Study On Life Prediction Modeland Numerical Simulation For Remanufactured Impeller Of Centrifugal Compressor

Mechanical equipment manufacturing is animportant technical fieldforremanufacturing industry development and cycling economy constructing.For thatreason, a program named basic scientific problems of mechanical equipmentmanufacturingis supported by the Major State Basic Research Development Program ofchina (973Program)(No.2011CB013400).With proposed to make technologicalbreakthrough, centrifugal compressor as a typical object is used to study some basicscientific problemsinvolvemechanical equipment manufacturing, such as life predictionof remanufactured parts. Life prediction of remanufactured parts urgently needs thesupport of theories and methods. This problem has become one of the key technologiesof mechanical parts remanufacturing. Study on life prediction model and numericalsimulationfor remanufactured impeller of centrifugal compressor is supported by asubproject named life prediction of remanufactured parts and service securityverification of remanufactured product(No.2011CB013400-5). The purpose of thestudy is providing theory and method to the mechanism analysis and the safetyperformance evaluation of remanufactured impeller.Firstly, this paper developeda life prediction model of remanufactured impeller ofcentrifugal compressorbased on fracture mechanics and damage accumulation theory.The remanufacturing process repaired structure features and the service characteristicload are also integrated the model. Existing life prediction method oftest specimen isextended toremanufactured impeller of centrifugal compressor.Service life predictionmodel of remanufactured impeller is established. Its core contains geometry precisionmodeling method based on more failure features, passage adaptive meshing methodbased on domain virtual planning, service characteristic load solution method based onthe numerical analysis, life calculation by FE-SAFE software and remanufacturingprocess life correction test. The model provides a theory method to judge safetyperformance of the remanufactured impeller.Secondly,a precise geometric model of remanufactured impeller of centrifugalcompressor is constructed by remanufactured impeller geometric modelingmethod.Because remanufactured impeller geometric model is always absent or existingmodel can’t response remanufactured featuresin the analysis.By researching keytechnologies such as finite element mesh error estimation theory, the key areas identification of remanufactured impeller parts, virtual planning of calculation domain,the grid generation algorithm and node encryption algorithm, the adaptive precisionhexahedron mesh of remanufactured impeller was generated.Then, four kinds of typical characteristics loads of centrifugalcompressorremanufactured impeller are analyzed and discussed by ANSYS simulationtechnique. Finite element heat transfer theory, elastic-plastic mechanics and calculusprinciple are also integrated the analysis procedure. The analyses focused onthermallyinduced residual stress during laser cladding repair process and assembly stress loadfrom assembly process. The high speed centrifugal stress and pneumatic equivalentstress is also simulated.The analysis and simulation resultsprovide the load spectrumamplitude for the subsequent life prediction of remanufactured impeller.Finally,it carried out application research onservice life prediction model ofremanufactured impeller.Service load spectrum of remanufacturing impeller isestablished according to the five stages characteristics and four kinds typical loadduring remanufactured impeller service. The service life of remanufactured impeller canbe calculated by usinglife prediction model and numerical simulation method. Lifecorrection coefficient was getting from laser cladding tests of the substratematerialFV520B is used. Also,it explored the influence of remanufacturing processloads to service life of remanufactured impeller.