Method of manufacturing superstructure seal ring

Abstract

This invention discloses a method for manufacturing a superstructure sealing ring, comprising the following steps: establishing a simulation model of the mechanical seal structure and extracting load distribution data of the sealing ring under predetermined working conditions; designing a functionally graded material (FJT) model of the sealing ring based on the load distribution data, such that the elastic modulus, thermal conductivity, and coefficient of thermal expansion of the sealing ring continuously and smoothly change along the radial and axial directions without interface abrupt changes; optimizing and iterating the FJT model; outputting the optimized FJT model; converting the optimized FJT model into an additive manufacturing recognizable executable file, and forming the sealing ring through additive manufacturing. The manufacturing method of the superstructure sealing ring according to embodiments of this invention facilitates a continuous and smooth transition between sealing ring materials and properties, avoids interface abrupt changes, enables the sealing ring to adapt to gradient loads, has controllable deformation, requires no external additional structures, and has advantages such as high molding efficiency and good consistency.

Description

Technical Field

[0001] This invention relates to the field of mechanical seal technology, and more specifically, to a method for manufacturing a superstructure sealing ring. Background Technology

[0002] Mechanical seal structures in related technologies employ external structures such as elastic compensation structures, cooling and lubrication structures, and stationary ring displacement adjustment structures to improve the sealing state of the dynamic and stationary rings, addressing issues like deformation, leakage, and wear at the sealing end faces. However, these external structures significantly increase the number of components and overall volume of the sealing system, complicating the assembly process. Furthermore, multi-component linkages are prone to motion interference and localized stress concentration, adding additional failure points and further reducing equipment reliability. On the other hand, extreme operating conditions such as high temperature, high pressure, high speed, and strong variable loads can cause stress relaxation in elastic elements, thermal aging and swelling of rubber auxiliary components, and jamming and failure of the adjustment mechanism. Moreover, the effectiveness of these external compensation structures is limited, failing to fundamentally suppress the deformation problems caused by large gradient loads. Summary of the Invention

[0003] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a method for manufacturing a superstructure sealing ring. This method facilitates a smooth and continuous transition between the sealing ring material and its properties, avoids abrupt interface changes, enables the sealing ring to adapt to gradient loads, has controllable deformation, requires no external additional structures, and has advantages such as high molding efficiency and good consistency.

[0004] To achieve the above objectives, an embodiment of the present invention proposes a manufacturing method for a superstructure sealing ring, wherein the superstructure sealing ring is a sealing ring of a mechanical seal structure, the sealing ring is a functionally graded material component, and the manufacturing method includes the following steps: establishing a simulation model of the mechanical seal structure and extracting load distribution data of the sealing ring under predetermined working conditions; Based on the load distribution data, a functionally graded material model for the sealing ring is designed so that the elastic modulus, thermal conductivity, and coefficient of thermal expansion of the sealing ring change smoothly and continuously along the radial and axial directions without any abrupt interface changes. The functionally graded material model is optimized and iterated. Output the optimized functionally graded material model; The optimized functional graded material model is converted into an additive manufacturing recognizable executable file, and the sealing ring is formed through additive manufacturing.

[0005] The manufacturing method of the superstructure sealing ring according to the present invention can facilitate a smooth and continuous transition of sealing ring material and performance, avoid abrupt interface changes, enable the sealing ring to adapt to gradient loads, controllable deformation, and eliminate the need for external additional structures, and has the advantages of high molding efficiency and good consistency.

[0006] In addition, the manufacturing method of the superstructure sealing ring according to the above embodiments of the present invention may also have the following additional technical features: According to one embodiment of the present invention, the simulation model is a fluid-structure-thermal coupling model.

[0007] According to one embodiment of the present invention, the sealing ring has a sealing surface and a substrate surface, and the design of the functionally graded material model of the sealing ring further includes: The sealing surface is made of a material with high wear resistance, low thermal expansion, and high rigidity, while the base surface is made of a material with high toughness and high strength, so that the material composition and properties between the sealing surface and the base surface are smoothly transitioned.

[0008] According to an embodiment of the present invention, the optimization iteration of the functionally graded material model includes: With the deformation uniformity of the sealing surface of the sealing ring and the overall structural stress as optimization objectives, and with load distribution, material properties, and structural strength as constraints, the number of gradient layers, material composition ratio, and performance gradient curve are optimized iteratively.

[0009] According to one embodiment of the present invention, the load distribution data includes at least radial pressure gradient, axial pressure gradient, temperature gradient and centrifugal force gradient.

[0010] According to one embodiment of the present invention, the sealing ring is the same size as a standard sealing ring.

[0011] According to one embodiment of the present invention, the sealing ring is integrally formed by the additive manufacturing process, wherein the additive manufacturing process is laser selective melting, coaxial powder deposition, or photopolymerization.

[0012] According to one embodiment of the present invention, after forming the sealing ring by additive manufacturing, the method further includes: The sealing ring is precision ground on its end face.

[0013] According to one embodiment of the present invention, after the end face finishing of the sealing ring is performed, the process further includes: The sealing ring is subjected to dimensional accuracy testing, flatness testing, and deformation testing.

[0014] According to one embodiment of the present invention, the sealing ring includes a dynamic ring and a stationary ring.

[0015] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0016] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a flowchart of a method for manufacturing a superstructure sealing ring according to an embodiment of the present invention.

[0017] Figure 2 This is a partial structural schematic diagram of the sealing ring according to the manufacturing method of the superstructure sealing ring of the present invention. Detailed Implementation

[0018] This application is based on the findings and understanding of the following facts and issues: Mechanical seal structures in related technologies employ external structures such as elastic compensation structures, cooling and lubrication structures, and stationary ring displacement adjustment structures to improve the sealing state of the dynamic and stationary rings, addressing issues like deformation, leakage, and wear at the sealing end faces. However, these external structures significantly increase the number of components and overall volume of the sealing system, complicating the assembly process. Furthermore, multi-component linkages are prone to motion interference and localized stress concentration, adding additional failure points and further reducing equipment reliability. On the other hand, extreme operating conditions such as high temperature, high pressure, high speed, and strong variable loads can cause stress relaxation in elastic elements, thermal aging and swelling of rubber auxiliary components, and jamming and failure of the adjustment mechanism. Moreover, the effectiveness of these external compensation structures is limited, failing to fundamentally suppress the deformation problems caused by large gradient loads.

[0019] Specifically, in the mechanical seal structure of related technologies, the dynamic and static rings are made of homogeneous materials. Under high temperature, high pressure, high speed, and strong variable load conditions, the sealing rings will simultaneously bear multiple non-uniform loads such as radial and axial pressure gradients, temperature gradients, and centrifugal force gradients. Since the properties of homogeneous materials are uniform across the entire range, they cannot adaptively adjust their mechanical and thermal properties according to the load distribution. The sealing end face is prone to irregular deformations such as warping, taper, and local opening. Moreover, after the sealing end face is deformed, the fitting accuracy of the dynamic and static rings drops sharply, which directly leads to an increase in the amount of medium leakage and an increase in the friction and wear of the end face. Long-term operation will lead to problems such as seal instability and sealing ring failure, triggering a chain of failures. The reliability and service life of the seal are greatly reduced, resulting in frequent failures in equipment operating under extreme conditions in continuous operation and high maintenance costs.

[0020] Some sealing rings in related technologies are prepared using processes such as sintering, vapor deposition, thermal spraying, and lamination. However, these processes can only achieve discrete layered gradients and cannot achieve continuous gradual changes in performance or overall gradient design of the ring body. There are obvious interface abrupt changes between layers, and stress concentration is prone to occur at the interface. Under alternating loads, delamination and cracking occur. The processing accuracy and molding consistency are poor. Moreover, the processing steps are numerous, the cycle is long, and the cost is high. It is also difficult to form standard specifications, which are incompatible with the standard sealing ring installation dimensions, resulting in high equipment modification costs.

[0021] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0022] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0024] The following describes a method for manufacturing a superstructure sealing ring according to an embodiment of the present invention with reference to the accompanying drawings.

[0025] like Figure 1 and Figure 2 As shown, the superstructure sealing ring is a sealing ring of a mechanical seal structure, the sealing ring is a functionally graded material component, and the manufacturing method includes the following steps: A simulation model of the mechanical seal structure is established, and the load distribution data of the sealing ring under predetermined working conditions is extracted; Based on the load distribution data, a functionally graded material model for the sealing ring is designed so that the elastic modulus, thermal conductivity, and coefficient of thermal expansion of the sealing ring change smoothly and continuously along the radial and axial directions without any abrupt interface changes. The functionally graded material model is optimized and iterated. Output the optimized functionally graded material model; The optimized functional graded material model is converted into an additive manufacturing recognizable executable file, and the sealing ring is formed through additive manufacturing.

[0026] According to the manufacturing method of the superstructure sealing ring of the present invention, by making the sealing ring a functionally graded material component, the elastic modulus, thermal conductivity, and coefficient of thermal expansion of the sealing ring are continuously and smoothly varied radially and axially without interface abrupt changes. Compared with homogeneous sealing rings in related technologies, the sealing ring manufactured by the manufacturing method of the present invention can adapt to external gradient loads. Through the gradient structure of the sealing ring itself, it suppresses force-thermal coupling deformation, keeping the warping, gap, and taper deformation of the sealing end face under control. This significantly reduces media leakage and end face wear, and significantly improves the stability, reliability, and service life of the seal under extreme operating conditions. It solves the problem that homogeneous sealing rings cannot match gradient loads under extreme operating conditions, leading to uncontrolled end face deformation and decreased fitting accuracy under force-thermal coupling. It also solves the problems of large leakage, severe wear, seal instability, and short service life caused by abnormal deformation of the sealing ring. Experimental verification shows that the end face deformation is reduced by more than 60%.

[0027] Furthermore, the sealing ring manufactured using the manufacturing method of this invention can adapt to external gradient loads and suppress force-thermal coupling deformation through the gradient structure of the sealing ring itself. It eliminates the need for additional external structures such as various control, cooling, lubrication, and compensation systems, simplifying the entire sealing system, reducing assembly difficulty and the risk of motion interference and stress concentration, and reducing sources of failure. At the same time, it eliminates the dependence on easily failed external components, and significantly improves the overall ability to withstand high temperature, high pressure, high speed, and strong alternating loads. It solves the problems of system complexity, assembly difficulty, and increased failure points caused by adding external auxiliary structures. It also solves the problems of weak resistance to extreme working conditions and limited compensation effect of external compensation structures.

[0028] Furthermore, by forming the sealing ring through additive manufacturing, a continuous and smooth transition of material composition and properties can be achieved without interface abrupt changes, avoiding interface stress concentration and cracking problems. It is convenient to complete the high-precision molding of complex gradient ring structures in one go, with high molding efficiency and good product consistency. Compared with sealing rings manufactured by processes such as sintering, vapor deposition, thermal spraying, and lamination in related technologies, it can completely break through the limitations of mass production and application of gradient sealing rings, and solve the problems of difficulty in achieving continuous and gradual changes in material properties, interface abrupt changes, and easy stress cracking in the preparation process of related technologies.

[0029] Therefore, the manufacturing method of the superstructure sealing ring according to the present invention can facilitate a smooth and continuous transition of sealing ring material and performance, avoid abrupt interface changes, enable the sealing ring to adapt to gradient loads, controllable deformation, and eliminate the need for external additional structures, and has the advantages of high molding efficiency and good consistency.

[0030] The following describes a method for manufacturing a superstructure sealing ring according to a specific embodiment of the present invention with reference to the accompanying drawings.

[0031] Specifically, the simulation model is a fluid-structure-thermal coupling model. This facilitates the simulation of the coupling effects of the mechanical seal structure under fluid mechanics, solid mechanics, and heat conduction, resulting in a mechanical seal structure that more closely approximates reality and improving the accuracy and reliability of optimizing the functionally graded material model of the sealing ring.

[0032] Advantageously, the sealing ring has a sealing surface and a substrate surface, and the functionally graded material model for designing the sealing ring further includes: The sealing surface is made of a material with high wear resistance, low thermal expansion, and high rigidity, while the base surface is made of a material with high toughness and high strength, so that the material composition and properties between the sealing surface and the base surface are smoothly transitioned.

[0033] The sealing surface is made of a highly wear-resistant, low-thermal-expansion, and high-rigidity material, which facilitates accurate end-face contact and reduces wear and thermal deformation. The base surface is made of a high-toughness and high-strength material, which enhances the overall structural load-bearing capacity and resistance to alternating loads. The smooth transition in material composition and properties between the sealing surface and the base surface avoids localized stress concentration.

[0034] More specifically, the optimization iteration of the functionally graded material model includes: With the deformation uniformity of the sealing surface of the sealing ring and the overall structural stress as optimization objectives, and with load distribution, material properties, and structural strength as constraints, the number of gradient layers, material composition ratio, and performance gradient curve are optimized iteratively.

[0035] This further facilitates the optimization of the functionally graded material model.

[0036] Optionally, the load distribution data includes at least the radial pressure gradient, axial pressure gradient, temperature gradient, and centrifugal force gradient. This allows for a full consideration of the load distribution of the sealing ring under various conditions, facilitating improved reliability and accuracy of optimization.

[0037] More advantageously, the dimensions of the sealing ring are the same as those of the standard sealing ring. This allows the external installation dimensions of the sealing ring to be consistent with those of the standard sealing ring in related technologies, enabling the installation dimensions of the sealing ring to follow standard specifications. It can directly replace the standard sealing ring in related technologies without modifying the supporting equipment and pipelines, reducing equipment modification costs and implementation barriers, improving the applicability of the sealing ring, and solving the problems of non-universal sealing ring dimensions, high replacement and modification costs, and narrow application range.

[0038] Optionally, the sealing ring is integrally formed through additive manufacturing, which can be laser selective melting, coaxial powder deposition, or photopolymerization. This facilitates the one-time integral forming of the sealing ring, improves forming efficiency and consistency, and further avoids interface abrupt changes.

[0039] Furthermore, after forming the sealing ring by additive manufacturing, the process further includes: The sealing ring is precision ground on its end face.

[0040] This allows the sealing ring of the additively constructed blank to be ground, making it easier to form a smooth sealing interface.

[0041] Furthermore, after the end face of the sealing ring is precision ground, the process further includes: The sealing ring is subjected to dimensional accuracy testing, flatness testing, and deformation testing.

[0042] This allows for the inspection of the polished sealing ring, and the finished sealing ring is obtained after passing the inspection.

[0043] Optionally, the sealing ring includes a rotating ring and a stationary ring. In other words, the sealing ring can be either a rotating ring or a stationary ring. The manufacturing method of the superstructure sealing ring can be used to manufacture either the rotating ring or the stationary ring. The rotating ring and the stationary ring can use the same or different functional gradient material distributions to meet the different requirements of different mechanical seal mechanisms.

[0044] Other components and operations of the manufacturing method of the superstructure sealing ring according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here.

[0045] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0046] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A method for manufacturing a superstructure sealing ring, characterized in that, The superstructure sealing ring is a mechanical seal structure sealing ring, the sealing ring is a functionally graded material component, and the manufacturing method includes the following steps: A simulation model of the mechanical seal structure is established, and the load distribution data of the sealing ring under predetermined working conditions is extracted; Based on the load distribution data, a functionally graded material model for the sealing ring is designed so that the elastic modulus, thermal conductivity, and coefficient of thermal expansion of the sealing ring change smoothly and continuously along the radial and axial directions without any abrupt interface changes. The functionally graded material model is optimized and iterated. Output the optimized functionally graded material model; The optimized functional graded material model is converted into an additive manufacturing recognizable executable file, and the sealing ring is formed through additive manufacturing.

2. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The simulation model is a fluid-structure-thermal coupling model.

3. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The sealing ring has a sealing surface and a base surface, and the functional graded material model for designing the sealing ring further includes: The sealing surface is made of a material with high wear resistance, low thermal expansion, and high rigidity, while the base surface is made of a material with high toughness and high strength, so that the material composition and properties between the sealing surface and the base surface are smoothly transitioned.

4. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The optimization and iteration of the functionally graded material model includes: With the deformation uniformity of the sealing surface of the sealing ring and the overall structural stress as optimization objectives, and with load distribution, material properties, and structural strength as constraints, the number of gradient layers, material composition ratio, and performance gradient curve are optimized iteratively.

5. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The load distribution data includes at least the radial pressure gradient, axial pressure gradient, temperature gradient, and centrifugal force gradient.

6. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The dimensions of the sealing ring are the same as those of the standard sealing ring.

7. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The sealing ring is integrally formed by the additive manufacturing process, which can be laser selective melting, coaxial powder deposition, or photopolymerization.

8. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, After forming the sealing ring by additive manufacturing, the method further includes: The sealing ring is precision ground on its end face.

9. The method for manufacturing the superstructure sealing ring according to claim 8, characterized in that, After the end face of the sealing ring is precision ground, the process further includes: The sealing ring is subjected to dimensional accuracy testing, flatness testing, and deformation testing.

10. The method for manufacturing the superstructure sealing ring according to claim 1, characterized in that, The sealing ring includes a moving ring and a stationary ring.

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