the second cover plate and is connected with the first cover plate to form a physical anchoring point, even if microcracks occur at the connecting interface of the outer second cover plate and the blades, the supporting piece and the first cover plate in the inner part can still provide mechanical support, so that the crack is prevented from diffusing, and the structural stability of the slurry pump impeller is improved.
In some embodiments, the blade is made of a carbon fiber composite material.
In the technical scheme of the embodiment of the application, the traditional ceramic blade is difficult to meet the high-lift requirement due to the fact that the brittleness is large and the diameter of the impeller is limited. The blade provided by the application is made of a carbon fiber composite material, the tensile strength of the carbon fiber composite material (CFRP) is higher than that of steel, and the blade has excellent impact toughness, can bear larger centrifugal force, and allows the diameter of the slurry pump impeller to be larger, so that the conveying lift is improved. The density of the carbon fiber composite material is low, the weight of the blade can be reduced, and the load of centrifugal force on the metal core bar is reduced, so that the stress amplitude of the root is reduced, and the fatigue life is prolonged. The carbon fiber composite material also has extremely high corrosion resistance, and can effectively avoid the corrosion of the blade by phosphogypsum slurry mixing water (or tailing backwater).
In a second aspect, the present application provides a method for manufacturing a slurry pump impeller of the first aspect, the method comprising the steps of connecting a first cover plate to one end of a plurality of support plates, step S200 of installing a disposable inner mold between the plurality of support plates and then connecting another first cover plate to the other end of the plurality of support plates to obtain a metal core, and step S300 of placing the metal core with the disposable inner mold into a molding die and injection molding to obtain the slurry pump impeller.
According to the technical scheme provided by the embodiment of the application, one end of a plurality of supporting sheets is connected to one of a pair of first cover plates in the step S100, the positions of the plurality of supporting sheets are fixed, a disposable internal mold is arranged between the plurality of supporting sheets from one end of the supporting sheets, which is not connected with the cover plates, then the other first cover plate is connected with the other end of the plurality of supporting sheets to obtain metal core bars, the internal mold precisely fills gaps of the supporting sheets, nonmetallic materials (such as carbon fiber prepreg and corrosion-resistant engineering plastics) are ensured to uniformly wrap the metal core bars during injection molding, stress concentration caused by eccentricity or uneven wall thickness is avoided, and finally, the metal core bars with the disposable internal mold are put into a molding mold and subjected to injection molding in the step S300, so that the slurry pump impeller is obtained. The other first cover plate is connected with the supporting plate after the disposable inner die is installed between the supporting plates, so that the installation flow of the disposable inner die is simplified, an operator can conveniently adjust and determine the position of the disposable inner die, the risk of metal core bar eccentricity or uneven wall thickness is reduced, the disposable inner die is adopted to complete the molding of the whole inner cavity of the slurry pump impeller, the wall of the inner cavity of the prepared slurry pump impeller is smooth, and the conditions of burrs, uneven and the like of the inner cavity which is formed by splicing a plurality of inner dies are avoided. The manufacturing method of the slurry pump impeller realizes the precise molding of the impeller with high lift and large size by the mode of prefabrication of the metal core bar and auxiliary injection molding of the internal mold, and provides a manufacturing scheme of the slurry pump impeller with high efficiency, high reliability and low environmental load.
In some embodiments, a transition layer is arranged on the molding surface of the metal core, wherein the molding surface is the surface of the metal core contacted with the molding liquid through the transition layer, M is more than or equal to 3, the innermost N layers of transition materials are first materials, M is more than or equal to 1, M is more than or equal to the first materials and are in close contact with the molding surface, the outermost K layers of transition materials are second materials, the second materials have adhesiveness, M is more than or equal to 1, M is more than or equal to L layers of transition materials positioned between the first materials and the second materials are third materials, the third materials have low thermal conductivity, M is more than or equal to 1, and N+K+L is less than or equal to M.
In the technical scheme of the embodiment of the application, when the molding liquid is injected, as the third material has lower heat conductivity, the amount of thermal expansion caused by the heat of the molding liquid absorbed by the metal core is reduced due to the self-temperature rise of the molding liquid, the first material deforms along with the expansion of the metal core, the metal core is retracted in volume due to the self-temperature reduction in the cooling stage of the molding liquid, the transition layer is adhered to the molding surface of the metal core to keep close contact, the first material synchronously deforms along with the retraction of the metal core, meanwhile, the second material has high fluidity and self-sealing property, and the second material can fill gaps between the molding body formed after the cooling of the molding liquid and the third material, so that the transition layer can fill gaps left after the retraction of the metal core and gaps appearing after the cooling and hardening of the molding liquid, and the probability of defects such as cavities or holes appearing between the molding liquid and the metal core in the cooling and hardening stage of the molding liquid is reduced.
In some embodiments, the first material is silicone rubber.
According to the technical scheme provided by the embodiment of the application, the first material is silicon rubber, has low elastic modulus characteristic and excellent flexibility, can be stably attached to the metal core, and can compensate the thermal expansion amount of the metal core in the injection molding process through self elastic deformation, so that the condition that a cavity exists between the metal core and the blade and the second cover plate due to thermal expansion and cold contraction of the metal core is avoided, and the integral density of the slurry pump impeller is improved.
In some embodiments, the second material is an epoxy-based nanocomposite.
In the technical scheme of the embodiment of the application, the second material is an epoxy resin-based nanocomposite, and the epoxy resin-based nanocomposite can infiltrate the surfaces of the blade and the second cover plate facing the metal core bar and form a compact structure after solidification. The high adhesiveness can enhance the interfacial binding force between the metal core bar and the blade and the second cover plate, reduce the defect of the surface of the blade and the second cover plate facing the metal core bar, and improve the connection stability of the metal core bar and the blade and the second cover plate.
In some embodiments, the third material is a ceramic-based coating.
In the technical scheme of the embodiment of the application, the third material is a ceramic-based coating, and the ceramic-based coating has low thermal conductivity (< 30W/m.K) and high temperature stability (> 1000 ℃), so that the heat of the forming liquid can be effectively blocked from being conducted to the metal core, the thermal expansion amplitude of the metal core is reduced, and the expansion amount of the metal core is prevented from exceeding the compensatory amount of the first material, thereby reducing the risk of a cavity between the metal core and the blade and the second cover plate.
Additional aspects and advantages of the application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the application.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view of the overall structure of a slurry pump impeller according to some embodiments of the present application;
FIG. 2 is a side view of a slurry pump impeller according to some embodiments of the present application;
FIG. 3 is a cross-sectional view at A-A in FIG. 2;
FIG. 4 is a schematic view of a metal core bar according to some embodiments of the present application;
FIG. 5 is a flow chart of a method of manufacturing a slurry pump impeller according to some embodiments of the present application;
FIG. 6 is a schematic cross-sectional view of a transition layer provided in some embodiments of the application;
FIG. 7 is a flow chart of a method of manufacturing a slurry pump impeller according to further embodiments of the present application;
FIG. 8 is a schematic view of a metal core bar according to other embodiments of the present application;
The icons are 1-metal core bar, 10-first cover plate, 11-supporting sheet, 12-forming surface, 13-through hole, 2-blade, 20-root, 21-end, 3-second cover plate, 4-transition layer, 40-first material, 41-second material, 42-third material and X-first direction.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present application more apparent, the technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application, and it is apparent that the described embodiments are some embodiments of the present application, but not all embodiments of the present application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs, the terms used in the description of this application in this application are for the purpose of describing particular embodiments only and are not intended to be limiting of the application, and the terms "comprising" and "having" and any variations thereof in the description of this application and the claims and the above description of the drawings are intended to cover non-exclusive inclusions. The terms first, second and the like in the description and in the claims or in the above-described figures, are used for distinguishing between different objects and not necessarily for describing a particular sequential or chronological order.
Reference in the specification to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the application. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Those of skill in the art will explicitly and implicitly appreciate that the described embodiments of the application may be combined with other embodiments.
In the description of the present application, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "attached" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected, directly connected, indirectly connected through an intermediary, or may be in communication with the interior of two elements. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art according to the specific circumstances.
The term "and/or" in the present application is merely an association relation describing the association object, and indicates that three kinds of relations may exist, for example, a and/or B may indicate that a exists alone, while a and B exist together, and B exists alone. In the present application, the character "/" generally indicates that the front and rear related objects are an or relationship.
The term "plurality" as used herein means two or more (including two), and similarly, "plural sets" means two or more (including two), and "plural sheets" means two or more (including two).
According to some embodiments of the present application, as shown in fig. 3 to 4, optionally, the present application provides a slurry pump impeller, wherein the slurry pump impeller includes a metal core 1 and a plurality of blades 2, the metal core 1 includes a pair of first cover plates 10 and a plurality of support pieces 11, the pair of first cover plates 10 are disposed opposite to each other along a first direction X, the support pieces 11 are disposed between the pair of first cover plates 10 and fixedly connected to the cover plates, the blades 2 are disposed with root portions 20 and end portions 21 along a length direction thereof, wherein the plurality of blades 2 are circumferentially arrayed with the first direction X as an axis, the root portions 20 are closer to axes of the plurality of blades 2 than the end portions 21, the support pieces 11 penetrate the blades 2, and the support pieces 11 support the blades 2, the support pieces 11 are disposed closer to the end portions 21 among the end portions 21 and the root portions 20, and the plurality of blades 2 are in one-to-one correspondence with the plurality of support pieces 11.
The material of the metal core 1 may be, but not limited to, 2205 duplex stainless steel, CD4MCu duplex stainless steel, or the like.
The material of the blade 2 may be, but not limited to, ceramic, carbon fiber reinforced ceramic, carbon fiber composite, or the like.
One of the first cover plates 10 may be connected to the rotation shaft.
The diameter of the slurry pump impeller is 700-900mm, the rotating speed n=980 rpm, the whole pump with the slurry pump impeller provided by the application needs to bear 4.0MPa pressure, the flow is 900-1300m < 3 >/h, and the lift is 70-90m.
The supporting piece 11 and the cover plates can be welded, adhered or integrally formed, or the supporting piece 11 can be integrally formed with one of the two cover plates and welded or adhered to the other cover plate, so that one end of the supporting piece 11 which is not connected with the cover plates can pass through the blade 2 first and then be welded or adhered to the cover plates, and the assembly difficulty is reduced.
The blades 2 cover the supporting sheet 11 to prevent slurry formed by mixing phosphogypsum tailings and phosphogypsum slurry mixing water (or tailing backwater) from contacting the supporting sheet 11 and corroding the supporting sheet 11.
The stress cycle suffered by the slurry pump impeller in the use process is mainly caused by a rotation periodic load and a vibration load, wherein the rotation periodic load is formed by one circle of rotation of the impeller, each part is subjected to a complete stress cycle, the vibration load is high-frequency alternating stress caused by water flow disturbance, mechanical resonance or external excitation, the effect of the rotation load on the root 20 and the end 21 of the blade 2 is that the number of times of the cycle of the root 20 and the end 21 is the same (each rotation), but the stress amplitude increases from the root 20 to the end 21, and the effect of the vibration load on the root 20 and the end 21 of the blade 2 is that the root 20 can bear more frequent stress fluctuation due to the constraint effect due to the fact that the constraint effect suffered by the blade 2 decreases from the root 20 to the end 21. In summary, the end portion 21 of the blade 2 receives a large stress (e.g., centrifugal force), but the number of cycles is mainly from the rotational speed, the frequency is low, the root portion 20 of the blade 2 receives a small stress (e.g., centrifugal force), but the number of cycles is from both the rotational speed and the vibration, and the frequency is high.
In conventional designs, the root 20 of the blade 2 experiences rapid fatigue failure of the metal skeleton due to cyclic stress concentrations. According to the application, the support piece 11 is close to the end 21 of the blade 2, so that the stress distribution is changed, the support piece 11 with high fatigue limit metal supports the end 21, the root 20 is supported by the material with fatigue resistance of the blade 2, so that the end 21 can bear more centrifugal force, the root 20 shares load due to the support piece 11 close to the end 21, the local stress amplitude is reduced, the stress born by the root 20 is smaller, and the fatigue resistance of the material (such as ceramic, carbon fiber composite material and the like) of the blade 2 can resist the generation of fatigue damage in the process of high-speed cyclic stress, so that the whole service life of the blade 2 is prolonged.
The metal core 1 has the advantages that the overall rigidity of the impeller is improved through the squirrel-cage structure formed by the combination of the cover plate and the supporting piece 11, particularly, the bending deformation of the blades 2 caused by centrifugal force is restrained under high-speed rotation, and for the blades 2 made of brittle materials (such as ceramics), the supporting of the metal core 1 can reduce the stress concentration of the end parts 21 of the blades 2, avoid brittle fracture and allow the diameter of the impeller to be increased so as to meet the requirement of high lift.
The design of the circumferential array of the blades 2, the supporting sheets 11 are in one-to-one correspondence with the blades 2, the supporting sheets 11 which are uniformly distributed ensure that the stress of each blade 2 is balanced, the local overload risk is reduced, and the running stability of the impeller is improved.
The anti-fatigue property refers to the comprehensive ability of the material to resist the initiation and propagation of fatigue cracks until final fracture under the action of repeated cyclic load. It reflects the overall resistance of a material to fatigue damage, typically quantified by fatigue life (number of cycles) or crack growth rate.
The fatigue limit refers to the maximum alternating stress amplitude at which the material does not fracture under an infinite number of stress cycles. If the fatigue limit of the material is high, it is said to have a high fatigue limit.
According to some embodiments of the present application, optionally, as shown in fig. 4, a plurality of through holes 13 are provided on each of the support sheet 11 and the first cover plate 10.
The plurality of through holes 13 may be the same in size, or the plurality of through holes 13 may be different in size.
When the sizes of the plurality of through holes 13 are different, the size of a part of the through holes 13 close to the connection part of the supporting piece 11 and the first cover plate 10 can be smaller than the sizes of other through holes 13, the connection part of the supporting piece 11 and the first cover plate 10 is stressed more, the influence of the arrangement of the through holes 13 on the strength of the connection part of the supporting piece 11 and the first cover plate 10 can be reduced due to the smaller size of the through holes 13 in the area, and therefore the risk of damage to the connection part of the supporting piece 11 and the first cover plate 10 is reduced.
The supporting piece 11 and the first cover plate 10 are respectively provided with a plurality of through holes 13, and the through holes 13 can obviously lighten the weight of the supporting piece 11 and the cover plate, so that the overall mass of the metal core bar 1 is reduced, and the cyclic load of centrifugal force to the root 20 of the blade 2 during high-speed rotation is reduced. After the weight is lightened, the bending moment and the inertia force born by the root 20 of the blade 2 are reduced, so that the fatigue damage accumulation of the root 20 is further delayed, and the service life of the slurry pump impeller provided by the application is prolonged. The through holes 13 provide mechanical anchor points for the material of the blade 2 during the manufacturing process, and slurry or adhesive infiltrates into the holes to form a 'locking structure', so that the interface bonding strength is improved, and the risk of the metal core 1 and the blade 2 being separated is reduced.
According to some embodiments of the present application, as shown in fig. 8, optionally, the dimension from the end of the supporting piece 11 near the root 20 to the end near the end 21 is the length dimension of the supporting piece 11, the axes of the blades 2 pass through the axes of the first cover plates 10, the axes of one of the pair of first cover plates 10 is connected with the driving piece, the axes of the other pair of first cover plates 10 are provided with liquid inlets, the length dimension of the side of the supporting piece 11 near the driving piece is R1, the length dimension of the side of the supporting piece 11 near the liquid inlets is R2, and R1> R2 is satisfied.
The first cover plate 10 directly connected with the driving piece in the metal core 1 is limited by the driving piece, a certain distance is reserved between the other first cover plate 10 and the driving piece, the control effect of the driving piece is weaker, when R1> R2 is met, the length dimension of one end of the supporting piece 11 close to the driving piece is larger than the dimension of one end of the supporting piece 11 close to the liquid inlet, the dimension of one end of the supporting piece 11 close to the liquid inlet is smaller, the weight of the part of the metal core 1 far away from the driving piece is smaller, the inertia of the part is smaller, the weaker control effect of the driving piece can be adapted, the part of the metal core 1 far away from the driving piece is prevented from vibrating relative to the driving piece, the normal rotation of the impeller is influenced, moreover, after the material enters the impeller, the impeller is enabled to continuously flow towards the impeller along the axial direction of the impeller under the action of the suction force of negative pressure, until the first cover plate 10 connected with the driving piece is blocked, the material is enabled to continuously contact with the blade 2 after contacting the first cover plate 10 connected with the driving piece, namely the part of the impeller, the part of the supporting piece close to the impeller is enabled to be smaller, the part of the supporting piece is enabled to continuously contact with the impeller, the part of the impeller is enabled to be capable of being provided with the impeller, the weaker control effect is avoided, the part is enabled to be capable of providing a longer supporting effect, and the part close to the supporting part is capable of the part is longer than the supporting part, and the part is enabled to be longer than the part.
According to some embodiments of the present application, alternatively, as shown in fig. 8, an end of the supporting sheet 11 near the end 21 is flush with the outer circumferential surface of the first cover plate 10.
The end of the supporting piece 11 close to the end 21 is flush with the outer peripheral surface of the first cover plate 10, so that the space size of the centers of the supporting pieces 11 is gradually reduced from the suction inlet to the driving piece, the shape of the supporting piece 11 is matched with the shape of the impeller, so that the size of the opening at the center of the impeller is gradually reduced from the suction inlet to the driving piece, and the arrangement gradually narrows a channel through which materials flow in the process of entering the impeller until being blocked and turned, so that water flow is concentrated and sprinting is performed, and energy dissipation is reduced.
According to some embodiments of the present application, as shown in fig. 1-2, the blade assembly further comprises a pair of second cover plates 3, the pair of second cover plates 3 are oppositely arranged along the first direction X, the first cover plate 10 is located inside the second cover plates 3, the blade 2 is located between the pair of second cover plates 3, and the blade 2 is fixedly connected with the second cover plates 3.
The material of the second cover plate 3 may be the same as that of the blade 2, or the material of the second cover plate 3 may be different from that of the blade 2.
On the one hand, the second cover plate 3 is used as an outer protective cover, the first cover plate 10 is wrapped in, slurry formed by mixing phosphogypsum tailings and phosphogypsum slurry mixing water (or tailing backwater) is prevented from directly flushing the first cover plate 10 made of metal, and the risk of corrosion damage to the first cover plate 10 is remarkably reduced. On the other hand, the blades 2 are fixedly connected with the second cover plate 3, so that part of centrifugal force is transmitted to the wheel shaft connected with the slurry pump blade through the second cover plate 3, and the stress amplitude of the root 20 is reduced, so that the risk of damaging the root 20 is reduced.
According to some embodiments of the present application, alternatively, two ends of the supporting sheet 11 extend into the pair of second cover plates 3 to be respectively connected with the pair of first cover plates 10.
The two ends of the supporting sheet 11 are fixedly connected with the first cover plate 10 and the second cover plate 3 respectively to form rigid connection penetrating through the inner layer and the outer layer, the metal core bar 1 and the second cover plate 3 are integrated into a three-dimensional supporting frame, the integral bending rigidity of the impeller is improved, and the radial deformation of the blade 2 under high centrifugal force is restrained. The second cover plate 3 and the blades 2 wrap the whole metal core 1, so that slurry formed by mixing phosphogypsum tailings and phosphogypsum slurry mixing water (or tailing backwater) is prevented from contacting the metal core 1. The supporting piece 11 passes through the second cover plate 3 and is connected with the first cover plate 10 to form a physical anchoring point, even if microcracks occur at the connecting interface of the outer second cover plate 3 and the blade 2, the supporting piece 11 and the first cover plate 10 inside can still provide mechanical support, prevent crack diffusion and improve the structural stability of the slurry pump impeller.
According to some embodiments of the application, the blade 2 may be made of a carbon fiber composite material.
The material of the blade 2 may be, but not limited to, carbon fiber/epoxy resin composite material, carbon fiber/polyimide resin composite material, carbon fiber/phenolic resin composite material, or the like.
The traditional ceramic blade 2 is difficult to meet the requirement of high lift because of large brittleness and limited impeller diameter. The blade 2 provided by the application is made of a carbon fiber composite material, the tensile strength of the carbon fiber composite material (CFRP) is higher than that of steel, and the blade has excellent impact toughness, can bear larger centrifugal force, and allows the diameter of a slurry pump impeller to be larger, so that the conveying lift is improved. The density of the carbon fiber composite material is lower, the weight of the blade 2 can be reduced, and the load of centrifugal force on the metal core bar 1 is reduced, so that the stress amplitude of the root 20 is reduced, and the fatigue life is prolonged. The carbon fiber composite material also has extremely high corrosion resistance, and can effectively avoid the corrosion of the blade 2 by phosphogypsum slurry mixing water (or tailing backwater).
According to some embodiments of the present application, as shown in fig. 5, optionally, the present application provides a manufacturing method of a slurry pump impeller for manufacturing the slurry pump impeller described above, comprising the steps of S100, connecting one first cover plate 10 to one end of a plurality of supporting plates 11, S200, installing a disposable inner mold between the plurality of supporting plates 11, and then connecting the other first cover plate 10 to the other end of the plurality of supporting plates 11 to obtain a metal core1, and S300, placing the metal core1 with the disposable inner mold into a molding die and injection molding to obtain the slurry pump impeller.
The disposable inner mold is a temporary support structure for forming an internal cavity during injection of molding fluid for producing complex shaped parts. The disposable inner mold may be made of degradable material, foam, gypsum, salt, etc. to facilitate handling after use.
The support sheet 11 may be welded to the first cover plate 10.
Injection molding, also known as injection molding, is a method of injection and molding. And stirring the completely melted material (namely forming liquid) by a screw at a certain temperature, injecting the material into a die cavity (a forming cavity of a forming die) by high pressure, and cooling and solidifying to obtain the formed part. The method is suitable for mass production of parts with complex shapes, and is one of important processing methods. The injection molding process can be divided into six stages, namely mould closing, glue injection, pressure maintaining, cooling, mould opening and product taking out.
The molten molding liquid injected into the molding die has a certain temperature, i.e., an injection molding temperature.
In step S100, one end of the plurality of support plates 11 is connected to one of the pair of first cover plates 10, the positions of the plurality of support plates 11 are fixed, in step S200, a disposable inner mold is installed between the plurality of support plates 11 from the end of the support plate 11 which is not connected with the cover plates, then the other first cover plate 10 is connected to the other end of the plurality of support plates 11 to obtain the metal core bar 1, the inner mold precisely fills the gap between the support plates 11, non-metal materials (such as carbon fiber prepreg and corrosion resistant engineering plastics) are ensured to uniformly wrap the metal core bar 1 during injection molding, stress concentration caused by eccentricity or uneven wall thickness is avoided, and finally, in step S300, the metal core bar 1 with the disposable inner mold is placed into a molding mold and injection molded, and a slurry pump impeller is obtained. The other first cover plate 10 is connected with the supporting plate 11 after the disposable inner die is installed between the supporting plates 11, so that the installation flow of the disposable inner die is simplified, an operator can conveniently adjust and determine the position of the disposable inner die, the risks of eccentricity or uneven wall thickness of the metal core bar 1 are reduced, the molding of the whole inner cavity of the slurry pump impeller is completed by adopting one disposable inner die, the wall of the inner cavity of the prepared slurry pump impeller is smooth, and the conditions of burrs, uneven and the like which can occur when the inner cavities made by splicing a plurality of inner dies are avoided. The manufacturing method of the slurry pump impeller realizes the precise molding of the impeller with high lift and large size by the mode of prefabricating the metal core bar 1 and assisting injection molding by the internal mold, and provides a manufacturing scheme of the slurry pump impeller with high efficiency, high reliability and low environmental load.
According to some embodiments of the present application, as shown in fig. 6-7, optionally, step S400 is further included between step S200 and step S300, where a transition layer 4 is disposed on the forming surface 12 of the metal core 1, the forming surface 12 is a surface of the metal core 1 contacted with the forming liquid through the transition layer 4, the transition layer 4 is composed of M layers of transition materials, M is greater than or equal to 3, the innermost N layers of transition materials are first materials 40, the first materials 40 have elasticity, M > N is greater than or equal to 1, the first materials 40 are in close contact with the forming surface 12, the outermost K layers of transition materials are second materials 41, the second materials 41 have adhesion, M > K is greater than or equal to 1, the L layers of transition materials located between the first materials 40 and the second materials 41 are third materials 42, the third materials 42 have low thermal conductivity, M > L is greater than or equal to 1, and n+k+l is less than or equal to M.
The molten molding liquid injected into the molding die has a certain temperature, i.e., an injection molding temperature.
The molding temperature range of the carbon fiber composite material is different due to different matrix materials (resin or high-temperature matrix) and processes, and the casting temperature range of the carbon fiber is extremely wide, for example, medium-low temperature resin-based carbon fiber (120-230 ℃) and high-temperature thermoplastic carbon fiber (300-400 ℃) and ultra-high temperature carbon/carbon composite material (> 800 ℃). The material of the transition layer 4 may be selected during the actual processing according to the actual processing temperature.
When the molding liquid is injected, as the third material 42 has lower heat conductivity, the amount of thermal expansion caused by the heat of the metal core 1 absorbing the molding liquid is reduced due to the self-temperature rise of the metal core 1, the first material 40 deforms along with the expansion of the metal core 1, the metal core 1 is retracted in volume due to the self-temperature reduction in the cooling stage of the molding liquid, the transition layer 4 is adhered to the molding surface 12 of the metal core 1 and kept in close contact, the first material 40 synchronously deforms along with the retraction of the metal core 1, meanwhile, the second material 41 has high fluidity and self-sealing property, and the second material 41 can fill gaps between the molded body formed after the cooling of the molding liquid and the third material 42, so that the transition layer 4 can fill gaps left after the retraction of the metal core 1 and gaps appearing after the cooling and hardening of the molding liquid, and the probability of defects such as cavities or holes appearing between the molding liquid and the metal core 1 in the cooling and hardening stage of the molding liquid is reduced.
According to some embodiments of the application, the first material 40 is optionally silicone rubber.
The temperature resistant range (-60 ℃ to 250 ℃) of the silicon rubber covers most injection molding process requirements. And during high-temperature injection molding, the silicone rubber cannot be thermally decomposed or permanently deformed, so that the integrity of the elastic layer is ensured.
The first material 40 is silicon rubber, has low elastic modulus characteristic and excellent flexibility, can be stably attached to the metal core 1, and can compensate the thermal expansion amount of the metal core 1 in the injection molding process through self elastic deformation, so that the condition that a cavity exists between the metal core 1 and the blade 2 and the second cover plate 3 due to thermal expansion and contraction of the metal core 1 is avoided, and the integral density of the slurry pump impeller is improved.
According to some embodiments of the application, the second material 41 is optionally an epoxy-based nanocomposite.
The epoxy resin-based nanocomposite is epoxy resin added with nano particles (such as carbon nano tubes and graphene), and has good fluidity.
The second material 41 is an epoxy-based nanocomposite material, which is capable of infiltrating the surfaces of the blade 2 and the second cover plate 3 facing the metal core 1, and forming a dense structure after curing. The high adhesiveness of the metal core bar can enhance the interfacial binding force between the metal core bar 1 and the blade 2 and the second cover plate 3, reduce the defect that the blade 2 and the second cover plate 3 face the surface of the metal core bar 1, improve the connection stability of the metal core bar 1 and the blade 2 and the second cover plate 3, and further improve the compactness of the interior of the slurry pump impeller.
According to some embodiments of the application, the optional third material 42 is a ceramic-based coating.
The ceramic based coating may be, but is not limited to, alumina, boron nitride, and the like.
The third material 42 is a ceramic-based coating, which has low thermal conductivity (< 30W/m·k) and high temperature stability (> 1000 ℃) and can effectively block heat of the forming liquid from being conducted to the metal core 1, reduce the thermal expansion amplitude of the metal core 1, and avoid the expansion of the metal core 1 exceeding the compensatory amount of the first material 40, thereby reducing the risk of occurrence of cavities between the metal core 1 and the blade 2 and the second cover plate 3.
While the application has been described with reference to a preferred embodiment, various modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the application. In particular, the technical features mentioned in the respective embodiments may be combined in any manner as long as there is no structural conflict. The present application is not limited to the specific embodiments disclosed herein, but encompasses all technical solutions falling within the scope of the claims.
Claims (10)
1. A slurry pump impeller, comprising:
a metal core comprising a pair of first cover plates and a plurality of support plates;
the pair of first cover plates are oppositely arranged along the first direction;
the supporting sheets are positioned between the pair of first cover plates and fixedly connected with the cover plates;
a plurality of blades provided with roots and ends along a length direction thereof;
wherein a plurality of the blades are circumferentially arrayed with the first direction as an axis;
The root portion is closer to the axis of the plurality of blades than the end portion;
The supporting sheet passes through the blade, and the supporting sheet supports the blade;
The support piece is configured to be closer to the end portion among the end portion and the root portion;
The blades are in one-to-one correspondence with the supporting sheets.
2. The slurry pump impeller of claim 1, wherein the support plate and the first cover plate are each provided with a plurality of through holes.
3. The slurry pump impeller of claim 1, wherein a dimension from an end of the support sheet proximate the root portion to an end proximate the end portion is a length dimension of the support sheet;
the axes of the blades penetrate through the axle center of the first cover plate;
the axle center of one of the pair of first cover plates is connected with the driving piece, and the axle center of the other one is provided with a liquid inlet;
the length dimension of one side of the supporting piece close to the driving piece is R1;
The length dimension of one side of the supporting sheet close to the liquid inlet is R2;
satisfying R1> R2.
4. A slurry pump impeller according to claim 3, wherein an end of the support piece adjacent to the end portion is flush with the outer peripheral surface of the first cover plate.
5. The slurry pump impeller of claim 1, further comprising a pair of second cover plates;
the pair of second cover plates are oppositely arranged along the first direction;
the first cover plate is positioned inside the second cover plate;
the blades are positioned between the pair of second cover plates, and the blades are fixedly connected with the second cover plates.
6. The slurry pump impeller of claim 5, wherein the two ends of the support plate extend into a pair of the second cover plates and are respectively connected with a pair of the first cover plates.
7. The slurry pump impeller of claim 1, wherein the blade is a carbon fiber composite.
8. A method for manufacturing the slurry pump impeller according to any one of claims 1 to 7, comprising:
step S100, connecting one first cover plate to one end of a plurality of supporting sheets;
step 200, a disposable internal mold is installed among a plurality of supporting sheets, and then the other first cover plate is connected to the other ends of the supporting sheets so as to obtain the metal core bars;
And step 300, placing the metal core bar provided with the disposable internal mold into a forming mold and performing injection molding to obtain the slurry pump impeller.
9. The method for manufacturing a slurry pump impeller according to claim 8, further comprising a step S400 of providing a transition layer on a molding surface of the metal core between the step S200 and the step S300;
wherein the molding surface is the surface of the metal core bar contacted with the molding liquid through the transition layer;
the transition layer is composed of M layers of transition materials, wherein M is more than or equal to 3;
The transition material of the innermost N layers is a first material, the first material has elasticity, M is more than or equal to 1, and the first material is tightly contacted with the molding surface;
the transition material on the outermost K layer is a second material, and the second material has adhesiveness, and M > K is more than or equal to 1;
The transition material of the L layer between the first material and the second material is a third material, the third material has low heat conductivity, M is more than or equal to 1, and N+K+L is less than or equal to M.
10. The method for manufacturing a slurry pump impeller according to claim 9, the novel high-strength silicone rubber is characterized in that the first material is silicone rubber.
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| CN114876863A (en) * | 2021-12-08 | 2022-08-09 | 青岛海英荷瑞机械设备有限公司 | Explosion-proof ventilation blower and double-pipe wall system thereof |
| CN220706025U (en) * | 2023-09-11 | 2024-04-02 | 寿宁县金源机电制造有限公司 | Automobile water pump impeller with reinforced blade edge |
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| JP3026791B2 (en) * | 1998-06-10 | 2000-03-27 | 株式会社ミツヤ送風機製作所 | Variable blade axial flow fan |
| US7896617B1 (en) * | 2008-09-26 | 2011-03-01 | Morando Jorge A | High flow/high efficiency centrifugal pump having a turbine impeller for liquid applications including molten metal |
| EP2298373A1 (en) * | 2009-09-22 | 2011-03-23 | ECP Entwicklungsgesellschaft mbH | Fluid pump with at least one turbine blade and a seating device |
| GB201001974D0 (en) * | 2010-02-08 | 2010-03-24 | Rolls Royce Plc | An outlet guide vane structure |
| JP5264859B2 (en) * | 2010-10-24 | 2013-08-14 | 三菱電機株式会社 | Rotor of motor for pump, pump, air conditioner, floor heating device and hot water supply device |
| CN105952661A (en) * | 2016-06-15 | 2016-09-21 | 浙江工业大学 | Visual experiment device for centrifugal pump impeller |
| CN109296544A (en) * | 2018-11-29 | 2019-02-01 | 江苏振达环保科技有限公司 | A kind of sewage pump with waste residue shredding mechanism |
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| CN114876863A (en) * | 2021-12-08 | 2022-08-09 | 青岛海英荷瑞机械设备有限公司 | Explosion-proof ventilation blower and double-pipe wall system thereof |
| CN220706025U (en) * | 2023-09-11 | 2024-04-02 | 寿宁县金源机电制造有限公司 | Automobile water pump impeller with reinforced blade edge |
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