Pressure Loss Modeling of Y-shaped Flow Channel Based on Additive Manufacturing

doi:10.3901/JME.2021.24.147

Abstract

Abstract: Additive manufacturing(AM) technology is applied for the high integrated and lightweight hydraulic system because of its ability to form complicated structure. However, the surface roughness of flow channel formed by AM is different from traditional drilling and casting ones, especially in complicated pipeline system. It is urgent to study the pressure loss mathematic model of flow channel formed by AM because the classical pressure loss mathematic model can not be used directly. Y-shaped flow channel, a typical flow channel, is taken as the research object. The pressure loss mathematic model of Y-shaped flow channel is established based on Bernoulli equation, Momentum theorem, and Darcy formula. The influence of AM forming Angle on the surface roughness is analyzed. The influence laws on the splitting ratio, branch Angle, and flow channel diameter of pressure loss are studied by simulation. The Y-shaped flow channel test platform is built and the models of Y-shaped flow channel are manufactured by AM. Then the pressure loss of the flow channels under different splitting ratio, branch Angle and flow channel diameter is measured. The results show that the average error of pressure loss between simulation and calculation is less than 9% and the one between experiment and calculation is less than 8%. Research can lay a foundation for the design of low pressure loss pipeline formed by AM.

Key words: additive manufacturing, Y-shaped flow channel, pressure loss, mathematic model, surface roughness

CLC Number:

TH137

YAO Jing, SONG Yingzhe, DUAN Yiman, ZHANG Hao, ZHANG Jianqi, WANG Pei. Pressure Loss Modeling of Y-shaped Flow Channel Based on Additive Manufacturing[J]. Journal of Mechanical Engineering, 2021, 57(24): 147-157.

References

[1] 张磊,祝毅,杨华勇. 基于增材制造的液压复杂流道轻量化设计与成形[J]. 液压与气动,2018,327(11):1-7. ZHANG Lei,ZHU Yi,YANG Huayong. Lightweight design and manufacturing of complex hydraulic passageway based on additive manufacturing[J]. Chinese Hydraulics & Pneumatics,2018,327(11):1-7.
[2] ALSHARE A A,CALZONE F,MUZZUPAPPA M. Hydraulic manifold design via additive manufacturing optimized with CFD and fluid-structure interaction simulations[J]. Rapid Prototyping Journal,2019, 25(9):1516.
[3] SEMINI C,GOLDSMITH J,MANFREDI D,et al. Additive manufacturing for agile legged robots with hydraulic actuation[C]//International Conference on Advanced Robotics. IEEE. 2015:123-129.
[4] Renishaw. Hydraulic block manifold redesign for additive manufacturing[EB/OL].[2020-12-26]. https://www.renishaw.com/en/hydraulic-block-manifold-redesign-for-additive-manufacturing--38949.
[5] 李莹,张玉莹,柳宝磊,等. 基于增材制造的液压阀块流道过渡区优化研究[J]. 液压与气动,2021,(01):56-66. LI Ying,ZHANG Yuying,LIU Baolei,et al. Optimization of flow channel transition area in hydraulic valve block based on additive manufacturing[J]. Chinese Hydraulics & Pneumatics,2021(1):56-66.
[6] 苏猛猛. 基于增材制造的液压阀块优化设计与工艺研究[D]. 大连:大连理工大学,2018. SU Mengmeng. Optimization design and process research of hydraulic valve block based on additive manufacturing[D]. Dalian:Dalian University of Technology,2018.
[7] SHER D. First 3D printed hydraulic manifold successfully flies on airbus A380 aircraft[EB/OL].[2021-01-25]. http://www.3ders.org/.
[8] SCHMELZLE J,KLINE E V,DICKMAN C J,et al. (Re) Designing for part consolidation:understanding the challenges of metal additive manufacturing[J]. Journal of Mechanical Design,2015,137(11):111404.
[9] ZHU Y,YANG Y,WANG Y N,et al. Localized property design and gradient processing of a hydraulic valve body using selective laser melting[J]. IEEE/ASME Transactions on Mechatronics,2020,26(2):1151-1160.
[10] MALMSTROM T G. Pressure drops in T-junctions——a comparison[J]. Ashrae Transactions,2000,106(1):359-364.
[11] COSTA N P,MAIA R,PROENC A,et al. Edge effects on the flow characteristics in a 90 deg tee junction[J]. Journal of Fluids Engineering,2006,128(6):1204-1217.
[12] 石喜,陶虎,柴媛媛,等. UPVC斜三通阻力损失及流动特征数值模拟[J]. 中国农村水利水电,2018(11):170-174. SHI Xi,TAO Hu,CAI Yuanyuan,et al. Numerical simulation of resistance loss and flow characteristics on UPVC slope tee pipes[J]. China Rural Water and Hydropower,2018(11):170-174.
[13] 茅泽育,罗昇,赵璇,等. 矩形断面压力管道汇流口局部能量损失[J]. 水利水电科技进展,2006,26(3):62-66. MAO Zeyu,LUO Sheng,ZHAO Xuan,et al. Local energy loss at junction of pressurized pipes with rectangular cross section[J]. Advances in Science and Technology of Water Resources,2006,26(3):62-66
[14] 茅泽育,赵凯,赵璇,等. 管道汇流口局部阻力试验研究[J]. 水利学报,2007,38(7):812-818. MAO Zeyu,ZHAO Ka,ZHAO Xuan,et al. Experimental study on local flow resistance at junctions of circular pipes[J]. Journal of Hydraulic Engineering,2007,38(7):812-818.
[15] 秦慧敏. 关于通风管三通的局部阻力系数问题[J]. 建筑技术通讯(暖通空调),1980(3):10-13. QIN Huimin. The problem of local resistance coefficient of three-way ventilation pipe[J]. Construction technology of communication(Heating Ventilation Air Conditioning),1980(3):10-13.
[16] 陈文创,张蕊,张文远,等. 复杂非对称岔管数值模拟中湍流模型的影响[J]. 清华大学学报,2018,58(8):752-760. CHEN Wenchuang,ZHANG Rui,ZHANG Wenyuan,et al. Effect of turbulence models on the simulation of the flow in a complex asymmetric penstock[J]. Journal of Tsinghua University,2018,58(8):752-760.
[17] 魏善思,吴仁智,米智楠. 弯管流动阻力数值仿真分析[J]. 流体传动与控制,2016(3):5-8. WEI Shansi,WU Renzhi,MI Zhinan. Flow resistance characteristic research on bending pipe[J]. Fluid Power Transmission and Control,2016(3):5-8.
[18] 周传辉,翁维安. 流体阻力系数的计算方法[J]. 制冷与空调,2004,18(3):35-36. ZHOU Chuanhui,WEN Weian. Calculational methods about the friction factor of fluid[J]. Refrigeration & Air Conditioning,2004,18(3):35-36.
[19] ZHU Y,ZHOU L,WANG S,et al. On friction factor of fluid channels fabricated using selective laser melting[J]. Virtual and Physical Prototyping,2020,15(4):496-509.