基于数值仿真的大型塔式磨机工作特性分析

doi:10.13229/j.cnki.jdxbgxb20210466

摘要/Abstract

摘要：

针对大型塔式磨机在设计阶段驱动功率、螺旋主轴应力和出料粒度分布（PSD）等指标的预测不准确问题，提出了基于流固耦合（CFD-DEM）联合仿真的塔式磨机工作过程数值模拟方法，对工作过程中研磨介质运动分布、力链分布、碰撞谱以及驱动功率进行分析，并将载荷信息作用到有限元模型中对磨机螺旋主轴应力状态及分布进行计算；此外，建立塔式磨机磨矿过程的数学模型，以分析不同工艺参数对磨矿效果的影响。通过实测不同装球量条件下的驱动功率验证了流固耦合仿真结果的正确性，并通过一系列磨矿试验确定了数学模型中的关键参数。分析结果表明：研磨介质尺寸、填充量以及螺旋搅拌器速度等参数是影响塔式磨机作业性能的主要因素。

关键词: 机械设计, 塔式磨机, 工作特性, 流固耦合, 数值仿真

Abstract:

To precisely evaluate key working performance such as driving power， the stress state of the screw with liners， and product particle size distribution of large vertical screw stirring mill， a fluid-structure interaction method （CFD-DEM coupling） was conducted for the calculation. To be more specific， the particle motion distribution， interactive force distribution， collision rate， and power consumption were evaluated under different working conditions. Furthermore， the load applied on the screw with liner was extracted from coupled simulations into FEM calculations for the stress state analysis based on which the value and distribution of maximum stress were studied. Besides， a numerical model was constructed for the prediction of product particle size distribution of vertical screw stirring mill to accomplish the evaluations of the impact of different milling parameters on the results. Field tests were taken for the validation of the effectiveness of coupling simulations based on the data of driving power under different amounts of milling balls. Lab experiments were conducted for the determination of the parameters applied in the theoretical model. According to the fitting results of the lab data， a numerical calculation program was established for the prediction of product particle size distribution under different milling conditions. The analysis results indicate that the rotate speed of screw with liner， the filling rate， and the size of milling ball are the main factors that have complex influence on the working performance of a vertical screw stirring mill.

Key words: mechanical design, vertical screw stirring mill, working performance, fluid-structure interaction, numerical simulation

中图分类号:

TD453

姚宗伟,高旭东,刘刚,毕秋实. 基于数值仿真的大型塔式磨机工作特性分析[J]. 吉林大学学报(工学版), 2021, 51(5): 1642-1650.

Zong-wei YAO,Xu-dong GAO,Gang LIU,Qiu-shi BI. Research on working performance of vertical screw stirring mill based on numerical simulations[J]. Journal of Jilin University(Engineering and Technology Edition), 2021, 51(5): 1642-1650.

图/表 16

图1

表1

表2

图2

图3

图4

图5

图6

图7

表3

图8

图9

表4

机理模型关键参数拟合结果"

组别	A/min^-1	$α$	$?$	$γ$	$β$
1	2.980	1.35	0.32	5.80	0.45
2	2.364	1.34	0.32	5.81	0.45
3	2.112	1.35	0.31	5.78	0.44
4	1.956	1.36	0.32	5.80	0.46
5	1.174	1.35	0.33	5.82	0.45
6	1.890	1.33	0.32	5.79	0.46

表4

表5

图10

图11

参考文献 18

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结构参数	数值
筒体外径/mm	4500
筒体内径/mm	4200
筒体高度/mm	4775
搅拌器直径/mm	3300
搅拌器轴径/mm	550
法兰盘直径/mm	1000
叶片边缘厚度/mm	100
螺旋个数	2
螺旋导程/mm	2900
搅拌器与筒体底部距离/mm	420

仿真参数	数值
矿石比重	3200
筒体/钢球恢复系数	0.8
筒体/钢球静摩擦系数	0.25
筒体/钢球滚动摩擦系数	0.5
整体仿真时间/s	6

试验磨机参数	数值
筒体外径/mm	350
筒体内径/mm	336
筒体高度/mm	425
搅拌器直径/mm	256
搅拌器轴径/mm	48
螺旋个数	2
导程/mm	235
搅拌器与筒底距离/mm	42

参数	试验组
参数	1	2	3	4	5	6
钢球尺寸/mm	10	12	10	10	12	10
尖端速度/（m·s^-1）	1.608	1.608	1.474	1.608	1.474	1.541
比功耗/（kW·h·t^-1）	2.45	2.38	2.23	2.01	1.81	1.89
计算数值/min^-1	2.956	2.260	2.166	2.132	1.232	1.786
拟合数值/min^-1	2.980	2.364	2.112	1.956	1.174	1.890