Design Calculations And Manufacturing Process Research Of4000Hp Fracturing Pump Head

Pump head is the core components of the fracturing fluid pump end, and works under very high pressure. In the design of the pump head, not only the mechanical performance requirements must be met, but also the safety and reliability of the pump head must be met during operation. So for pump head to improve the design and finite element analysis, research, and manufacturing processes, to improve the reliability and rationality of product design is of great significance.In this paper, the motion theory of the fracturing pump fluid end is analyzed aiming at how to extend the service life of the new-type pump head. According to relevant requirements, the model of the fracturing fluid pump end and the type of the fluid end have been selected and determined; a three-dimensional model of the pump head have been established and a finite element analysis have been done based on ABAQUS; the design model have been improved according to the stress concentration and fatigue deformation; analysis of the corresponding research have been done to the manufacturing process of the pump head as well.(1) The law of motion^the pulsating flow and the pressure fluctuation caused by the pulsating flow have been analyzed and it provides a theoretical basis for the design and improvement of the pump head of the fracturing fluid pump end. According to the conditions, the material of pump head was determined.(2) According to the use and needs in field of the new-type fracturing fluid pump end, the type of the pump has been selected as horizontal five cylinder single acting piston pump, the type of the fluid end has been selected as four direct hydraulic end. Thus, the diameter of the plunger has been determined and the design of the size of the pump head is based on this and the check of strength has been done. An entity model of the pump head has been established by the three-dimensional software Solidworks.(3) According to the three-dimensional model of the pump end, fem simulative analysis has been done based on ABAQUS to find out which point is the most serious of stress concentration and which areas are the worst of fatigue deformation; the improvement measures have been put forward, after which a fem simulative analysis was been done again. After all these, the stress concentration and fatigue deformation were greatly improved and the effectiveness of the improvement measures is verified.(4) The research on the manufacturing of the pump head has been studied. The quenching and tempering treatment has been done to the blank and the machining of the hole has been analyzed; the manufacturing of the hole on the pump head also has been determined; the strengthening treatment to the pump head can extend the service life effectively was proposed and the roll extrusion and self enhancement has been analyzed and calculated.(5) The hydrostatic pressure test has been done to verify the improved design and the strength of the pump head and the matching condition of the size.