高温柱塞阀曲柄滑块机构热变形分析与卡涩故障预测

钱秋朦; 张健平; 但志宏; 谢璐; 王宏伦; 张松; 田斌; 陈玉涛

doi:10.13224/j.cnki.jasp.20250084

高温柱塞阀曲柄滑块机构热变形分析与卡涩故障预测

doi: 10.13224/j.cnki.jasp.20250084

钱秋朦^{1, 2,},
张健平^3,*, ,,
但志宏²,
谢璐²,
王宏伦¹,
张松²,
田斌³,
陈玉涛²

1.
北京航空航天大学自动化科学与电气工程学院，北京 100191
2.
中国航发四川燃气涡轮研究院，四川绵阳 621703
3.
西南科技大学制造科学与工程学院制造过程测试技术教育部重点实验室，四川绵阳 621010

基金项目: 稳定支持专项（CJCZ-0302-05）

详细信息

作者简介:
钱秋朦（1988-），男，高级工程师，博士生，主要从事航空发动机高空模拟试验技术及高空环境模拟控制与仿真等方面工作

通讯作者:
张健平（1978-），女，副教授、硕士生导师，博士，主要从事多相流数值模拟及应用。E-mail：zjp2009@mail.ustc.edu.cn

中图分类号: V233.91
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出版历程
- 收稿日期: 2025-02-21
- 网络出版日期: 2025-08-20

Analysis of thermal deformation and prediction of jam faults on the crank-slider mechanism for the high-temperature plunger valve

1.
School of Automation Science and Electrical Engineering，Beihang University，Beijing 100191，China
2.
Sichuan Gas Turbine Establishment，Aero Engine Corporation of China，Mianyang Sichuan 621703，China
3.
Key Laboratory of Testing Technology for Manufacturing Process，Ministry of Education，School of Manufacturing Science and Engineering，Southwest University of Science and Technology，Mianyang Sichuan 621010，China

摘要

摘要:
某高空台柱塞阀由活塞（滑块）、摇臂（曲柄）和连杆组成的正偏置曲柄滑块运动机构来实现流量调节，试验气流温度较高时，导向杆和套筒的热变形远大于轴套和活塞，易造成柱塞阀卡涩故障，直接影响航空发动机试验安全。为此，通过数值模拟分析进口温差（20～360 ℃）和开度（30°、60°）对运动机构热变形的影响，提出一种运动机构热变形卡涩故障的预测依据。结果表明：导向杆和活塞热变形随进口最终温度的增大而增大；其最大热变形量随进口温差增大而线性增大。在此基础上，对圆柱轴和圆柱壳体结构热变形表达式进行了修正，建立了导向杆和活塞的最大热变形量的数学模型。然后结合轴和孔的配合间隙理论基础知识，建立了导向杆与轴套，活塞与套筒配合发生卡涩故障的临界温升数学模型，通过验证分析表明其相对误差分别为7%和11%，符合工程应用的允许偏差要求，表明该模型可用于预测高温柱塞阀机构热变形卡涩故障，为减少高温柱塞阀在航空发动机高空模拟试验中的运行故障发生概率提供理论依据。
- 高温柱塞阀 /
- 正偏置曲柄滑块机构 /
- 热变形 /
- 卡涩故障 /
- 临界温升
Abstract:
A positive offset crank-slider mechanism composed of a piston (slider), rocker arm (crank), and connecting rod was used to regulate flow in the plunger valve for a certain altitude test facility. The guide rod was prone to bending, and the piston was prone to deformation when the test airflow temperature was high and the temperature difference was significant, which often led to jam faults, and directly affected the safety of aero-engine testing. So the influences of inlet temperature differences (20 °C to 360 °C) and opening angles (30°, 60°) on the thermal deformation of the mechanism were analyzed through numerical simulation. Aiming to establish a predictive basis for thermal deformation induced sticking faults. The results showed that the thermal deformation of the guide rod and piston increased withthe final inlet temperature, and the maximum thermal deformation increased linearly with the inlet temperaturedifference. The thermal deformation expressions for the cylindrical shaft and cylindrical shell were revised, and amathematical model for the maximum thermal deformation of the guide rod and piston was established. Bycombining the theoretical fundamentals of shaft-hole fit clearance, a critical temperature rise mathematical modelwas developed to predict sticking faults between the guide rod and bushing, as well as between the piston andsleeve. The relative errors of the predicted value of critical temperature rise were 7% and 11%, respectively, when the guide rod was matched with the shaft sleeve, and the piston was matched with the sleeve. Thus these errors met the requirements of allowable deviation in engineering application. Therefore, this critical temperature rise model could be used to predict the thermal deformation-induced jam faults for high-temperature plunger valve mechanisms, helping to provid a theoretical basis for reducing the probability of operational faults in high-temperature plunger valves during high-altitude simulation tests of aero-engines.
- high-temperature plunger valve /
- positive offset crank-slider mechanism /
- thermal deformation /
- jam faults /
- critical temperature rise

HTML

图 1 高温柱塞阀结构示意图

Figure 1. Structure of the high-temperature plunger valve

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图 2 正偏置曲柄滑块机构示意图

Figure 2. Diagram of the positive offset crank-slider mechanism

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图 3 高温柱塞阀卡涩故障

1 导向杆轴向长度；2 阀体与套筒耳座的间距；3 阀体耳座开档距；4 活塞轴套开档距；5 套筒开档距；6 轴套孔。

Figure 3. Jam faults of the high-temperature plunger valve

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图 4 高温柱塞阀简化模型和计算域示意图

Figure 4. Simplified model and computational domain of the high-temperature plunger valve

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图 5 网格无关性验证

Figure 5. Validation of mesh independence

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图 6 开度为30°高温柱塞阀流体域的网格模型

Figure 6. Mesh of the 30° the high-temperature plunger valve

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图 7 高温柱塞阀核心构件的网格划分

Figure 7. Meshing of the key components of the high-temperature plunger valve

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图 8 高温柱塞阀导向杆变形分布云图

Figure 8. Deformation distribution contour of guide rod for the high-temperature plunger valve

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图 9 高温柱塞阀导向杆和活塞变形分布云图

Figure 9. Deformation distribution contour of guide rod and piston for the high-temperature plunger valve

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图 10 柱塞阀导向杆和活塞最大热变形量与进口温差变化曲线

Figure 10. Variation curve of the maximum thermal deformation of the guide rod and the piston with the inlet temperature difference

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图 11 验证工况机构变形分布云图

Figure 11. Deformation distribution contour of the mechanism in condition of verifying

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图 12 导向杆与轴套配合间隙分布云图

Figure 12. Fitting clearance contour between the guide rod and the bearing sleeve

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图 13 活塞与套筒配合的间隙分布云图

Figure 13. Fitting clearance contour between t between the piston and the sleeve

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表 1 DN900高温柱塞阀的结构尺寸

Table 1. Structural size of the DN900 high-temperature plunger valve mm

公称直径	活塞外径	活塞厚度	套筒内径	套筒壁厚	导向杆外径	轴套内径
900	746	14	750	15	50	50

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表 2 高温柱塞阀材料参数

Table 2. Material parameters of the high-temperature plunger valve

构件（材料）	弹性模量/ GPa	泊松比	密度/ （kg/m³）	热膨胀系数/ 10⁻⁶ ℃⁻¹	导热系数/ （W/（m· ℃））	抗拉强度/ MPa	条件屈服强度/MPa
轴套、套筒（1Cr18Ni9Ti）	210	0.274	7930	16	16.2	520	205
导向杆、活塞（1Cr17Ni2）	207	0.25	7800	10	20.9	800	600

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表 3 网格划分节点数和单元数

Table 3. Nodes and elements of the meshing

开度/（°）	节点数	单元数
30	1237913	6434601
60	1297106	6715787

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表 4 模拟分析工况

Table 4. Scheme of simulation analysis

影响因素	固定条件	温度因素变量/ ℃
进口最终温度	1）进口压力为500 kPa	60
	2）出口压力为101325 Pa	100
	3）温度变化速度为30 ℃/min	200
	4）进口初温为40 ℃	300
	5）开度为30°和60°	400

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表 5 模拟方法的验证结果

Table 5. Validation results of the simulation method

序号	开度/（°）	阀前温度/℃	压力/kPa		阀门出口流量/（kg/s）		相对误差/%
序号	开度/（°）	阀前温度/℃	阀前	阀后	试验值	模拟值	相对误差/%
1	40.9	347.0	428.64	122.01	45.2	46.1	1.9
2	42.9	171.7	370.56	137.43	48.0	46.5	3.1
3	44.7	348.2	406.09	155.77	47.8	45.1	5.6
4	44.7	345.7	401.80	154.68	47.4	45.3	4.5
5	45.4	306.5	395.04	152.51	48.7	46.5	4.6
6	46.2	264.4	387.15	152.25	50.3	53.6	6.5
7	46.4	276.1	383.14	152.39	49.8	52.4	5.2
8	49.6	337.6	404.87	173.41	54.6	52.6	3.7
9	50.1	329.5	400.04	173.28	55.1	57.9	5.0
10	50.7	345.7	400.00	176.73	54.4	52.7	3.2

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表 6 验证分析表

Table 6. Verified analysis

条件构件	进口最终温度为650 ℃			进口最终温度为700 ℃
条件构件	变形量模拟值/mm	变形量计算值/mm	相对误差/%	变形量模拟值/mm	变形量计算值/mm	相对误差/%
导向杆	0.304	0.335	9.25	0.328	0.360	8.89
活塞	2.873	2.981	3.62	3.102	3.201	3.09

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表 7 导向杆与轴套配合间隙

Table 7. Fitting clearance between the guide rod and the bearing sleeve mm

机构类型	零件参数	公称直径	上偏差	下偏差	公差
导向杆（轴零件）	外径	50	−0.08	−0.12	0.04
轴套（孔零件）	内径	50	0.12	0.02	0.1
导向杆与轴套配合的间隙	最大间隙	0.24
导向杆与轴套配合的间隙	最小间隙	0.1

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表 8 活塞与套筒配合间隙

Table 8. Fitting clearance between the piston and the sleeve mm

机构类型	零件尺寸	公称直径	上偏差	下偏差	公差
活塞（轴零件）	外径	746	0.3	−0.3	0.6
套筒（孔零件）	内径	750	0.38	0	0.38
活塞与套筒配合的间隙	最大间隙		2.68
活塞与套筒配合的间隙	最小间隙		−0.3

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