Search Results (136)

During perforation operations, high-speed jet penetration into the casing-cement sheath-formation assembly damages the bonding interfaces, resulting in fluid flow along these interfaces within the wellbore. This can compromise the wellbore seal integrity and shorten the lifespan of the oil and gas well. To address this, a numerical model was developed using fluid-solid coupling algorithms, combined with a cohesive zone damage model and the ALE algorithm. The model was employed to analyze the dynamic damage evolution of the bonding interfaces during the jet penetration process and quantify the effects of the cement sheath’s mechanical parameters (shear modulus and compressive strength) and geological stress on the axial damage length and area. The results indicate that both the casing-cement sheath and cement sheath-formation interfaces exhibit significant damage, with the former showing a larger damage area under identical mechanical conditions; as the cement sheath’s shear modulus increases, the damaged area at the casing-cement sheath interface expands, while that at the cement sheath-formation interface reduces. Conversely, an increase in the cement sheath’s compressive strength reduces the damage extent at both interfaces, as does elevated geological stress. Based on engineering cases, different cement slurry types were compared to minimize perforation-induced interface damage. This study provides theoretical and practical guidance for optimizing cement selection and assessing bonding interface integrity during perforation. Full article

The honeycomb sealing surface serves as the critical sealing structure between the rotor and stator of an engine, and its sealing performance significantly impacts engine efficiency. To address the challenge of effectively controlling the overcutting depth during the electrolytic grinding of honeycomb sealing surfaces, this study quantitatively determined the actual volumetric equivalent electric charge of the honeycomb grid surface based on Faraday’s law of electrolysis. Nonlinear fitting was employed to establish the decay characteristics of current density and machining efficiency. Machining experiments were designed with voltage and feed speed set as independent variables, and an empirical model coupling the electrolytic proportion with overcutting depth was fitted on the basis of the obtained experimental results. The new parameters were validated, with the model’s predicted values showing an error of approximately 3.5% compared to actual measurements. By selecting the processing parameters using the established empirical prediction model, the overcutting depth of honeycomb seals can be controlled within 0.01 mm while ensuring excellent surface quality, which further meets the high-precision machining requirements for key components such as aviation engine seals. Full article

The secondary air system plays important roles in gas turbines, such as cooling hot-end components, sealing the rim, and balancing axial forces. In this paper, the flow structure and the heat transfer characteristics of the rotating disk cavity with two inlets and single outlet is studied by CFD (Computational Fluid Dynamics) approach. The effect and mechanism under higher rotational speed and larger mass flow rate are also discussed. The results show that a large-scale vortex is induced by the central inlet jet in the low-radius region of the cavity, while the flow structure in the high-radius region is significantly influenced by rotational speed and flow rate. Increasing the rotational speed generally enhances heat transfer because it amplifies the differential rotational linear velocity between the disk surface and nearby wall flow, consequently thinning the boundary layer. Increasing the mass flow rate enhances heat transfer through two primary mechanisms: firstly, it elevates the turbulence intensity of the near-wall fluid; secondly, the higher radial velocity results in a thinner boundary layer. Full article

In recent years, pneumatic proportional valves have become increasingly prevalent in ventilators, particularly proportional solenoid valves. However, these traditional valves face challenges, including a slow response, being prone to overheating from long-term work, and high power consumption. This study presents the development of a fast response, high flow rate, and low power consumption pneumatic proportional valve specifically designed for medical ventilators. Utilizing a piezoelectric bimorph as the actuator, we innovatively eliminate movable components such as springs while ensuring effective sealing of the valve. A support structure was designed to enhance the mechanical performance of the piezoelectric bimorph. A testing platform was established to rigorously assess the valve’s performance. The results indicate that the valve can achieve a maximum output flow rate of approximately 130 L/min at an input pressure of 4 bar, with a hysteresis rate of 25.3%, a response time of under 10 ms, and a power consumption of just 0.07 W. Furthermore, a comparative analysis with existing commercial proportional solenoid valves demonstrated that it has superior performance in terms of response speed, flow rate, and power efficiency. The piezoelectric proportional valve developed in this study holds the potential to replace conventional proportional solenoid valves, significantly enhancing the response speed of ventilators, reducing their overall power consumption, and facilitating the development of portable ventilators. Full article

Rotary lip seals serve as critical sealing components in industrial equipment, traditionally relying on the reverse pumping theory for their sealing mechanism. However, increasing operational demands characterized by high fluid pressure differentials, elevated speeds, and multi-physics coupling environments have revealed limitations in the applicability of the classical theory. This study aims to develop a comprehensive model to quantitatively characterize rotary lip seal performance, specifically frictional torque and reverse pumping rate, and to elucidate underlying mechanisms beyond classical theory. We developed a Mixed Thermo-Hydrodynamic Lubrication (MTHL) model that explicitly integrates fluid–solid–thermal coupling effects to simulate seal behavior under complex operating parameters. The simulations reveal that reverse pumping rate increases near-linearly with rotational speed from −8.54 mm³/s (0 m/s) to 122.82 mm³/s (3 m/s) and 220.27 mm³/s (6 m/s), validating classical theory, while under elevated fluid pressure differentials, a distinct non-monotonic trend emerges: rates evolve from 122.82 mm³/s (0.10 MPa) to 172.93 mm³/s (0.12 MPa), then decline to 52.67 mm³/s (0.18 MPa), and recover to 69.87 mm³/s (0.22 MPa), a phenomenon that cannot be explained by classical sealing mechanisms. Mechanistic analysis indicates that this anomaly stems from a competitive interaction between pressure-driven and shear-driven flow. This discovery not only enhances the reverse pumping theoretical system but also provides a theoretical foundation for optimizing sealing performance under diverse operational conditions. Full article

Preventive maintenance treatments are widely applied to asphalt pavements to mitigate deterioration and extend service life. This study evaluated four common technologies: a high-elasticity ultra-thin overlay, an Stone Mastic Asphalt (SMA)-10 thin overlay, micro-surfacing (MS-III), and a chip seal. Laboratory testing focused on skid resistance, surface texture, and low-temperature cracking resistance. Skid resistance was measured with a tire–pavement dynamic friction analyzer under controlled load and speed, while surface macrotexture was assessed using a laser scanner. Low-temperature cracking resistance was determined through three-point bending beam tests at −10 °C. The results showed that chip seal achieved the highest initial friction and texture depth, immediately enhancing skid resistance but exhibiting rapid texture loss and gradual friction decay. Micro-surfacing also demonstrated good initial skid resistance but experienced a sharp reduction of over 30% due to fine aggregate polishing. By contrast, the high-elastic ultra-thin overlay and SMA thin overlay provided more stable skid resistance, lower long-term friction loss, and excellent crack resistance. The polymer-modified ultra-thin overlay achieved the highest low-temperature bending strain ≈40% higher than untreated pavement, indicating superior crack resistance, followed by the SMA thin overlay. Micro-surfacing with a chip seal layer only slightly improved low-temperature performance. Overall, the high-elastic ultra-thin overlay proved to be the most balanced preventive maintenance option under heavy-load traffic and cold climate conditions, combining durable skid resistance with enhanced crack resistance. Full article

This paper focuses on the sealing failure problem of double-lip seal rings for high-speed ball bearings used in unmanned aerial vehicles. By using ANSYS 2023R1 software, a thermal–stress–wear coupled finite element model was established. Taking the contact pressure and volume loss due to wear as indicators to evaluate sealing performance, this study analyzed the influence of lip seal structural parameters on sealing performance, performed response surface optimization of the seal structure parameters and conducted a comparative test on lip seals before and after optimization. The research results show that the contact pressure at the main lip of the lip seal was the greatest, which was 0.79 MPa, and the volume loss due to wear lip seal was 7.94 × 10⁻⁷ mm³. Optimal sealing performance is achieved when the seal lip inclination angle is 41.68°, the middle width of the lip seal is 0.153 mm, the main lip height is 0.179 mm, the spring center distance is 0.37 mm and the radial interference is 0.0034 mm. After optimization, the grease leakage rate of the sealing ring decreased by 48% compared to before optimization. Full article

Permanent magnetic couplings provide critical advantages for deep-sea systems through static-sealed, contactless power transmission. However, conventional metallic isolation sleeves incur significant eddy current losses, limiting efficiency and high-speed operation. Limited torque capacities fail to meet the operational demands of harsh marine environments. This study presents a novel permanent magnet coupling featuring a ceramic isolation sleeve engineered for deep-sea cryogenic ammonia submersible pumps. The ceramic sleeve eliminates eddy current losses and provides exceptional corrosion resistance in acidic/alkaline environments. To withstand 3.5 MPa hydrostatic pressure, a 6-mm-thick sleeve necessitates a 10 mm operational air gap, challenging magnetic circuit efficiency. To address this limitation, an improved 3D magnetic equivalent circuit (MEC) model was developed that explicitly accounts for flux leakage and axial end-effects, enabling the accurate characterization of large air gap fields. Leveraging this model, a Taguchi method-based optimization framework was implemented by balancing key parameters to maximize the torque density. This co-design strategy achieved a 21% increase in torque density, enabling higher torque transfer per unit volume. Experimental validation demonstrated a maximum torque of 920 Nm, with stable performance under simulated deep-sea conditions. This design establishes a new paradigm for high-power leak-free transmission in corrosive, high-pressure marine environments, advancing applications from deep-sea propulsion to offshore energy systems. Full article

To analyze the wear performance induced by rotor–stator rubbing in an aero-engine sealing structure under authentic operating conditions, a transonic rotor system with double bearing is constructed. This system incorporates the disk, shaft, blades, joint bolts, and auxiliary support structure. The system was evaluated in terms of its critical speed, vibration characteristics, component strength under operational conditions, and response characteristics in abnormal extreme scenarios. A ball screw-type feeding system is employed to achieve precise rotor–stator rubbing during rotation by controlling the coating feed. Additionally, a quartz lamp heating system is used to apply thermal loads to coating specimens, and the appropriate heat insulation and cooling measures are implemented. Furthermore, a high-frequency rubbing force test platform is developed to capture the key characteristics caused by rubbing. The test rig can conduct response tests of the system with rotor–stator rubbing and abrasion tests with tip speeds reaching 425 m/s, feed rates ranging from 2 to 2000 μm/s, and heating temperatures up to 1200 °C. Test debugging has confirmed these specifications and successfully executed rubbing tests, which demonstrate stability throughout the process and provide reliable rubbing force test results. This designed test rig and analysis methodology offers valuable insights for developing high-speed rotating machinery. Full article

The gap seal ring is a critical component in high-speed centrifugal pumps. The leakage rate and performance of the pump are sensitive to variation in seal ring parameters. This study investigates the influence of seal ring tooth profile on the leakage flow of pump chambers. Numerical simulation and experimental tests are used to analyze the impact of four different tooth-height labyrinth seal ring structures on the pressure pulsation characteristics of pump leakage chambers. It can be concluded that the use of labyrinth seal rings can significantly reduce the pressure pulsation and leakage rate of pump chambers. For the Case 2 structure with a tooth height of 0.18 mm, the pressure pulsation in the pump chamber can be reduced by a maximum of 22.5%, and the leakage rate can be reduced by 41.1%. For the Case 3 structure with a tooth height of 0.23 mm, the pressure pulsation in the pump chamber can be reduced by a maximum of 30.3%, and the leakage rate can be reduced by 40.6%. The use of labyrinth seal rings significantly reduces the pressure pulsation intensity of the impeller surfaces, which improves the force stability of the high-speed centrifugal pump impeller. This study is helpful in providing theoretical support for the design of labyrinth seal rings in high-speed centrifugal pumps. Full article

As designers push engine efficiency closer to thermodynamic limits, the analysis of flow instabilities developed in a high-pressure turbine (HPT) is crucial to minimizing aerodynamic losses and optimizing secondary air systems. Purge flow, while essential for protecting turbine components from thermal stress, significantly impacts the overall efficiency of the engine and is strictly connected to cavity modes and rim-seal instabilities. This paper presents an experimental investigation of these instabilities in an HPT stage, tested under engine-representative flow conditions in the short-duration turbine rig of the von Karman Institute. As operating conditions significantly influence instability behavior, this study provides valuable insight for future turbine design. Fast-response pressure measurements reveal asynchronous flow instabilities linked to ingress–egress mechanisms, with intensities modulated by the purge rate (PR). The maximum strength is reached at PR = 1.0%, with comparable intensities persisting for higher rates. For lower PRs, the instability diminishes as the cavity becomes unsealed. An analysis based on the cross-power spectral density is applied to quantify the characteristics of the rotating instabilities. The speed of the asynchronous structures exhibits minimal sensitivity to the PR, approximately 65% of the rotor speed. In contrast, the structures’ length scale shows considerable variation, ranging from 11–12 lobes at PR = 1.0% to 14 lobes for PR = 1.74%. The frequency domain analysis reveals a complex modulation of these instabilities and suggests a potential correlation with low-engine-order fluctuations. Full article

Soft-growing robots based on the eversion principle are renowned for their ability to rapidly extend along their longitudinal axis, allowing them to access remote, confined, or otherwise inaccessible spaces. Their inherently compliant structure enables safe interaction with delicate environments, while their simple actuation mechanisms support lightweight and low-cost designs. Despite these benefits, implementing effective navigation mechanisms remains a significant challenge. Previous research has explored the use of pneumatic artificial muscles mounted externally on the robot’s body, which, when contracting, induce directional bending. However, this method only offers limited bending performance. To enhance maneuverability, pneumatic artificial muscles embedded in between the walls of double-walled eversion robots have also been considered and shown to offer superior bending performance and force output as compared to externally attached muscle. However, their adoption has been hindered by the complexity of the current manufacturing techniques, which require individually sealing the artificial muscles. To overcome this multi-stage fabrication approach in which muscles are embedded one by one, we propose a novel single-step method. The key to our approach is the use of non-heat-sealable inserts to form air channels during the sealing process. This significantly simplifies the process, reducing production time and effort and improving scalability for manufacturing, potentially enabling mass production. We evaluate the fabrication speed and bending performance of robots produced in this manner and benchmark them against those described in the literature. The results demonstrate that our technique offers high bending performance and significantly improves the manufacturing efficiency. Full article

We propose a wind spectrum–response surface dual-domain coupling method to study the reliability optimization of tall structures under the action of unsteady wind fields. Unlike traditional research, the dual-domain coupling analysis can quickly and accurately capture structural response defects and optimize size. The first parametric modeling technology establishes a high-precision finite element model of the movable boom structure by establishing a dual-domain coupling framework of pulsating wind and structural optimization. Using MATLAB (instructional R2024b version), the pulsating wind is simulated with uncertainty. The pulsating wind speeds at different heights are converted into wind loads acting on the net-sealed movable boom structure. Secondly, the boom structure’s dynamic response analysis and response surface optimization design were carried out. The final results show that the maximum value of displacement of the optimized net sealer boom is reduced by about 8.06%, the maximum value of stress is reduced by about 11.04%, and the stiffness is improved through the stress monitoring of the existing structure. It showed that the wind-resistant capability of the boom studied by this method is enhanced, improving the study’s efficiency. Full article

Poly-ether-ether-ketone (PEEK) is widely used in dynamic sealing applications due to its excellent properties. However, its tribological performance as a sealing material still has limitations, as its relatively high friction coefficient may lead to increased wear of sealing components, affecting sealing effectiveness and service life. To optimize its lubrication performance, this study employs surface modification techniques to synthesize a thin polyimide (PI) film on the surface of PEEK. When paired with bearing steel, this modification reduces the friction coefficient and enhances the anti-wear performance of sealing components. The tribological properties of a friction pair composed of GCr15 steel and PI-modified PEEK were systematically investigated using a nematic liquid crystal as the lubricant. The friction system was analyzed through various tests. The experimental results show that, under identical conditions, the friction coefficient of the PI-modified PEEK system decreased by 83.3% compared to pure PEEK. Under loads of 5 N and 25 N and rotational speeds ranging from 50 rpm to 400 rpm, the system exhibited induced alignment superlubricity. At 50 rpm, superlubricity was maintained when the load was below 105 N, while at 200 rpm, this occurred when the load was below 125 N. Excessively high rotational speeds (above 300 rpm) might affect system stability. The friction coefficient initially decreased and then increased with increasing load. The friction system demonstrated induced alignment superlubricity under the tested conditions, suggesting the potential application of PI-modified PEEK in friction components. Full article

With increasing demands for energy efficiency and environmental sustainability in pump stations, the development of digital and intelligent pump systems has become crucial. In this study, we focus on three speed ratios of pumps and propose a classification algorithm for pump performance curve fitting using the polyfit function based on the least squares principle. Software programs were developed to model and analyze pump performance curves. Additionally, the impact of seal ring clearance on pump performance and energy consumption was analyzed for pumps with specific speeds of 96.2, 185.5, and 493.3. External characteristic tests were conducted to evaluate these effects. When the clearance value of the sealing ring increases, the head and efficiency of the submersible sewage pump gradually decrease, while the shaft power of the pump presents different variation trends with an increase in the specific speed of the pump. When the specific speed is low–medium, the shaft power of the pump gradually increases. However, when the specific speed is relatively high (n_s > 300), the shaft power initially decreases, then increases, and finally decreases again. For intelligent monitoring, key variables and auxiliary power parameters were identified and mathematical models (Q-P and Q-H) were established as the basis for a soft measurement system. The results show that the Q-H, Q-P, and Q-η curves are generally fitted with polynomial curves of the third~fourth order. The maximum polynomial degree without inflection points is 3, while the maximum number of inflection points is 4, the two inflection points are fitted by segmentation. The pump monitoring system can integrates with an industrial cloud platform, enabling real-time parameter display, control, alarm of functions, recording and analyzing the historical data and operation trends. This research is significant for safe operation monitoring and energy conservation in pump systems. Full article