Numerical investigation of the flow front behaviour in the co‐injection moulding process

This paper presents a three‐dimensional (3D) solution algorithm for solving the sequential co‐injection moulding process. The flow of skin and core materials inside a rectangular cavity is investigated both numerically and experimentally. A 3D finite element flow analysis code is used to solve the governing equations of the non‐isothermal sequential co‐injection moulding. The predicted flow front behaviour is compared to the experimental observations for various skin/core volume ratio, injection speed, injection temperature, and core injection delay. Simulation results are in good agreement with experimental data and indicate correctly the trends in solution change when processing parameters are changing. Solutions are also shown for the filling of a spiral‐flow mould. The numerical approach is shown to predict the core expansion phase during which the flow front of core and skin materials advance together without breakthrough. Breakthrough phenomena is also predicted and the numerical solution is in good agreement with the experiment. Copyright © 2005 Crown in the right of Canada. Published by John Wiley & Sons, Ltd.     

Mixing Characteristics in a Supersonic Combustor with Gaseous Fuel Injection Upstream of a Cavity Flameholder

Non-reacting experiments and numerical simulations have been performed to investigate the mixing characteristics in a supersonic combustor with gaseous fuel injection upstream of a flameholding cavity in a supersonic vitiated air flow with stream Mach number 1.7. Using helium as simulated fuel, the acetone vapor is adulterated into the fuel jet. The fuel distribution in spanwise and streamwise direction is imaged by the planar laser-induced fluorescence (PLIF) measurement. According to the similarity of experimental observations with different cavities, the typical L/D = 7 cavity with aft wall angle 45° is chosen and the flowfield with the injection is calculated by Large Eddy Simulation. Experimental and numerical results have shown that most of the fuel flow away upon the open cavity with the lifting counter-rotating vortex structures induced by the transverse jet. Only a small portion of the fuel is convected into the cavity shear layer by the vortex interaction of the jet with cavity shear layer, and then transported into the cavity due to the cavity shear layer motion and the interaction of the shear layer with the cavity trailing edge.     

Numerical simulation of a turbulent flow with droplets injection in annular heated air tube using the Reynolds stress model

This work presents computational fluid dynamics (CFD) simulations of single-phase and two-phase flow. The droplets are injected in annular heated air tube. The numerical simulation is performed by using a commercial CFD code witch uses the finite-volume method to discretize the equations of fluid flow. The Reynolds-averaged Navier–Stokes equations with Reynolds stress model were used in the computation. The governing equations are solved by using a SIMPLE algorithm to treat the pressure terms in the momentum equations. The results of prediction are compared with the experimental data.     

Three-dimensional discrete element models for the granular statics and dynamics of powders in cavity filling

Rapid granular flow from a moving container and angle of repose formation were investigated by numerical simulations using the discrete element method (DEM) and experiments. Grain models of various geometrical complexity were studied and their ability to reproduce the experiments in those regimes was explored. The predictive power of the most realistic model for gravity driven cavity filling was assessed. Good agreement between computed and measured density distributions within the filled cavities provides a basis for numerical process variations aiming at homogenized density distributions. The effect of numerical coarse graining was found to be negligible for all properties of interest provided that force laws are scaled properly and corrections for boundary effects are taken into account. The proposed scaling was tested for a certain set of force laws but could be applied to different DEM forces as well. An analytic mass flow law for powder discharge from a moving container was derived and verified by our DEM simulations.     

Numerical modeling of the generation of internal waves by uniform stratified flow over a thin vertical barrier

Numerical simulations of two‐dimensional stratified flow past an obstacle (thin vertical strip) were performed at relatively low Reynolds numbers. A finite differences solver was adopted to simultaneously solve Navier–Stokes equations together with transport equations for salinity (stratifying agent), and the standard Smagorinsky turbulent closure scheme was called in whenever necessary to account for turbulence. The emphases were on the evaluation of code for unsteady stratified flow applications as well as identification of transient and steady internal‐wave processes during flow past obstacles. Simulations were compared with laboratory experiments, where observations were made using a high resolution Schlieren technique and conductivity probes. Blocking was observed upstream of the obstacle, surrounded by near‐zero frequency internal waves, the phase lines of which joined those of lee waves through a transition zone in the proximity of the obstacle. This pattern was preceded by initial transients of the starting flow in which propagating internal waves played a dominant role. Confluence of isopycnals passing over/under the obstacle in the wake led to interesting flow phenomena, including the radiation of internal waves. The numerical simulations were in good agreement with observations, except that some phenomena could not be captured due to resolution issues of either numerical or experimental techniques. The efficacy of the code in point for stratified flow calculations with relevance to the atmosphere and oceans was confirmed. Copyright © 2011 John Wiley & Sons, Ltd.     

Elastic and viscous effects on flow pattern of elasto-viscoplastic fluids in a cavity

Inertialess flows of elasto-viscoplastic fluids inside a leaky cavity are numerically analyzed using the finite element technique, with the goal of understanding the influence of both the elastic and viscous effects on the topology of the yield surfaces of an elasto-viscoplastic material. Assuming that the collapse of the material microstructure is instantaneous, a mechanical model is composed of the governing equations of mass and momentum for incompressible fluids, and associated with a hyperbolic equation for the extra-stress tensor based on the Oldroyd-B model (Nassar et al., 2011). The main feature of the model is the consideration of the viscosity and relaxation time as functions of the strain rate to allow the shear-thinning of the viscosity and to restrict the elastic effects to the unyielded regions of the material. The numerical simulations are performed through a three-field Galerkin least-squares-type method in terms of the extra-stress tensor and the pressure and velocity fields. The results indicate that the material yield surfaces are strongly influenced by the interplay between the elastic and viscous effects, in accordance with recent experimental visualization of elasto-viscoplastic flows.     

Freezing of Water in a Differentially Heated Cubic Cavity

An experimental and numerical study has been made of transient natural convection of water freezing in a cube-shaped cavity. The effect of the heat transfer through the side walls is studied in two configurations: with the cavity surrounded by air and with the cavity immersed in an external water bath of constant temperature. The experimental data for the velocity and temperature fields are obtained using liquid crystal tracers. The transient development of the ice/water interface is measured. The collected data are used as an experimental benchmark and compared with numerical results obtained from a Finite-difference code with boundary fitted grid generation. The computational model has been adopted to simulate as closely as possible the physical experiment. Hence, fully variable fluid properties are implemented in the code, and, to improve modelling of the thermal boundary conditions, the energy equation is also solved inside the bounding walls. Although the general behaviour of the calculated ice front and its volume matches observations, several details of the flow structure do not. Observed discrepancies between experimental and numerical results indicate the necessity of verifying and improving the usual assumptions for modelling ice formation.     

Newtonian and Power-Law fluid flow in a T-junction of rectangular ducts

The aim of the present study is the numerical investigation of the shear-thinning and shear-thickening effects of flow in a T-junction of rectangular ducts. The employed CFD code incorporates the SIMPLE scheme in conjunction with the finite volume method with collocated arrangement of variables. The code enables multi-block computations in domains with multiple apertures, thus coping with the two-block, two-outlet layout of the current 3D computational domain. The shear-thinning and shear-thickening behaviours of the flow are covered by changing the index n of the Power-Law model within a range from 0.20 to 1.25, and the subsequent effects are investigated by means of different flow parameters namely the Reynolds (Re) number and the boundary conditions at the outlets. Results exhibit the extent of the effect of the Re number on the velocity profiles at different positions in the domain for both Newtonian and non-Newtonian cases. Similarly, the trend of the effect of shear-thinning and shear-thickening behaviours on the flow rate ratio between inlet and outlets, in the case of equal pressure imposed on outlets, is shown.     

The melt processing of monodisperse and polydisperse polystyrene melts within a slit entry and exit flow

This paper presents experimental results and numerical simulations for mono, blended and polydisperse polstryrenes of different molecular weights flowing within a slit geometry. Flow experiments were carried out on small (less than 10 g) quantities of polymer using a multi-pass rheometer and flow-induced birefringence images were obtained for well-defined flow boundary conditions. Experimental flow birefringence observations illustrate the similarities and differences in the flow behaviour between monodisperse and polydisperse polystyrene. For the case of monodisperse polystyrene a transition from “near-Newtonian” stress patterns for low molecular weight polystyrenes, to a highly unstable flow at high molecular weight was observed. Both blending and polydispersity enabled stable flows to be achieved at high flowrates.Experimental flow birefringence results and some pressure difference predictions were compared with numerical predictions. Two different computational approaches were followed, one using a viscoelastic integral K-BKZ/Wagner model within the finite element method solver Polyflow, and the other using the tube theory-based Pom-Pom constitutive equation and Lagrangian-Eulerian code flowSolve. Both numerical methods were able to capture certain experimental observations reasonably well in the stable flow regime, but were not able to predict the onset of the experimentally observed flow instabilities.     

Numerical simulation of shear-thinning flow problems in mixing vessels

In many applications of chemical and process engineering numerous important flow situations appear, in which the shear-thinning properties of the fluid dominate the normal stress effects and time-dependent elastic effects. A mixed finite element method for steady incompressible flow is presented taking as a basis the model of a generalized Newtonian fluid. An augmented Lagrangian functional is constructed corresponding to the equations of motion and the continuity constraint together with appropriate boundary conditions. The treatment of the resulting nonlinear system of equations by the Newton-Raphson scheme is made for general models of the viscosity function. The linear subproblems are solved by Uzawa's algorithm. The method is applied to the numerical simulation of various mixing problems in cylindrical unbaffled vessels. The computations were performed for a real polymer liquid (CMC in water), where the viscosity data were found experimentally and were fitted to a suitable mathematical model. Several numerical results are discussed and as far as possible compared with experimental data.This work was supported by Deutsche Forschungsgemeinschaft.     

Numerical and experimental investigation of a serpentine inlet duct

This article presents a numerical and experimental investigation of the flow inside an ultra-compact, serpentine inlet duct. The numerical analysis used two flow solvers: FLUENT®, a commercial code, and UNS3D, an in-house code. The flow was modelled using the Reynolds-averaged Navier-Stokes equations. The turbulence effects were modelled by using the shear-stress transport k–ω model. The numerical investigation was compared against experimental data obtained in an open-circuit, low-speed wind tunnel in the Fluid Dynamics Laboratory at Texas A&M University. The numerical simulations and experimental testing were performed to reveal the separation points and the strong secondary flow phenomena within the inlet. UNS3D overpredicted the location of the first separation point by 9 mm and the location of the second separation point by 1 mm, while the area-averaged pressure loss coefficient was 5% higher than in the experiment. The numerical results of UNS3D agreed better with the experiment than those of FLUENT.     

Simulation of unsteady hypersonic combustion around projectiles in an expansion tube

The temporal evolution of combustion flowfields established by the interaction between wedge-shaped bodies and explosive hydrogen-oxygen-nitrogen mixtures accelerated to hypersonic speeds in an expansion tube is investigated. The analysis is carried out using a fully implicit, time-accurate, computational fluid dynamics code that we recently developed to solve the Navier-Stokes equations for a chemically reacting gas mixture. The numerical results are compared with experimental data from the Stanford University expansion tube for two different gas mixtures at Mach numbers of 4.2 and 5.2. The experimental work showed that flow unstart occurred for both the Mach 4.2 cases. These results are reproduced by our numerical simulations and, more significantly, the causes for unstart are explained. For the Mach 5.2 mixtures, the experiments and numerical simulations both produced stable combustion. However, the computations indicate that in one case the experimental data were obtained during the transient phase of the flow; that is, before steady state had been attained. Received 7 February 2000/ Accepted 20 February 2001     

Towards numerical simulations of supersonic liquid jets using ghost fluid method

A computational tool based on the ghost fluid method (GFM) is developed to study supersonic liquid jets involving strong shocks and contact discontinuities with high density ratios. The solver utilizes constrained reinitialization method and is capable of switching between the exact and approximate Riemann solvers to increase the robustness. The numerical methodology is validated through several benchmark test problems; these include one-dimensional multiphase shock tube problem, shock–bubble interaction, air cavity collapse in water, and underwater-explosion. A comparison between our results and numerical and experimental observations indicate that the developed solver performs well investigating these problems. The code is then used to simulate the emergence of a supersonic liquid jet into a quiescent gaseous medium, which is the very first time to be studied by a ghost fluid method. The results of simulations are in good agreement with the experimental investigations. Also some of the famous flow characteristics, like the propagation of pressure-waves from the liquid jet interface and dependence of the Mach cone structure on the inlet Mach number, are reproduced numerically. The numerical simulations conducted here suggest that the ghost fluid method is an affordable and reliable scheme to study complicated interfacial evolutions in complex multiphase systems such as supersonic liquid jets.     

Numerical simulations of non-isothermal three-dimensional flows in an extruder by a finite-volume method

This study considers numerical applications of a finite-volume method to steady non-isothermal flows in geometries close to a single-screw extruder. Two geometrical configurations of the channel, with gap and zero gap, are investigated. The simulations concern incompressible fluids obeying different constitutive equations: Newtonian, generalized Newtonian with shear-thinning properties (Carreau–Yasuda law), and two viscoelastic differential models, the upper convected maxwell (UCM) and the Phan–Thien/Tanner (PTT). The temperature dependence is described by a Williams–Landel–Ferry (WLF) equation. For discretizing the equations and unknowns, we use a staggered grid with a QUICK scheme for the convective-type terms and solve the set of governing equations by a decoupled algorithm, stabilized by a pseudo-transient stress term and an elastic viscous stress splitting (EVSS) technique, in the viscoelastic case for the UCM model. The numerical results enable us to state the influence of temperature and rheological properties on the flow characteristics in the geometries investigated and underline the complex behaviour of the materials in such configurations.     

Velocity overshoots in gradual contraction flows

This study reports the results of a systematic numerical investigation, using the upper-convected Maxwell (UCM) and Phan-Thien–Tanner (PTT) models, of viscoelastic fluid flow through three-dimensional gradual planar contractions of various contraction ratios with the aim of investigating experimental observations of extremely large near-wall velocity overshoots in similar geometries [R.J. Poole, M.P. Escudier, P.J. Oliveira, Laminar flow of a viscoelastic shear-thinning liquid through a plane sudden expansion preceded by a gradual contraction, Proc. Roy. Soc. Lond. Ser. A 461 (2005) 3827]. We are able to obtain good qualitative agreement with the experiments, even using the UCM model in creeping-flow conditions, showing that neither inertia, second normal-stress difference nor shear-thinning effects are required for the phenomenon to be observed. Guided by the numerical results we propose a simple explanation for the occurrence of the velocity overshoots and the conditions under which they arise.     

Discrete element parameter calibration and the modelling of dragline bucket filling

The Discrete Element Method (DEM) is useful for modelling granular flow. The accuracy of DEM modelling is dependent upon the model parameter values used. Determining these values remains one of the main challenges. In this study a method for determining the parameters of cohesionless granular material is presented. The particle size and density were directly measured and modelled. The particle shapes were modelled using two to four spheres clumped together. The remaining unknown parameter values were determined using confined compression tests and angle of repose tests. This was done by conducting laboratory experiments followed by equivalent numerical experiments and iteratively changing the parameters until the laboratory results were replicated. The modelling results of the confined compression tests were mainly influenced by the particle stiffness. The modelling results of the angle of repose tests were dependent on both the particle stiffness and the particle friction coefficient. From these observations, the confined compression test could be used to determine the particle stiffness and with the stiffness known, the angle of repose test could be used to determine the particle friction coefficient. Usually DEM codes do not solve the equations of motion for so-called walls (non-granular structural elements). However, in this study a dynamic model of a dragline bucket is developed and implemented in a commercial DEM code which allows the dynamics of the walls to be modelled. The DEM modelling of large systems of particles is still a challenge and procedures to simplify and speed up the modelling of dragline bucket filling are presented. Using the calibrated parameters, numerical results of bucket filling are compared to experimental results. The model accurately predicted the orientation of the bucket. The model also accurately predicted the drag force over the first third of the drag, but predicted drag forces too high for the subsequent part of the drag.     

Experimental evaluation of numerical simulation of cavitating flow around hydrofoil

Cavitation in hydraulic machines causes different problems that can be related to its unsteady nature. An experimental and numerical study of developed cavitating flow was performed. Until now simulations of cavitating flow were limited to the self developed “in house” CFD codes. The goal of the work was to experimentally evaluate the capabilities of a commercial CFD code (Fluent) for simulation of a developed cavitating flow. Two simple hydrofoils that feature some 3D effects of cavitation were used for the experiments. A relatively new technique where PIV method combined with LIF technique was used to experimentally determine the instantaneous and average velocity and void ratio fields (cavity shapes) around the hydrofoils. Distribution of static pressure on the hydrofoil surface was determined. For the numerical simulation of cavitating flow a bubble dynamics cavitation model was used to describe the generation and evaporation of vapour phase. An unsteady RANS 3D simulation was performed. Comparison between numerical and experimental results shows good correlation. The distribution and size of vapour structures and the velocity fields agree well. The distribution of pressure on the hydrofoil surface is correctly predicted. The numerically predicted shedding frequencies are in fair agreement with the experimental data.     

Natural convection in a liquid metal heated from above and influenced by a magnetic field

Natural convection in a liquid metal heated locally at its upper surface and affected by a vertical magnetic field is investigated both experimentally and numerically. The experiments are conducted in a cylindrical test cell of large aspect ratio which is typical for application. The cell is filled with the liquid alloy GaInSn in eutectic composition. Temperature and velocity are measured using thermocouples and an electric potential probe, respectively. In the absence of the magnetic field the experimental results indicate a dependence of the Nusselt number on the Rayleigh number according to the law Nu∝Ra^0.191. The particular value of the scaling exponent is in excellent agreement with the prediction of a scaling analysis for laminar, boundary layer-type flow in a low-Prandtl number fluid. Furthermore the experiments demonstrate that the Nusselt number and therefore the convective heat losses can be decreased by about 20% when a magnetic field of moderate strength (B=0.1 T) is present. The numerical simulations solve the Boussinesq equations in an axisymmetric geometry using a finite element method. The results of the simulations are both quantitatively and qualitatively in good agreement with the experimental observations. Deviations are attributed to the three-dimensional characteristics of the flow.     

注塑模充模过程动态分析

注塑成型是利用型腔模制造理想制品主要的成型加工方式 ,塑料熔体的流动行为将直接影响着最终塑件的质量 ,塑料熔体在三维薄壁型腔内的流动属于带有运动边界的粘性不可压缩流体的流动 ,本文针对塑料注塑成型特点 ,经过量纲分析和引入合理而必要的假设 ,得到了适合于充模分析的数学模型。控制方程的求解主要包括三个阶段 :压力场、温度场和流动前沿位置的确定。数值求解采用有限元法求解压力场、有限差分法求解温度场、并利用控制体积法跟踪熔体前沿 ,实现了充模过程的动态模拟