干摩擦釜用机械密封DLC涂层-石墨配副摩擦磨损与温度变形场分析

doi:10.16085/j.issn.1000-6613.2024-0953

摘要/Abstract

摘要：

干摩擦釜类设备的机械密封散热及润滑条件较差，其密封端面存在较大热力变形和磨损问题，对密封端面进行沉积类金刚石（diamond-like carbon，DLC）涂层强化，可有效降低摩擦系数并抑制端面热力变形以延长密封寿命。基于反应釜的密封结构和密封环的基体材料以及DLC特性，使用摩擦磨损试验机测试了不同厚度DLC涂层在变工况条件下与浸树脂石墨形成摩擦副时的摩擦系数和磨损率；采用实验获得的摩擦系数，利用有限元软件建立釜用机械密封热-结构耦合分析模型，分析了典型DLC涂层厚度下的端面温度场和变形场，结合实验结果针对DLC涂层的减磨效果进行了分析。分析结果表明，与无DLC涂层的摩擦副相比，DLC涂层具有优异的减磨效果，在不同p_cv值下DLC涂层最大能够使摩擦系数降低43.9%，使磨损率降低67.53%，稳态温度和变形分别平均降低18％和25％左右；6μm DLC涂层相较于2μm 涂层形成的摩擦副性能更优，最大能够使峰值温度和变形进一步降低2.23%和2.52%。DLC涂层的使用令端面磨损率、稳态温度、变形量均得到降低，可为干摩擦釜用机械密封延长服役年限和提高密封稳定性提供借鉴。

关键词: 反应釜, 机械密封, 磨损, 数值模拟, 传热, 端面变形, 端面强化

Abstract:

Under dry friction conditions, the mechanical seals of kettle equipment experience poor heat dissipation and lubrication, leading to significant thermal deformation and wear problems on their seal faces. Strengthening the seal end face by deposition of diamond-like carbon, DLC coating can effectively decrease the coefficient of friction and prevent thermal deformation, thereby extending the seal's lifespan. Based on the seal structure of the reactor and considering the basic material of the seal ring and the characteristics of DLC, friction coefficients and wear rates of the frictional pairs formed by different thicknesses of DLC coatings and resin-impregnated graphite were tested by using a friction and wear testing machine under various working conditions. The friction coefficients obtained from the experiments were utilized to establish a thermal-structural integrated model of mechanical seals using finite element software. The temperature field and deformation field of the end face with typical DLC coating thicknesses were analyzed in conjunction with the experimental results. The wear reduction effect of DLC coating was also analyzed based on the experimental results. The analysis results indicated that the DLC coating had a significant wear reduction effect compared with the friction pair without DLC coating. At different pcv values, the DLC coating could decrease the friction coefficient by 43.9%, the wear rate by 67.53%, and the steady-state temperature and deformation by approximately 18% and 25% on average, respectively. The frictional pair formed by the 6μm DLC coating had a better performance than that formed by the 2μm coating, with the peak temperature and deformation were further reduced by 2.23% and 2.52% at the maximum. The DLC coating could reduce the wear rate of the end face, steady-state temperature and deformation, offering reference for prolonging the life of reactor mechanical seals under dry friction conditions and enhancing seal stability.

Key words: reactors, mechanical seals, attrition, numerical simulation, heat transfer, end face deformation, end face strengthening

中图分类号:

TB42

张天昊, 李双喜, 贾祥际, 胡鼎国, 崔瑞焯, 李世聪. 干摩擦釜用机械密封DLC涂层-石墨配副摩擦磨损与温度变形场分析[J]. 化工进展, 2024, 43(S1): 121-133.

ZHANG Tianhao, LI Shuangxi, JIA Xiangji, HU Dingguo, CUI Ruizhuo, LI Shicong. Analysis of the effect of thermal deformation and friction wear of reinforced DLC film on the end face of high-speed mechanical seals[J]. Chemical Industry and Engineering Progress, 2024, 43(S1): 121-133.

图/表 26

图1 反应釜机械密封安装位置示意

图2 密封结构示意图

图3 表面形貌测量仪

图4 摩擦磨损试验工装结构示意

图5 动环与静环实物图

图6 不同转速下的摩擦系数

图7 不同端面比压下的摩擦系数

图8 不同条件下石墨体积磨损率

图9 动环表面宏观形貌

图10 变转速实验动静环表面微观形貌

图11 变压力实验动静环表面微观形貌

图12 不同实验工况下石墨扫描电镜结果

图13 模拟分析流程

表1 材料属性

参数	MAT4000	SiC	S30403	DLC
密度/kg·m^-3	1820	3100	7750	3500
热导率/W·(m·K)^-1	80	58.6	15.1	32.4
热膨胀系数/K^-1	5.2×10^-6	4.5×10^-6	1.7×10^-5	3.6×10^-6
弹性模量/GPa	25	380	193	210
泊松比	0.26	0.27	0.31	0.30

图14 模型边界条件示意图

表2 网格无关性验证表

网格数量	轴向最大接触力/N	误差
3163	442.51	—
4125	460.14	3.98%
5072	501.54	8.99%
5951	574.39	14.53%
6805	582.09	1.34%
8041	583.66	0.27%

图15 网格数量与轴向最大接触力关系

图16 网格布置示意

图17 密封结构温度场云图

图18 不同转速下的端面峰值温度

图19 不同比压下的端面峰值温度

图20 端面接触力分布

图21 静环端面位移示意

图22 不同转速下的静环端面变形

图23 不同比压下的静环端面变形

图24 石墨环磨损深度与相对滑移距离的关系

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