Numerical simulation and visualization of fiber suspension in a turbulent round jet

The turbulent properties of the fiber suspension in a turbulent round jet are numerically simulated and visualized, and some of the results are compared with the experimental data. The effects of the Reynolds number, fiber volume fraction, and aspect ratio are analyzed. The results show that the fiber injection in the flow has a delay effect on the streamwise velocity decay along the jet axis, and such an effect becomes more obvious with the increases in the fiber volume fraction and aspect ratio and the decrease in the Reynolds number. The flow with fibers shows an increase in the streamwise velocity along the radial direction, and the increase magnitude is directly proportional to the fiber volume fraction and aspect ratio and inversely proportional to the Reynolds number. The presence of fibers makes the turbulent kinetic energy and Reynolds stress increase, and the extent increases with the fiber volume fraction, Reynolds number, and fiber aspect ratio.     

An experimental study of flow-induced fiber orientation and concentration distributions in a concentrated suspension flow through a slit channel containing a cylinder

Flow-induced fiber orientation and concentration distributions were measured in a concentrated fiber suspension (CFS) and a dilute one (DFS). The channel has a thin slit geometry containing a circular cylinder. In the previous work, many researchers have qualitatively studied fiber orientation and concentration distributions in injection-molded products of fiber-reinforced plastics. In the present work, however, they are quantitatively estimated by direct observation of fibers in the concentrated suspension flow. For the CFS, some fibers rotate in an expansion part between the channel wall and the circular cylinder, and the fiber orientation becomes almost random state. On the other hand, fibers are perfectly aligned along the flow direction owing to the elongational flow near the centerline downstream of the cylinder. The fiber concentration has a flat distribution except near the channel wall and the centerline. For the DFS a minimum in the fiber concentration distribution was clearly observed on the centerline, and two peaks beside the centerline and near the channel wall. This characteristic distribution is caused by the fiber-wall and fiber-cylinder interactions. It is found that the obstacle such as the circular cylinder in the channel significantly affects the fiber orientation downstream of the obstacle for the CFD, while it affects the fiber concentration distribution for the DFS.     

Numerical simulation of flow kinematics for suspensions containing continuously dispersed aspect ratio fibers

Fiber suspension flow and fiber orientation through a parallel-plate channel were numerically simulated for fiber suspensions including continuously dispersed aspect ratios from 10 to 50. In the simulations, both the fiber–fiber and fiber–wall interactions were not taken into account. A statistical scheme that proceeds by evaluating the orientation evolution of a large number of fibers from the solution of the Jeffery equation along the streamlines was confirmed to be a very useful and feasible method to accurately analyze the orientation distribution of fibers with continuously dispersed aspect ratios. For monodisperse suspensions with small-aspect-ratio fibers, flip-over or oscillation phenomenon of the orientation ellipsoid caused the wavy patterns of the velocity profile and the streamlines as well as the abrupt and complex variation of the shear stress and the normal stress difference near the channel wall as proven in one of our former works. On the other hand, continuous dispersions containing from small- to large-aspect-ratio fibers were able to induce smoother evolutions of the fiber orientation and the flow kinematics. In the processing of fiber composites, the length of suspended fibers is always continuously distributed because of fiber breakage during processing; thus, the smooth evolutions of the flow kinematics and the stress distribution can be attained.This paper was presented at the Annual Meeting of the European Society of Rheology, Grenoble, April 2005.     

Investigation of fiber motion near solid boundaries in simple shear flow

In this paper, fiber motion near a planar wall was investigated using a planar shear flow apparatus. Fibers were placed (one at a time) perpendicular to the flow direction at various locations throughout the flow field. The location and orientation of each fiber versus time was measured, using an image processing system, until the fiber aligned with the flow direction. When the centroid of the fiber was located at distances greater than a fiber length from the wall, Jeffery's equations governing particle motion were verified. For distances less than a fiber length and greater than a fiber diameter from the wall, the fiber experienced an increased rate of rotation. In this regime, the motion of the fiber could be described by Jeffery's equations if an increased effective shear rate was used. The effective shear rate was found to increase logarithmically with decreasing separation distance. The wall effect was higher for longer aspect ratio fibers and was also a function of orientation; fibers oriented perpendicular to the wall rotated faster than those oriented parallel to the wall at the same separation distance. Once the fiber aligned with the flow direction, it ceased to rotate within the field of view. In this orientation, the wall had a stabilizing effect on the fiber. In efforts to relate the increase in shear rate to the aspect ratio of the fiber and the separation distance between the fiber and a solid wall, a translation model based on the work of De Mestre and Russel was explored. This model allows one to quantify the increase in shear rate experienced by the fiber due to the presence of a wall or obstruction in the flow field. However, the model has its limitations and care should be taken when applying this model outside its realm of validity. When compared to experimental data, the translation model provides a very good estimate of the increased shear rate experienced by the fiber when it is located less than 2/3 of a fiber length from a planar wall. Received: 20 April 2000 Accepted: 28 September 2000     

Numerical simulation of flow kinematics and fiber orientation for multi-disperse suspension

The development of flow kinematics and fiber orientation distribution from the parabolic velocity profile and isotropic orientation at the channel inlet was computed in multi-disperse suspension flow through a parallel plate channel and their predictions were compared with those of mono- and bi-disperse suspensions. A statistical scheme (orientations of a large number of fibers are evaluated from the solution of the Jeffery equation along the streamlines) was confirmed to be very useful and feasible method to analyze accurately the orientation distribution of fibers in multi-disperse fiber suspension flow as well as mono- and bi-dispersions, instead of direct solutions of the orientation distribution function of fibers or the evolution equation of the orientation tensor which involves a closure equation. It was found that the flow kinematics and the fiber orientation depend completely on both the fiber aspect-ratio and the fiber parameter for multi-disperse suspension when the fiber–fiber and fiber-wall interactions are neglected. Furthermore, the addition of large aspect-ratio fibers as well as an increase in the fiber parameter related to the large aspect-ratio fibers could suppress the complex velocity field and stress distributions which are observed in suspensions containing small aspect-ratio fibers. From a practical point of view, therefore, the mechanical and physical properties of fiber composites should be improved with an increase in the volume fraction of large aspect-ratio fibers.     

Orientation behaviour of fibers in suspension flow through a branching channel

Fiber orientation and dispersion in the fiber suspension that flows through a T-shaped branching channel have been experimentally studied. The fiber dispersion is not uniform in a channel flow. In particular, in the suspension containing long fibers, there are no fibers near a wall at a low Reynolds number. However, the content ratio of fibers near the wall increases with an increasing Reynolds number. Fiber orientation angles of short fibers are widely distributed. Furthermore, a variance of orientation angle in the middle region of the channel has a minimum value at a Reynolds number from 10 to 20, and a size of secondary vortex in the branching corner also has a minimum value at a similar Reynolds number.     

Orientation distribution of fibers and rheological property in fiber suspensions flowing in a turbulent boundary layer

A model relating the translational and rotational transport of orientation distribution function （ODF） of fibers to the gradient of mean ODF and the dispersion coefficients is proposed to derive the mean equation for the ODE Then the ODF of fibers is predicted by numerically solving the mean equation for the ODF together with the equations of turbulent boundary layer flow. Finally the shear stress and first normal stress difference of fiber suspensions are obtained. The results, some of which agree with the available relevant experimental data, show that the most fibers tend to orient to the flow direction. The fiber aspect ratio and Reynolds number have significant and negligible effects on the orientation dis- tribution of fibers, respectively. The additional normal stress due to the presence of fibers is anisotropic. The shear stress of fiber suspension is larger than that of Newtonian solvent, and the first normal stress difference is much less than the shear stress. Both the additional shear stress and the first normal stress difference increase with increasing the fiber concentration and decreasing fiber aspect ratio.     

Analysis of rheological properties of fiber suspensions in a Newtonian fluid by direct fiber simulation. Part 3: Behavior in uniaxial extensional flows

The present work presents a predictive direct fiber simulation of fiber suspensions under uniaxial extensional flows by Stokesian dynamics, considering both near- and farfield hydrodynamic intrafiber interactions and lubrication approximation for interfibers. Initially, code validation is performed and simulation predictions compared with experimental data. Afterwards, the orientation tensor under flow is discussed as a function of volume fraction, aspect ratio and flexibility. Based on the results, a general constitutive equation with a proposed parameter is proposed and verified by comparing experimental data of high volume fraction and high aspect ratio systems.     

On the non-linear instability of fiber suspensions in a Poiseuille flow

The non-linear instability characteristics of fiber suspensions in a plane Poiseuille flow are investigated. The evolution equation of the perturbation amplitude analogous to Landau equation is formulated and solved numerically for different fiber parameters. It is found that the equilibrium amplitude decreases with the increase of the fiber aspect ratio and volume fraction, i.e. the addition of the fibers reduces the amplitude of the perturbation, and leads to the reduction of the flow instability. This phenomenon becomes significant for large volume concentration and aspect ratio. The mechanism of the reduction of the flow instability is also analyzed by taking into account of the modification of the mean flow and the energy transfer from the mean flow to the perturbation flow.     

The stress-microstructure relationship in an evolving mixing layer of fiber suspensions

The equations for fiber suspensions in an evolving mixing layer were solved by the spectral method, and the trajectory and orientation of fibers were calculated based on the slender body theory. The calculated spatial and orientation distributions of fibers are consistent with the experimental ones that were performed in this paper. The relationship between the microstructure of fibers and additional stress was examined. The results show that the spatial and orientation distributions of fibers are heterogeneous because of the influence of coherent vortices in the flow, which leads to the heterogeneity of the additional stress. The degree of heterogeneity increases with the increasing of St number and fiber aspect ratio. The fibers in the flow make the momentum loss thickness of the mixing layer thicker and accelerate the vorticity dispersion.The project supported by the Doctoral Program of Higher Education in China (20030335001)     

Fiber suspension flow in a tapered channel: The effect of flow/fiber coupling

A numerical model for predicting the flow and orientation state of semi-dilute, rigid fiber suspensions in a tapered channel is presented. The effect of the two-way flow/fiber coupling is investigated for low Reynolds number flow using the constitutive model of Shaqfeh and Fredrickson. An orientation distribution function is used to describe the local orientation state of the suspension and evolves according to a Fokker–Plank type equation. The planar orientation distribution function is determined along streamlines of the flow and is coupled with the fluid momentum equations through a fourth-order orientation tensor. The coupling term accounts for the two-way interaction and momentum exchange between the fluid and fiber phases. The fibers are free to interact through long range hydrodynamic fiber–fiber interactions which are modeled using a rotary diffusion coefficient, an approach outlined by Folgar and Tucker. Numerical predictions are made for two different orientation states at the inlet to the contraction, namely a fully random and a partially aligned fiber orientation state. Results from these numerical predictions show that the streamlines of the flow are altered and that velocity profiles change from Jeffery–Hamel, to something resembling a plug flow when the fiber phase is considered in the fluid momentum equations. This phenomenon was found when the suspension enters the channel in either a pre-aligned, or in a fully random orientation state. When the suspension enters the channel in an aligned orientation state, fiber orientation is shown to be only marginally changed when the two-way coupling is included. However, significant differences between coupled and uncoupled predictions of fiber orientation were found when the suspension enters the channel in a random orientation state. In this case, the suspension was shown to align much more quickly when the mutual coupling was accounted for and profiles of the orientation anisotropy were considerably different both qualitatively and quantitatively.     

Investigation of the abrupt contraction flow of fiber suspensions in polymeric fluids

Numerical simulations of the flow of rigid fibres through a 4:1 planar contraction, and the predicted flow pattern and fiber orientation are presented. Entirely new is the examination of the nature of the suspending matrix which may consist of either a Newtonian fluid or a polymer melt. In the case of a polymer matrix three rheological models, the Phan-Thien–Tanner, FENE-CR, and Carreau models have been used to investigate the effects of shear-thinning and elasticity on the flow and the orientation of the fibers. The effects of inertia are neglected, and the governing equations for the flow field, polymer stress, and fiber orientation are coupled and simultaneously solved. A parametric study is used to explore the effects of different dimensionless parameters on the velocity field, the fiber orientation, the pressure drop, as well as the vortex size measured by the dimensionless reattachment length. We particularly focus on the role of the fibers aspect ratio, volume fraction, and interaction coefficient which measures the intensity of fiber interaction in the suspension. Furthermore, we evaluate and compare the results of four different closure approximations: the quadratic, linear, hybrid A and T, and natural closures.     

EFFECTS OF TENSOR CLOSURE MODELS AND 3-D ORIENTATION ON THE STABILITY OF FIBER SUSPENSIONS IN A CHANNEL FLOW

IntroductionFlowoffibresuspensionshasbeenveryfamiliarinmanyindustrialfields.Fibreadditivesplayanimportantroleindragreductioninmanytypesofflow[1- 3].Inthesuspensions,somebehavioroftheflowmaybealteredbythefibres.Oneoftheimportantexamplesisthehydrodynamicsta…     

Simulation of fiber reinforced composite materials mold filling process and mechanical properties analysis

A dynamic simulation of fiber reinforced composite materials mold filling process with double inlets is presented based on the gas–solid–liquid model proposed by Yang et al. [B.X. Yang, J. Ouyang, J. Tao, C.T. Liu, Modeling and simulation of fiber reinforced polymer mold filling process by level set method, CMES – Computer Modeling in Engineering and Sciences 63 (3) (2010) 191–222]. Numerical results show that the fibers far away from the melt interface are in skin-core-skin structure, while those near the interface are almost parallel to the arc of the interface. When the two streams of melts meet, the weld line will be formed, where the orientation of fibers is perpendicular to the flow direction. The orientation of fibers of the numerical result shows well agreement with the experimental results. Finally, the mechanical properties of fiber reinforced composite materials are analyzed. The composite materials with skin-core-skin structure are regarded as laminated orthogonal plywood and the elastic modulus, the shear modulus and Poisson’s ratio are predicted under different slenderness ratios and fiber volume fractions.     

On the orientation of ellipsoidal particles in a turbulent shear flow

Direct numerical simulation (DNS) of small prolate ellipsoidal particles suspended in a turbulent channel flow is reported. The coupling between the fluid and the particles is one-way. The particles are subjected to the hydrodynamic drag force and torque valid for creeping flow conditions. Six different particle cases with varying particle aspect ratios and equivalent response times are investigated. Results show that, in the near-wall region, ellipsoidal particles tend to align with the mean flow direction, and the alignment increases with increasing particle aspect ratio. When the particle inertia increases, the particles are less oriented in the spanwise direction and more oriented in the wall-normal direction. In the core region of the channel, the orientation becomes isotropic.     

A study on validity of using average fiber aspect ratio for mechanical properties of aligned short fiber composites with different fiber aspect ratios

A closed-form solution using the actual distribution of the fiber aspect ratio is proposed for predicting the stiffness of aligned short fiber composite. The present model is the simplified form of Takao and Taya’s model and the extended version of Taya and Chou’s model, where Eshelby’s equivalent inclusion method modified for finite fiber volume fraction is employed. The validity of using average fiber aspect ratio for predicting the composite stiffness is justified in terms of the scatter of fiber aspect ratio, fiber volume fraction, and constituents‘ Young’s modulus ratio, comparing with the results by the present model. The guideline for selection of either the actual distribution or the average fiber aspect ratio is presented for the better prediction of the composite stiffness.     

Effect of modulus ratio on stress near a discontinuous fiber

The effect of the fiber to matrix modulus of elasticity ratio varying from 1.0 to 200 was investigated for a two-dimensional plane-stress composite configuration having a simulated fiber volume fraction of 0.45 and containing a discontinuous fiber. Uniaxial loading parallel to the fibers was considered. Two independent techniques were used: moiré strain analysis and finite-element analysis. Displacements were measured from four experimental models by utilizing optical fringe-multiplication techniques. The finite-element method yielded stresses which agreed closely with those obtained from the experimental analysis. Matrix stress-concentration factor near the discontinuous fiber was found to increase rapidly with increasing modulus ratio, reaching a value of 20 for a modulus ratio of 200. The finite-element method was shown to be a valuable tool for micromechanical stress analysis of composite materials, and the accuracy of strain analysis by moiré-fringemultiplication techniques was demonstrated for problems containing sever strain gradients.     

Bulk flow parameters in turbulent wall boundary layers near separation

Experiments were conducted in a turbulent boundary layer near separation along a flat plate. The pressure gradient in flow direction was varied such that three significant boundary layer configurations could be maintained. The flow in the test section thus had simultaneously a region of favourable pressure gradient, a region of strong adverse pressure gradient with boundary layer separation and a region of reattached boundary layer. Specially designed fine probes facilitated the measurements of skin friction and velocity distribution very close to the wall. Bulk flow parameters such as skin friction coefficient C _f, Reynold's number Re_δ2 and shape factors H and G, which are significant characteristics of wall boundary layers were evaluated. The dependence of these parameters on the Reynolds number and along the test section was explored and the values were compared with other empirical and analytical formulae known in the literature.     

Measurement of velocity profiles in a rectangular microchannel with aspect ratio <Emphasis Type="Italic">α</Emphasis> = 0.35

In this work, we measured 14 horizontal velocity profiles along the vertical direction of a rectangular microchannel with aspect ratio α = h/w = 0.35 (h is the height of the channel and w is the width of the channel) using microPIV at Re = 1.8 and 3.6. The experimental velocity profiles are compared with the full 3D theoretical solution, and also with a Poiseuille parabolic profile. It is shown that the experimental velocity profiles in the horizontal and vertical planes are in agreement with the theoretical profiles, except for the planes close to the wall. The discrepancies between the experimental data and 3D theoretical results in the center vertical plane are less than 3.6%. But the deviations between experimental data and Poiseuille’s results approaches 5%. It indicates that 2D Poiseuille profile is no longer a perfect theoretical approximation since α = 0.35. The experiments also reveal that, very near the hydrophilic wall (z = 0.5–1 μm), the measured velocities are significantly larger than the theoretical velocity based on the no-slip assumption. A proper discussion on some physical effects influencing the near wall velocity measurement is given.     

Experimental and theoretical study of short fiber orientation in diverging flows

Two types of experiments have been carried out to study the fiber orientation in flow through a divergent channel. First, a reinforced polyamid mold sprue containing two types of orientation was investigated: near the center, the fibers are mostly oriented perpendicular to the flow lines, whereas on the periphery, they are oriented parallel to them. Second, direct observation of copper fibers moving in a corn syrup was performed in a transparent diverging device: the fibers rapidly become oriented transverse to the flow lines. The solution of Stokes equations for the undisturbed fluid motion gives the shear rate and elongation rate, which are then substituted in Jeffery's orientation equations. The resolution shows two types of behavior: in a large area in the center, the fiber tends to a stable equilibrium position which depends strongly on the flow line on which it moves. On the periphery, the fiber follows a shear-like behavior. The strong influence of the elongational component relative to the shear component is demonstrated and the time necessary for orientation is calculated. The theoretical results are found to be in agreement with the observations.