Construction and application method for simulation calculation model for high-pressure high-efficiency mud pump

Abstract

The present invention relates to the technical field of simulation calculation for high-pressure mud pumps. Disclosed is a construction and application method for a simulation calculation model for a high-pressure high-efficiency mud pump. The method comprises: establishing a model on the basis of dynamic fluid-structure coupling parameters (mud pulsation pressure, dynamic stress of impellers, etc.), multi-phase rheological parameters of soil (particle phase volume fraction, viscous resistance coefficient, etc.) and transient resistance parameters of pipelines (transient pressure drop gradient, etc.), and incorporating factors such as rotational speed-power matching to calculate operating envelopes and critical failure threshold values; and developing a multi-physics coupling analysis system including a parameter configuration module, a dynamic simulation module (integrating a flow field solver and a structural vibration solver) and a safety assessment module, inputting measured data and customized parameters, then acquiring dynamic flow velocity distributions, pressure pulsation characteristics, etc. by means of a two-way fluid-structure coupling calculation, and generating an optimized configuration scheme. The system supports database management, multi-rheology model matching and three-dimensional visualization, and improves the simulation accuracy and engineering efficiency, thereby providing support for performance optimization and safety assessment under high-pressure operating conditions.

Description

A Method for Constructing and Applying a Simulation Calculation Model of a High-Pressure and High-Efficiency Mud Pump Technical Field

[0001] This invention relates to the field of high-pressure mud pump simulation calculation technology, specifically to a method for constructing and applying a high-pressure, high-efficiency mud pump simulation calculation model. Background Technology

[0002] In modern engineering, high-pressure mud pumps, as fundamental construction equipment, are widely used in mining, tunnel excavation, oil and gas drilling, and other scenarios. Their performance directly affects construction efficiency, safety, and equipment lifespan. With increasing engineering complexity, higher demands are placed on the reliability and energy efficiency of mud pumps under high pressure, high load, and multiple operating conditions. However, traditional mud pump design and optimization rely on physical experiments and empirical formulas, which suffer from high costs, long development cycles, and insufficient coverage of operating conditions. Furthermore, they struggle to accurately simulate complex physical phenomena in actual construction, such as fluid-structure interaction, multiphase flow characteristics, and transient cavitation risks.

[0003] In existing technologies, mud pump simulation models often neglect a refined description of dynamic fluid-structure interaction effects. For example, they only consider static pressure distribution, failing to incorporate the dynamic load effect of pulsating mud pressure on the impeller structure, leading to inaccurate prediction of impeller fatigue damage. Simultaneously, the modeling of multiphase rheological properties of soil is rather coarse, typically simplifying mud as a single Newtonian fluid and ignoring the influence of parameters such as particle content, viscous drag coefficient, and thixotropic index on flow characteristics, resulting in significant deviations between simulation results and actual operating conditions. Furthermore, transient resistance analyses of pipeline systems are mostly based on steady-state flow assumptions, failing to consider the impact of transient pressure drop gradients, local resistance abrupt changes, and cavitation phenomena on the stability of mud pump operation, making it difficult to effectively identify critical failure conditions.

[0004] At the system development level, traditional simulation tools lack multiphysics coupling capabilities. Flow field and structural field analyses are independent, making real-time data interaction and iterative calculations impossible, resulting in simulation results that fail to reflect the actual physical coupling process. Parameter configuration modules are functionally limited, failing to meet the rapid modeling needs of diverse soil conditions and pipeline topologies. Furthermore, the safety assessment system is incomplete, lacking systematic analysis of the mud pump operating envelope and critical failure thresholds, thus failing to provide engineers with comprehensive operational safety guidance.

[0005] With the development of computer technology and computational fluid dynamics (CFD) and computational structural mechanics (CSM), multiphysics coupling simulation has become a key means to solve complex engineering problems. How to construct a high-precision simulation model covering dynamic fluid-structure interaction, multiphase rheological characteristics, and transient pipeline resistance, and develop an analysis system integrating parameter configuration, dynamic simulation, and safety assessment functions, has become a core technical challenge for improving the design and operation and maintenance of high-pressure mud pumps. The shortcomings of existing technologies in terms of model completeness, parameter refinement, and system integration urgently necessitate a more comprehensive and efficient simulation calculation method and system to meet practical engineering needs. Summary of the Invention

[0006] The purpose of this invention is to provide a method for constructing and applying a high-pressure, high-efficiency mud pump simulation calculation model, so as to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a method for constructing and applying a simulation calculation model of a high-pressure, high-efficiency mud pump, the method comprising:

[0008] A simulation model of a high-pressure mud pump is established based on the dynamic fluid-structure interaction parameters of the mud pump, the multiphase rheological parameters of the soil, and the transient resistance parameters of the pipeline. The dynamic fluid-structure interaction parameters include mud pulsating pressure and impeller dynamic stress. The multiphase rheological parameters of the soil include particle phase content and viscous resistance coefficient. The transient resistance parameters of the pipeline include transient pressure drop gradient and local resistance abrupt change coefficient.

[0009] The simulation calculation model incorporates dynamic matching of pump speed and power, slurry flow stratification effect and pipeline transient cavitation risk factors, and calculates the pump operation envelope and critical failure threshold under different construction scenarios through the model.

[0010] Based on the simulation calculation model, a multiphysics coupling analysis system for high-pressure mud pumps was developed. The system includes a parameter configuration module, a dynamic simulation module, and a safety assessment module. The dynamic simulation module integrates a transient flow field solver and a structural vibration solver.

[0011] The measured transient performance data of the mud pump, the custom soil rheological properties, and the pipeline topology parameters are input through the parameter configuration module of the system. The measured transient performance data includes the pulsating power spectral density and the dynamic head fluctuation amplitude.

[0012] Based on the dynamic simulation module of the system, a two-way fluid-structure interaction calculation is performed to obtain the dynamic velocity distribution, pressure pulsation propagation characteristics and structural fatigue damage index of the mud pump at different speeds, and to generate an optimized configuration scheme for high-pressure working conditions.

[0013] Preferably, the dynamic fluid-structure interaction parameters further include the impeller clearance leakage vortex intensity coefficient and the thixotropic index of the non-Newtonian fluid in the mud.

[0014] Preferably, the parameter configuration module of the high-pressure mud pump multiphysics coupling analysis system includes:

[0015] Establish a mud pump transient performance database, a soil rheological property database, and a pipeline topology database, wherein the transient performance database stores the time-domain signal and frequency-domain energy distribution of pressure pulsation at different rotational speeds;

[0016] According to the mud pump model, the corresponding impeller geometry parameter set is matched from the database. The geometry parameter set includes blade wrap angle, hub ratio, and outlet installation angle.

[0017] A three-dimensional mesh model of the mud pump channel is generated based on the geometric parameter set and loaded into the flow field solver of the dynamic simulation module.

[0018] Preferably, the dynamic simulation module performs fluid-structure interaction calculations including:

[0019] The pulsating pressure field output by the flow field solver is mapped to the impeller surface mesh nodes of the structural vibration solver.

[0020] The dynamic stress distribution and modal participation factor of the impeller are calculated by the structural vibration solver, and the deformation displacement field is fed back to the flow field solver to update the calculation domain.

[0021] The calculation is iterated until the residual between the pressure pulsation amplitude and the structural vibration acceleration converges to the preset threshold.

[0022] Preferably, the security assessment module includes:

[0023] The peak equivalent stress and critical pressure for mud cavitation initiation at key locations of the impeller are extracted based on the dynamic simulation results.

[0024] Calculate the three-dimensional safety boundary surface of speed-head-power in the operating envelope of the mud pump, and mark the critical failure region;

[0025] Based on the safety boundary surface, generate a set of permissible operating condition configurations and corresponding risk level labels.

[0026] Preferably, the parameter configuration module further includes:

[0027] A mud multiphase rheological model selector is set up, which includes Bingham fluid model, power-law fluid model and thixotropic fluid model;

[0028] The corresponding rheological model is automatically matched based on the soil gradation parameters and loaded into the flow field control equation of the dynamic simulation module.

[0029] Preferably, the high-pressure mud pump multiphysics coupling analysis system further includes:

[0030] Design a main control interface, a parameter visualization interface, and a report generation interface. The main control interface integrates working condition configuration, simulation progress monitoring, and result comparison functions.

[0031] The parameter visualization interface synchronously displays the three-dimensional dynamic rendering results of the flow field velocity cloud map, pressure contour lines, and structural stress distribution.

[0032] Preferably, the operating condition configuration function includes:

[0033] Set the mud pump speed adjustment range, mud concentration gradient, and pipeline topology change sequence;

[0034] Based on the simulation calculation model, a dynamic performance comparison matrix under different configuration combinations is automatically generated. The matrix includes efficiency-power curves, pulsation amplitude-frequency spectrum, and fatigue life prediction values.

[0035] Preferably, the calculation of the critical failure threshold includes:

[0036] Establish a bivariate failure criterion for the impeller material SN curve and mud cavitation damage accumulation model;

[0037] The combined damage contribution factor of dynamic stress spectrum and pressure pulsation spectrum was extracted by rainflow counting method;

[0038] When the combined damage contribution factor exceeds the preset safety factor, the current working condition is marked as a high-risk state.

[0039] Preferably, the generation of the high-voltage operating condition optimized configuration scheme includes:

[0040] Based on the set of permissible operating conditions output by the safety assessment module, calculate the output-energy consumption ratio and equipment loss rate under each operating condition;

[0041] A multi-objective optimization algorithm is used to select the Pareto optimal solution set that satisfies the constraints, and a recommendation priority list is generated according to preset weights.

[0042] Compared with the prior art, the beneficial effects of the present invention are:

[0043] The simulation model constructed in this invention comprehensively incorporates dynamic fluid-structure interaction parameters (such as slurry pulsating pressure, impeller dynamic stress, leakage vortex intensity coefficient, etc.), soil multiphase rheological parameters (particle content, viscous drag coefficient, thixotropic index, etc.), and pipeline transient resistance parameters (transient pressure drop gradient, local resistance abrupt change coefficient, etc.), overcoming the limitation of traditional models in incomplete description of multiphysics coupling effects. Through refined modeling, it can accurately simulate the dynamic interaction between slurry flow and impeller structure, revealing the evolution law of flow stratification effect and pipeline cavitation risk under multiphase flow conditions, providing a more reliable theoretical basis for predicting the performance of mud pumps under different soil and pipeline conditions.

[0044] The multiphysics coupling analysis system achieves bidirectional fluid-structure interaction calculations through a dynamic simulation module, deeply integrating the flow field solver and the structural vibration solver. Through real-time mapping and iterative calculation of the pulsating pressure field and deformation displacement field, it ensures that the simulation results accurately reflect the physical coupling process during mud pump operation. This refined calculation can obtain key parameters such as dynamic velocity distribution, pressure pulsation propagation characteristics, and structural fatigue damage index. Compared with traditional methods that independently analyze the flow field or structural field, it significantly improves the accuracy and reliability of the simulation results, providing more precise data support for impeller structure optimization and fatigue life prediction.

[0045] The parameter configuration module establishes databases for transient performance of mud pumps, soil rheological properties, and pipeline topology. This enables rapid matching of geometric parameters (blade wrap angle, hub ratio, etc.) for different mud pump models and automatic generation of 3D mesh models of the flow channel. It also supports intelligent selection of multiphase rheological models such as Bingham fluid and power-law fluid. This design significantly simplifies the parameter input process, improves the system's adaptability to diverse construction scenarios, and allows engineers to quickly build simulation models that match actual working conditions by customizing soil properties and pipeline topology parameters. This significantly shortens the initial modeling time and improves work efficiency.

[0046] Based on dynamic simulation results, the safety assessment module extracts parameters such as the peak equivalent stress at key impeller locations and the critical pressure for mud cavitation to construct a three-dimensional safety boundary surface of speed-head-power. This clearly marks the critical failure region and generates a set of permissible operating condition configurations and risk level labels. This function provides systematic safety guidance for mud pump operation, allowing engineers to rationally select operating conditions based on risk levels, avoid entering high-risk areas, effectively reduce the probability of equipment failure, and improve construction safety. Simultaneously, through the application of bivariate failure criteria and rainflow counting, a quantitative assessment of the combined damage from dynamic stress and pressure pulsation is achieved, providing a scientific basis for preventative maintenance of mud pumps.

[0047] The system integrates operating condition configuration, simulation progress monitoring, and result comparison functions through the main control interface. It supports flexible adjustment of parameters such as pump speed, mud concentration, and pipeline topology, and automatically generates dynamic performance comparison matrices (including efficiency-power curves, pulsation amplitude-frequency spectra, etc.) under different configuration combinations. The parameter visualization interface synchronously displays flow field velocity cloud maps, pressure contour lines, and structural stress distribution in a 3D dynamic rendering format, making complex simulation results intuitive and easy to understand. The report generation interface can quickly output optimized configuration schemes, and combined with multi-objective optimization algorithms to screen Pareto optimal solution sets, it provides engineers with optimal operating condition recommendations that balance output, energy consumption, and equipment wear, significantly improving the overall efficiency of mud pump operation.

[0048] The method and system of this invention realize the full-process digitalization from model construction to simulation analysis, safety assessment, and optimized configuration, breaking away from the high-cost and long-cycle mode of traditional reliance on physical testing. By replacing some physical testing with simulation calculations, R&D and operation and maintenance costs can be significantly reduced. At the same time, by covering various extreme working conditions through virtual testing, potential risks can be identified in advance, providing strong technical support for the design iteration, construction scheme optimization, and intelligent operation and maintenance of high-pressure mud pumps, and promoting the development of mud pump simulation technology towards high efficiency, precision, and intelligence. Attached Figure Description

[0049] Figure 1 is a schematic diagram illustrating the working principle of the construction and application method of the high-pressure and high-efficiency mud pump simulation calculation model described in this invention.

[0050] Figure 2 is a schematic diagram of the working principle of the parameter configuration module;

[0051] Figure 3 is a flowchart of the fluid-structure interaction calculation.

[0052] Figure 4 is a schematic diagram of the working principle of the safety assessment module;

[0053] Figure 5 is a flowchart of the critical failure threshold calculation. Detailed Implementation

[0054] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] Please refer to Figures 1-5. The present invention relates to a method for constructing and applying a simulation calculation model of a high-pressure, high-efficiency mud pump. The specific implementation steps are as follows:

[0056] A simulation model of a high-pressure mud pump is established based on the dynamic fluid-structure interaction parameters of the mud pump, the multiphase rheological parameters of the soil, and the transient resistance parameters of the pipeline. The dynamic fluid-structure interaction parameters include mud pulsating pressure and impeller dynamic stress; the multiphase rheological parameters of the soil include particle content and viscous drag coefficient; and the transient resistance parameters of the pipeline include transient pressure drop gradient and local resistance abrupt change coefficient. By integrating these parameters, a basic model framework that reflects the actual working environment of the mud pump is constructed, providing data support for subsequent simulation calculations.

[0057] The simulation model incorporates dynamic matching of pump speed and power, slurry flow stratification effect, and transient cavitation risk factors in pipelines. It also calculates the pump operating envelope and critical failure threshold under different construction scenarios. By integrating key factors that may affect pump performance and safety in actual operation into the model, the model more closely reflects real-world conditions. The calculated operating envelope and critical failure threshold provide crucial reference indicators for the safe and stable operation of the pump.

[0058] A multiphysics coupling analysis system for high-pressure mud pumps was developed based on a simulation calculation model. This system includes a parameter configuration module, a dynamic simulation module, and a safety assessment module. The dynamic simulation module integrates a transient flow field solver and a structural vibration solver. By developing a dedicated analysis system, the model is transformed into a practically usable tool, enabling comprehensive analysis of the multiphysics coupling problem of mud pumps.

[0059] The system's parameter configuration module inputs measured transient performance data of the mud pump, custom soil rheological properties, and pipeline topology parameters. The measured transient performance data includes pulsating power spectral density and dynamic head fluctuation amplitude. This ensures the system can perform accurate calculations based on actual working conditions and environmental parameters, improving the accuracy and reliability of simulation results.

[0060] The system's dynamic simulation module performs fluid-structure interaction (FSI) calculations to obtain the dynamic velocity distribution, pressure pulsation propagation characteristics, and structural fatigue damage index of the mud pump at different speeds, generating an optimized configuration scheme for high-pressure conditions. Through FSI calculations, the physical characteristics of the mud pump under different operating conditions are analyzed in depth, providing a scientific basis for optimizing the pump's operating conditions.

[0061] The present invention will be further described below with reference to Embodiment 1:

[0062] Example 1:

[0063] Regarding dynamic fluid-structure interaction parameters, in addition to the aforementioned pulsating pressure of the slurry and dynamic stress of the impeller, the leakage vortex intensity coefficient of the impeller gap and the thixotropic index of the non-Newtonian fluid slurry also need to be included. The leakage vortex intensity coefficient of the impeller gap is a key parameter characterizing the fluid leakage characteristics at the gap between the impeller and the pump casing. Its value is related to factors such as the outer diameter of the impeller, the inner diameter of the pump casing, the impeller speed, and the viscosity of the slurry. In actual simulation calculation model construction, this coefficient needs to be obtained through fluid dynamics theory analysis or experimental measurement. For example, based on the Reynolds time-averaged equation (RANS) combined with a turbulence model, numerical simulation of the gap flow field can be performed to extract data such as the velocity vector and pressure distribution of the leakage vortex, and then calculate the leakage vortex intensity coefficient. This coefficient is used to describe the generation, development, and interference degree of leakage vortices in the gap with the mainstream field. It can more accurately reflect the flow loss and energy dissipation at the impeller gap, thus affecting the overall head and efficiency calculation of the slurry pump.

[0064] The thixotropic index of mud, a non-Newtonian fluid, is an important parameter for measuring its thixotropic properties. The thixotropic nature of mud is characterized by a decrease in viscosity with increasing shear time, followed by a gradual recovery of viscosity once the shearing action ceases. For mud containing colloidal substances such as clay particles, its thixotropic properties are significant. Determining the thixotropic index requires rheological experiments, such as using a rotational viscometer to measure the shear stress of the mud at different shear rates and times, plotting shear stress-time curves, and obtaining the thixotropic index through curve fitting. Incorporating this parameter into the model allows for accurate characterization of viscosity changes in mud during mixing and transportation due to varying shear histories, thereby affecting the velocity distribution and pressure loss calculations within the flow channel.

[0065] When developing the parameter configuration module of the high-pressure mud pump multiphysics coupling analysis system, it is necessary to establish a mud pump transient performance database, a soil rheological property database, and a pipeline topology database. The construction of the mud pump transient performance database requires collecting measured data from different mud pump models at various speeds, including pressure pulsation time-domain signals and frequency-domain energy distribution. Pressure pulsation time-domain signals can be acquired by high-frequency pressure sensors installed on the inlet and outlet pipes of the mud pump. The sampling frequency must satisfy the Nyquist sampling theorem to ensure signal integrity. The frequency-domain energy distribution is obtained by performing a Fast Fourier Transform (FFT) on the time-domain signal, reflecting the proportion of pressure pulsation energy at different frequency components. This database provides rich measured dynamic data for the model, which can be used to verify the accuracy of simulation calculation results. Furthermore, in practical applications, it allows for rapid retrieval of relevant performance data based on the mud pump model, improving simulation efficiency.

[0066] The soil rheological properties database stores multiphase rheological parameters under different soil conditions, including particle content, viscous resistance coefficient, and thixotropic index. Particle content is determined through sieving and weighing analysis of soil samples, while the viscous resistance coefficient is calculated based on Darcy's formula using flow tests of slurry in circular pipes. The database is categorized by soil type (e.g., clay, silt, sand) for easy retrieval of relevant parameters based on actual site conditions. The pipeline topology database records topological parameters for different pipeline layouts, such as pipeline length, diameter, number and radius of curvature of bends, and valve type. These parameters are obtained from pipeline design drawings or on-site measurements and are used to construct geometric models of the pipeline system, simulating the impact of different topologies on slurry flow.

[0067] When simulation calculations are required, the corresponding impeller geometry parameter set is matched from the database based on the mud pump model. This geometry parameter set includes the blade wrap angle, hub ratio, and outlet placement angle. The blade wrap angle is the angle between the inlet and outlet edges of the blades along the impeller circumference. Its magnitude directly affects the blade's driving effect on the mud and the energy transfer efficiency. A larger blade wrap angle increases the mud's contact time within the impeller, increasing the head, but may lead to increased flow resistance; a smaller blade wrap angle has the opposite effect. The hub ratio is the ratio of the impeller hub diameter to the impeller outer diameter, affecting the impeller's strength and the fluid flow state within the impeller. A larger hub ratio results in higher impeller strength, but reduces the flow channel cross-sectional area, potentially increasing the risk of flow blockage. The outlet placement angle is the angle between the blade outlet edge and the impeller circumference tangent, determining the absolute velocity direction and magnitude of the mud at the impeller outlet, affecting the mud pump's flow rate and power characteristics.

[0068] Based on the matched impeller geometry parameter set, a 3D mesh model of the mud pump flow channel is generated using professional 3D modeling software (such as ANSYS DesignModeler, SolidWorks, etc.). During the modeling process, the geometry of components such as the impeller, pump casing, suction chamber, and discharge chamber must be accurately described to ensure that the flow channel model is consistent with the actual mud pump structure. For complex structures such as the impeller, a modular modeling method can be used, modeling the impeller blades, hub, and rim separately before assembling them to improve modeling accuracy and efficiency.

[0069] After generating the 3D geometric model, it needs to be meshed. The mesh quality directly affects the accuracy and computational efficiency of the flow field solution. For areas with complex flow within the slurry pump channel (such as near the impeller blades or in the gaps), a finer tetrahedral or hexahedral mesh is used to capture subtle changes in the flow field. For areas with relatively stable flow (such as the suction and discharge chambers), a coarser mesh can be used to reduce computational load. After meshing, a mesh quality check is required to ensure that the mesh distortion rate, aspect ratio, and other parameters meet the solver's requirements.

[0070] The generated 3D mesh model of the mud pump channel is loaded into the flow field solver of the dynamic simulation module. The flow field solver, based on computational fluid dynamics (CFD) theory, uses the finite volume method (FVM) to discretize and solve the governing equations. The governing equations include the continuity equation, momentum equation, and energy equation. For non-Newtonian fluids, appropriate constitutive equations must be selected based on the rheological properties of the mud, such as the Bingham fluid model, power-law fluid model, or thixotropic fluid model (detailed in subsequent embodiments). During the calculation, boundary conditions are set, such as setting the inlet boundary as a velocity inlet or mass flow inlet, the outlet boundary as a pressure outlet or free outflow, and the wall boundaries using no-slip boundary conditions. Wall functions are also set as needed to handle near-wall flow.

[0071] In solving the flow field, the multiphase flow characteristics of the mud are considered. The mud is regarded as a mixture composed of a continuous phase (liquid phase) and a discrete phase (solid particles), and the Euler-Euler multiphase flow model or the Euler-Lagrange discrete phase model (DPM) is used for simulation. For mud with a high particle content, the Euler-Euler model is more suitable, as it can solve the momentum equations and continuity equations for each phase. For mud with a low particle content, the Euler-Lagrange model can track the trajectory of individual particles and more accurately describe the interaction between particles and fluid.

[0072] Simultaneously, by incorporating the impeller clearance leakage vortex intensity coefficient, the leakage flow at the impeller clearance is specifically treated in the flow field solver. Sliding mesh technology or a mixing plane model can be used to simulate the relative motion between the impeller and the pump casing, refining the mesh in the clearance region to capture the generation and evolution of leakage vortices. By calculating the leakage flow rate, leakage velocity distribution, and the degree of interference of leakage vortices on the main flow field at the clearance, the overall performance parameters of the mud pump can be corrected.

[0073] Furthermore, the thixotropic index of the non-Newtonian fluid slurry participates in the calculation by influencing the viscosity term in the flow field governing equations. In the thixotropic fluid model, viscosity is not only a function of the shear rate but also of the shear time, necessitating the introduction of a time-dependent viscosity correction term into the governing equations. Through iterative calculations, the viscosity value is gradually updated to reflect the thixotropic characteristics of the slurry due to changes in shear time during flow, making the flow field calculation results closer to actual working conditions.

[0074] After setting up the flow field solver and performing preliminary calculations, the calculation results need to be verified and debugged. By comparing the calculated values ​​with the measured data in the mud pump transient performance database, check the deviations between the calculated and measured values ​​of parameters such as pressure pulsation amplitude, frequency, head, and efficiency. If the deviation exceeds the allowable range, adjust parameters such as mesh generation, turbulence model, and boundary conditions until the calculation results match the measured data well, ensuring the accuracy of the flow field calculation.

[0075] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0076] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art 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 appended claims and their equivalents.

Claims

1. A method for constructing and applying a simulation calculation model of a high-pressure, high-efficiency mud pump, characterized in that, include: A simulation model of a high-pressure mud pump is established based on the dynamic fluid-structure interaction parameters of the mud pump, the multiphase rheological parameters of the soil, and the transient resistance parameters of the pipeline. The dynamic fluid-structure interaction parameters include mud pulsating pressure and impeller dynamic stress. The multiphase rheological parameters of the soil include particle phase content and viscous resistance coefficient. The transient resistance parameters of the pipeline include transient pressure drop gradient and local resistance abrupt change coefficient. The simulation calculation model incorporates dynamic matching of pump speed and power, slurry flow stratification effect and pipeline transient cavitation risk factors, and calculates the pump operation envelope and critical failure threshold under different construction scenarios through the model. Based on the simulation calculation model, a multiphysics coupling analysis system for high-pressure mud pumps was developed. The system includes a parameter configuration module, a dynamic simulation module, and a safety assessment module. The dynamic simulation module integrates a transient flow field solver and a structural vibration solver. The measured transient performance data of the mud pump, the custom soil rheological properties, and the pipeline topology parameters are input through the parameter configuration module of the system. The measured transient performance data includes the pulsating power spectral density and the dynamic head fluctuation amplitude. Based on the dynamic simulation module of the system, a two-way fluid-structure interaction calculation is performed to obtain the dynamic velocity distribution, pressure pulsation propagation characteristics and structural fatigue damage index of the mud pump at different speeds, and to generate an optimized configuration scheme for high-pressure working conditions.

2. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 1, characterized in that, The dynamic fluid-structure interaction parameters also include the impeller clearance leakage vortex intensity coefficient and the thixotropic index of the non-Newtonian fluid in mud.

3. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 2, characterized in that, The parameter configuration module of the high-pressure mud pump multiphysics coupling analysis system includes: Establish a mud pump transient performance database, a soil rheological property database, and a pipeline topology database, wherein the transient performance database stores the time-domain signal and frequency-domain energy distribution of pressure pulsation at different rotational speeds; According to the mud pump model, the corresponding impeller geometry parameter set is matched from the database. The geometry parameter set includes blade wrap angle, hub ratio, and outlet installation angle. A three-dimensional mesh model of the mud pump channel is generated based on the geometric parameter set and loaded into the flow field solver of the dynamic simulation module.

4. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 1, characterized in that, The dynamic simulation module performs fluid-structure interaction calculations, including: The pulsating pressure field output by the flow field solver is mapped to the impeller surface mesh nodes of the structural vibration solver. The dynamic stress distribution and modal participation factor of the impeller are calculated by the structural vibration solver, and the deformation displacement field is fed back to the flow field solver to update the calculation domain. The calculation is iterated until the residual between the pressure pulsation amplitude and the structural vibration acceleration converges to the preset threshold.

5. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 1, characterized in that, The security assessment module includes: The peak equivalent stress and critical pressure for mud cavitation initiation at key locations of the impeller are extracted based on the dynamic simulation results. Calculate the three-dimensional safety boundary surface of speed-head-power in the operating envelope of the mud pump, and mark the critical failure region; Based on the safety boundary surface, generate a set of permissible operating condition configurations and corresponding risk level labels.

6. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 5, characterized in that, The parameter configuration module also includes: A mud multiphase rheological model selector is set up, which includes Bingham fluid model, power-law fluid model and thixotropic fluid model; The corresponding rheological model is automatically matched based on the soil gradation parameters and loaded into the flow field control equation of the dynamic simulation module.

7. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 1, characterized in that, The high-pressure mud pump multiphysics coupling analysis system also includes: Design a main control interface, a parameter visualization interface, and a report generation interface. The main control interface integrates working condition configuration, simulation progress monitoring, and result comparison functions. The parameter visualization interface synchronously displays the three-dimensional dynamic rendering results of the flow field velocity cloud map, pressure contour lines, and structural stress distribution.

8. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 7, characterized in that, The operating condition configuration function includes: Set the mud pump speed adjustment range, mud concentration gradient, and pipeline topology change sequence; Based on the simulation calculation model, a dynamic performance comparison matrix under different configuration combinations is automatically generated. The matrix includes efficiency-power curves, pulsation amplitude-frequency spectrum, and fatigue life prediction values.

9. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 1, characterized in that, The calculation of the critical failure threshold includes: Establish a bivariate failure criterion for the impeller material SN curve and mud cavitation damage accumulation model; The combined damage contribution factor of dynamic stress spectrum and pressure pulsation spectrum was extracted by rainflow counting method; When the combined damage contribution factor exceeds the preset safety factor, the current working condition is marked as a high-risk state.

10. The method for constructing and applying the high-pressure, high-efficiency mud pump simulation calculation model according to claim 1, characterized in that, The generation of the high-voltage operating condition optimization configuration scheme includes: Based on the set of permissible operating conditions output by the safety assessment module, calculate the output-energy consumption ratio and equipment loss rate under each operating condition; A multi-objective optimization algorithm is used to select the Pareto optimal solution set that satisfies the constraints, and a recommendation priority list is generated according to preset weights.

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