湍动雾化射流液雾粒径分布的数值模拟

对水在空气中湍动雾化射流的气液两相流场进行了数值模拟.其中,气体流场采用k-ε湍流模型进行模拟,给出了载气轴向速度的分布情况.对喷雾粒子的运动采用颗粒轨道法,建立粒子破碎和碰撞的数值模型,研究了液雾粒径在不同工况下沿轴向的变化趋势.数值模拟结果与实验结果在多种气液比下进行了比较,两者吻合较好.同时,分析了初始粒径和粒子总数及喷嘴尺寸对液雾粒径变化趋势的影响,讨论了有助于粒径均匀分布的条件.     

石灰浆液喷嘴雾化特性

石灰浆液雾化喷嘴是烟气喷雾干燥净化系统的关键设备.利用Win212-2型激光粒度分析仪,对外混及内-外混相结合双流体石灰浆液喷嘴的雾化特性进行了试验研究,分析了气液质量比、石灰浆液浓度等参数对雾化粒径分布和雾化角的影响规律.结果表明,气液质量比增大,浆液液滴平均直径减小,但当气液比增大到一定值后,粒径变化趋于平缓;浆液浓度增加,液滴平均直径增加;气液质量比增加,雾化角减小.     

气泡雾化喷嘴喷雾平均直径在下游流场中的分布

文利用激光衍射粒度仪对气泡雾化喷嘴下游流场进行了实验研究,主要分析了雾化颗粒直径随径向和轴向距离变化的趋势．由于喷嘴出口处气液两相流型和颗粒自身重量的影响,液雾颗粒沿径向呈现非轴对称分布;而液雾颗粒直径随着轴向距离的增加呈现先减小、后增大的趋势,颗粒直径的减小是大量气泡爆炸的结果,而后的增加则是由于颗粒之间的相互粘结造成的。     

层流气体雾化制粉工艺粉末形貌及雾化机理

层流气体雾化制备的金属粉末具有粒径较小且粒度分布窄的优点,目前对层流气体雾化的研究主要集中在工艺参数对雾化效果和粉末特性的影响,其雾化机理仍不完全清楚.本文通过数值模拟和实验分析,系统地研究了层流气体雾化过程中的雾化气体流场、一次雾化和二次雾化机理以及最终的粉末颗粒形态.采用标准k-e湍流模型,研究了基于De Laval喷嘴的层流雾化单相气体流场,流场呈"项链"状结构,并伴有斜激波的膨胀波团.采用耦合水平集-体积分数法研究了一次雾化和二次雾化机理,并通过雾化实验得到了凝固碎片和粉末,验证了该模型的有效性,数值模拟结果也为层流气雾化制粉技术的实际应用和具体工艺提供了重要参考.研究表明,液柱周围的熔体主要以细丝或韧带的形式剥离,这显示出了增压低维度雾化的特点.二次雾化过程中球形液滴主要基于Rayleigh-Taylor不稳定变形和Sheet-Thinning破碎模式分解破碎,丝状熔体则主要以曲张波表面发生扰动从而引起波谷处破裂的方式进行破碎.     

三组元乳化液雾化特性的研究

采用Malvern粒度仪对柴油、甲醇和水三组元乳化液的雾化特性进行了研究。实验发现:对于压力雾化喷嘴来说,本文所涉及的乳化液由于粘度高于纯柴油,因此雾化效果比纯柴油差,而且喷射压力、乳化剂的粘度和乳化液的组份对乳化液的雾化特性具有显著的影响。随着喷射压力的升高,乳化液喷雾粒径将随之减小;若乳化液中柴油的含量(柴油不少于50％)降低,乳化液的雾化粒径将随之增加;若采用高粘度的乳化剂,相应乳化液喷雾的粒径也大。     

基于灰度图差分梯度的雾化角测量方法北大核心CSCD

雾场边界及雾化角作为雾场的重要特性参数,主要通过图像法进行测量。在图像处理过程中,一般是将灰度图转化为二值化图像,然后依次针对二值化图像进行处理和计算。由于雾场的多相流特性,得到的二值化阈值和图像与实际雾场是否一致缺少评判依据。提出根据喷雾的灰度图像直接处理,得到掩模板并作用于灰度图像,采用图像形态学和迭代方法,计算灰度图像的梯度值。通过得到梯度值最大时的灰度图像,计算雾场边界和雾化角。实验表明,该方法提供了一种雾场边界的数值判断依据,通过梯度最大值判断并提取雾场边界,从而通过程序自动实现雾场边界提取与雾化角拟合测量。     

环状出口气泡雾化喷嘴研究

本文对环状出口气泡雾化喷嘴出口下游液膜的破碎过程进行了研究,发现气体的介入是促使液膜破碎的主要原因。利用DUALPDA对其下游流场的速度分布、颗粒直径分布以及通量分布进行了实验测量。发现喷嘴出口附近主流区域存在大量具有负向速度的颗粒,并且此处的颗粒平均直径显著减小,为气泡雾化机理提供了佐证;在喷嘴出口下游轴心处液雾呈现逆向流动趋势,证明此处存在负压回流;沿轴向的速度分布曲线与颗粒直径分布曲线的变化趋势说明气泡"爆炸"发生在出口下游5-15 mm距离内。     

喷嘴雾化特性实验研究

液体雾化是当前两相流研究中非常重要的课题,在农业、能源以及环境工程中具有广泛的应用价值,进行深入系统的研究具有重要意义。本文以空气、水为工质,使用马尔文粒度仪对单相和两相雾化器喷嘴的雾化特性进行了比较实验研究。测量了不同压力配比条件下液体雾化粒子的粒径分布,详细讨论了压力对于喷嘴雾化效果的影响。同时得出了两相流量与压力之间的变化规律。     

电极感应熔化气雾化制粉技术中非限制式喷嘴雾化过程模拟

电极感应熔化气雾化(electrode induction melting gas atomization, EIGA)是一种制备超洁净无夹杂物的先进制粉技术,本文以粉末高温合金的氩气雾化过程为研究示例,对现有用于实际生产的国内某厂家提供的EIGA用非限制式喷嘴进行建模,采用商用计算流体力学软件FLUENT,分布采用欧拉-欧拉VOF(volume of fluid)多相流方法与欧拉-拉格朗日DPM (discrete phase model)离散相方法,对非限制式环缝喷嘴主雾化与二次雾化过程进行了数值模拟.通过对主雾化过程中多相流大涡模拟速度流场,主雾化过程中不同阶段高温熔体云图模拟以及二次雾化过程中TAB (Taylor analogy breakup)模型速度流场及TAB模型粒度分布的模拟研究,实现了对EIGA制粉技术中非限制式喷嘴雾化过程的全过程模拟,并预测了雾化后的粉末粒度分布.在此基础上,采用本文模拟使用的非限制式环缝喷嘴,设定与模拟条件一致(进气压力4 MPa,液流直径约4 mm)的实验条件,制备的粉末大部分颗粒的直径大小在100μm左右,该实验结果与模拟得到的粉末直径D50=100μm大小一致,进一步验证了模拟数据的合理性.该方法也适用于非限制式喷嘴里,其他金属或合金的雾化过的模拟研究.     

一种新型喷嘴的提出及流量特性的研究

本文在对各种气动喷嘴及其雾化机理分析基础上提出了一种新型的气动雾化喷嘴-"旋转型气-液雾化喷嘴"。在此喷嘴中,油与气分别从不同的槽道切向进入混合室,且油与气一一对应,油与气互相混合、旋转后从喷口喷出。其气液比在热态实验时为4%-6%(用压缩空气雾化),雾化状态良好。本文中对其流量系数及雾化角进行了系统的研究。主要考虑了喷嘴的结构参数,气液比(ALR),液体粘度等因素对流量系数的影响。通过实验测量与拟合,最后得到了喷嘴的流量系数和雾化角的表达式,可以用来指导喷嘴的设计。     

Visualization of two phase flow inside an effervescent atomizer

Effervescent atomization is one of the twin-fluid atomization methods while it has better performance in terms of smaller drop sizes and/or lower injection pressures. In order to investigate the effects of the internal flow patterns on droplet characteristics, a new kind of effervescent atomizer was designed and manufactured. The bubble forming process was visualized with a high-speed camera, while the droplet size was characterized with a LDV/PDA system. The experimental results show that there are three regimes of the two-phase flows inside the discharge orifice, one is bubbly flow, another is annular flow while the other is the intermittent flow. The flow patterns transfered from bubbly flow to intermittent flow and then to annular flow with decreasing of the water flow rate. In addition, with increasing of the working pressure or decreasing of the water flow rate, the SMD (Sauter mean diameter) of the droplets decreased and the axial mean velocity increased.     

燃油粒度对两相PDE爆震波速的影响

两相爆震燃烧的研究近来取得了较大的进步,但是仍有很多问题需要解决,诸如燃油的喷射、雾化和蒸发,燃油和氧化剂的混合,两相可爆混合物的短距离起爆等等．本文利用激光喷雾粒度分析仪分别就直射喷嘴与气动喷嘴研究了汽油的雾化情况,随着汽油流量的增加,两种喷嘴的雾化变化趋势相反．结合汽油、空气PDE模型机多循环爆震试验,发现汽油的粒度对模型机的爆震波速有较大的影响,粒度减小,波速增大,同时波速具有循环效应．     

Droplet formation by rapid expansion of a liquid

Molecular dynamics of two- and three-dimensional liquids undergoing a homogeneous adiabatic expansion provides a direct numerical simulation of the atomization process. The Lennard-Jones potential is used with different force cutoff distances; the cluster distributions do not depend strongly on the cutoff parameter. Expansion rates, scaled by the natural molecular time unit (about a picosecond), are investigated from unity down to 0.01; over this range the mean droplet size follows the scaling behavior of an energy balance model which minimizes the sum of kinetic plus surface energy. A second model which equates the elastic stored energy to the surface energy gives better agreement with the simulation results. The simulation results indicate that both the mean and the maximum droplet size have a power-law dependence upon the expansion rate; the exponents are -2d/3 (mean) and -d/2 (maximum), where d is the dimensionality. The mean does not show a dependence upon the system size, whereas the maximum does increase with system size, and furthermore, its exponent increases with an increase in the force cutoff distance. A mean droplet size of 2.8/eta(2), where eta is the expansion rate, describes our high-density three-dimensional simulation results, and this relation is also close to experimental results from the free-jet expansion of liquid helium. Thus, one relation spans a cluster size range from one atom to over 40 million atoms. The structure and temperature of the atomic clusters are described.     

A Numerical Calibration Approach to Obtain Cutting Fluid Droplet Sizes in a Turning Process via an Imaging System

Airborne inhalable particulate in the workplace can represent a significant health hazard, and one of the primary sources of particles is mist produced through the application of cutting fluids in machining operations. The atomization process is one of the principal mechanisms associated with cutting fluid mist formation and generates droplets from fifty to a few thousand micrometers in size. These particles subsequently undergo vaporization and settling effects resulting in an aerosol to which workers may be exposed. While a variety of equipment is available to characterize the fine particulate in the breathing zone, standard equipment to measure the size of the atomized droplets is not available. In this paper, an imaging system is employed to characterize the large droplets produced by atomization in turning. One of the drawbacks of such a system is the time‐consuming experimental calibration procedure that is required to improve the accuracy of the droplet size measurements and extend the depth of field of the imaging system. With this in mind, an approach is introduced to predict droplet diameter based on measurement data without physical system calibration. The relationship between the actual diameter and the measured diameter is established based on an imaging system simulation model that includes a three dimensional point spread function and an image formation relationship grounded in the principles of geometric optics. These two components are combined using convolution integral theory to derive an image intensity profile. The introduction of halo width into the simulation greatly extends the image depth of field, which is a critical factor in capturing more droplets in one image and also minimizing particle size distribution bias towards larger droplets. The model predicts droplet diameter as a function of measured diameter and halo width. Model behavior of predicted diameters from the simulation compares well with those from a physical calibration of the system. The numerical calibration model is then used in the study of cutting fluid atomization in a turning process, and the measured droplet size distribution compares favorably with droplet sizes predicted by a mechanistic atomization model.     

Numerical simulation of electrohydrodynamic (EHD) atomization

The objective of the present work was to use a commercial Computational Fluid Dynamics (CFD) code to simulate the electrohydrodynamic (EHD) atomization process. Although the physics of the atomization and cone formation has been discussed in numerous publications, a comprehensive theory has not been presented. Some of the previous approaches are discussed below. A CFD model can give a unique capability to describe and simulate the liquid cone formation and atomization. The approach in this work was to simultaneously solve the coupled (EHD) and electrostatic equations. The heat conduction equation, solved by the CFD solver, has been modified to solve the electrostatic field equations. From the electrostatic field, the electric body forces have been determined and included in the Navier–Stokes equations. The model does not include any current. The key liquid property for the coupling is the permittivity. The predicted velocity fields for heptane and ethanol and the operating window of heptane were found to be consistent with published results. The model does not include a droplet break-up model. If the jet is cylindrical, the droplet size can be calculated from the jet diameter. The droplet size of ethanol was predicted and compared well with experiments.     

A discrete droplet transport model for predicting spray coating patterns of an electrostatic rotary atomizer

Electrostatic spray (E-spray) coating is widely used for coating conductive substrates. The combination of a high-velocity shaping air, an imposed electric field and charged droplets, leads to higher transfer efficiency than conventional spray coating. In this paper, a mathematical model of droplet transport in E-spray is presented which enables simulating the coating deposition rate profile. A dilute spray assumption (no particle–particle interactions) allows modeling single-droplet trajectories resulting from a balance of electrostatic force, drag and inertia. Atomization of liquid droplets is not modeled explicitly—rather an empirical correlation is used for the mean droplet size while individual droplet sizes and starting locations are determined using random distributions. Strong coupling requires the electrostatic field and droplet trajectories be determined iteratively by successive substitution with relaxation. The influences of bell-cup voltage and atomization constant on the coating deposition rate profile, mass transfer efficiency and droplet trajectories are also shown. Using individually predicted droplet trajectories and impact locations, a static coating deposition rate profiles is determined. For the parametric values considered in this paper, the predicted spray is a cone hollow with no deposition in the center, a heavy ring near the center, and a tapering of thickness toward the outer edge.     

Stochastic modeling of atomizing spray in a complex swirl injector using large eddy simulation

Large-eddy simulation of an atomizing spray issuing from a gas-turbine injector is performed. The filtered Navier–Stokes equations with dynamic subgrid scale model are solved on unstructured grids to compute the swirling turbulent flow through complex passages of the injector. The collocated grid, incompressible flow algorithm on arbitrary shaped unstructured grids developed by Mahesh et al. (J. Comp. Phys. 197 (2004) 215–240) is used in this work. A Lagrangian point-particle formulation with a stochastic model for droplet breakup is used for the liquid phase. Following Kolmogorov’s concept of viewing solid particle-breakup as a discrete random process, the droplet breakup is considered in the framework of uncorrelated breakup events, independent of the initial droplet size. The size and number density of the newly produced droplets is governed by the Fokker–Planck equation for the evolution of the pdf of droplet radii. The parameters of the model are obtained dynamically by relating them to the local Weber number and resolved scale turbulence properties. A hybrid particle-parcel is used to represent the large number of spray droplets. The predictive capability of the LES together with Lagrangian droplet dynamics models to capture the droplet dispersion characteristics, size distributions, and the spray evolution is examined in detail by comparing it with the spray patternation study for the gas-turbine injector. The present approach is computationally efficient and captures the global features of the fragmentary process of liquid atomization in complex configurations.     

超声速气流中液体横向射流雾化过程数值模拟

为了更加深入了解超燃冲压发动机燃烧室中的燃料雾化机理,对来流Mach数为1.94的超声速气流中液体横向射流的雾化过程进行了数值模拟研究.计算采用Euler-Lagrange方法,液滴二次破碎模型采用K-H/R-T模型.计算结果表明:考虑液滴二次破碎时,采用雾化锥模型获得的射流穿透深度以及液滴速度分布与实验结果符合得很好;初始液滴直径对射流穿透深度和液滴分布的影响很小;随着初始雾化锥角的增加,相同横截面上的射流穿透深度逐渐减小.当不考虑液滴二次破碎时,液滴穿透深度及分布与所选的初始液滴直径有很大关系.      

Close-coupled nozzle atomization integral simulation and powder preparation using vacuum induction gas atomization technology

We simulate the gas-atomization process of a close-coupled annular nozzle for vacuum induction gas atomization at a three-dimensional scale.Moreover,the relationship between the simulated droplet type and experimentally metallic powder is established by comparing the morphology of droplets with powders.Herein,the primary atomization process is described by the volume-of-fluid(VOF)approach,whereas the prediction of powder diameter after secondary atomization is realized by the VOF-Lagrangian method.In addition,to completely reflect the breaking and deformation process of the metallic flow,we employ the VOF model to simulate the secondary atomization process of a single ellipsoidal droplet.The results show that the primary atomization process includes the formation of surface liquid film,appearance of serrated ligaments,and shredding of ligaments.Further,gas recirculation zone plays an important role in formation of the umbrella-shaped liquid film.The secondary atomization process is divided into droplet convergence and dispersion stages,and the predicted powder diameter is basically consistent with the experiment.In general,the four main powder shapes are formed by the interaction of five different typical droplets.