Numerical Simulation of Mixing Characteristics and Energy Consumption in Vane Extruders with Different Structure Parameters

Numerical simulation was performed with the Computational Fluid Dynamics (CFD) analysis software POLYFLOW (ANSYS, Inc., USA) to investigate the melt transportation energy consumption and mixing characteristics of vane extruders. By modifying related parameters in the numerical simulation models, the effects of vane arrangement and eccentricity between rotor and stator were studied. The results showed that for different vane arrangements, the vane unit with four vanes distributed uniformly had the lowest energy consumption per unit melt transported in one cycle and the best mixing characteristics. With the increase of eccentricity, the average rotational power transmitted by the vanes to the melt increased, and the rate of increase increased. The same tendency occurred for the maximum shear rate and stretching rate experienced by the particles in the vane extruder. This suggested that the mixing performance of the vane unit increased significantly with the increase of eccentricity.     

Hydrodynamic analysis of binary immiscible metallurgical flow in a novel mixing process: rheomixing

This paper presents a hydrodynamic analysis of binary immiscible metallurgical flow by a numerical simulation of the rheomixing process. The concept of multi-control is proposed for classifying complex processes and identifying individual processes in an immiscible alloy system in order to perform simulations. A brief review of fabrication methods for immiscible alloys is given, and fluid-flow aspects of a novel fabrication method: rheomixing by a twin-screw extruder (TSE), are analysed. Fundamental hydrodynamic micromechanisms in a TSE are simulated by a piecewise-linear volume-of-fluid (VOF) method coupled with the continuum surface force algorithm. This revealed that continuous reorientation in the TSE process could produce fine droplets and the best mixing efficiency. It is verified that a TSE is a better mixing device than a single-screw extruder and can achieve finer droplets. Numerical results show good qualitative agreement with experimental results. It is concluded that rheomixing by a TSE can be successfully employed for casting immiscible engineering alloys due to its unique characteristics of reorientation and surface renewal. PACS 47.11.+j; 68.05.Gh; 83.50.Xa     

Total Strain of Newtonian Fluids in a Vane Extruder

The vane extruder, which makes a polymer suffer elongation stress much larger than shearing stress, is an innovational equipment in polymer processing. A physical model and a mathematical model are established to analyze the mixing characteristics in polymer processing, namely, the two important functions of residence time distribution and strain distribution function are obtained. It is shown that the direction of total strain gradient is consistent with the orientation of the material flow. The results show that the vane extruder has an advantage over traditional screw extruders due to it being based on elongational rheology.     

Effect of Mixing Sequence on Phase Morphology and Mechanical Properties in Polyamide 6/Butadiene (Core) Styrene Acrylonitrile-G-Maleic Anhydride (Shell) Latex/Organoclay Ternary Nanocomposites

Ternary nanocomposites based on polyamide-6, maleated butadiene (core) -acrylonitrile-styrene (shell) rubber particles (PB-g-SAM), and modified montmorillonite (organoclay) were prepared by a twin-screw extruder. The glassy shell of the core-shell particles can act as a barrier which can resist the entrance of clay into the rubber phase. The influence of mixing sequence on the phase morphology and mechanical properties were studied. The microstructure of the ternary nanocomposites was characterized by X-ray diffraction, transmission electron microscopy, and scanning electron microscopy. It was found that the clay in the polyamide nanocomposites was partially exfoliated, exhibiting a mixture of exfoliated structures. The organoclay plates affected the interfacial adhesion between the polyamide-6 and the core-shell particles. The location of the organoclay plates in the blends with different mixing sequences produced differences of the mechanical properties. The results of mechanical testing revealed that the optimum mixing sequence to achieve balanced mechanical properties was mixing the polyamide-6 and organoclay first followed by mixing with the core-shell particles.     

Numerical investigation of the variable nozzle effect on the mixed flow turbine performance characteristics

There are various matching ways between turbocharger and engine, the variable nozzle turbine is the most significant method. The turbine design must be economic with high efficiency and large capacity over a wide range of operational conditions. These design intents are used in order to decrease thermal load and improve thermal efficiency of the engine. This paper presents an original design method of a variable nozzle vane for mixed flow turbines developed from previous experimental and numerical studies. The new device is evaluated with a numerical simulation over a wide range of rotational speeds, pressure ratios, and different vane angles. The compressible turbulent steady flow is solved using the ANSYS CFX software. The numerical results agree well with experimental data in the nozzleless configuration. In the variable nozzle case, the results show that the turbine performance characteristics are well accepted in different open positions and improved significantly in low speed regime and at low pressure ratio.     

高速流动PIV示踪粒子跟随性分析

通过理论推导提出了一种评价高速流动PIV示踪粒子随流能力的松弛特性分析模型,在法向Mach数大于1.4时具有良好的适用性.将新模型应用于试验测量,发展了高速流动PIV系统和示踪粒子布撒技术,验证了高速流动PIV的定量化测量能力.针对空间发展的二维超声速气固两相混合层,数值模拟了不同Stokes数和对流Mach数（M_c）下的粒子跟随性以及弥散和迁徙运动,结果表明:相同对流Mach数,粒径越小的示踪粒子跟随性越好,Stokes数在[1, 10]范围内的粒子有最大扩散距离.示踪粒子的直径大小决定其在超声速混合层大涡拟序结构中的分布特征,且粒径越小,气体与粒子的掺混越剧烈.相同粒径的粒子,对流Mach数越大跟随性越差.      

The effect of electrostatic force on the evolution of sand saltation cloud

In a wind-blown sand layer, it has been found that wind transport of particles is always associated with separation of electric charge. This electrification in turn produces some electrostatic forces in addition to the gravitational and fluid friction forces that affect the movement of saltating sand particles, further, the wind-blown sand saltation. To evaluate this effect quantitatively, this paper presents a simulation of evolution of wind-blown sand grains after the electrostatic forces exerted on the grains are taken into account in the wind feedback mechanism of wind-blown saltation. That is, the coupling interaction between the wind flow and the saltating sand particles is employed in the simulation to the non-stationary wind and sand flows when considering fluid drag, gravitation, and a kind of electrostatic force generated from a distribution of electric field changing with time in the evolution process of the sand saltation. On the basis of the proposed simulation model, a numerical program is given to perform the simulation of this dynamic process and some characteristic quantities, e.g., duration of the system to reach the steady state, and curves of the saltating grain number, grain transport rate, mass-flux profile, and wind profile varying with time during the non-stationary evolution are displayed. The obtained numerical results exhibit that the electrostatic force is closely related to the average charge-to-mass ratio of sand particles and has obvious influence on these characteristic quantities. The obtained results also show that the duration of the system to reach the steady state, the sand transport rate and the mass flux profile coincide well with experimental results by Shao and Raupach (1992) when the average charge-to-mass ratio of sand particles is 60 μC/kg for the sand particles with average diameter of 0.25 mm. When the average charge-to-mass ratios of sand particles are taken as some other certain values, the calculation results still show that the mass flux profiles are well in agreement with the experimental data by Rasmussen and Mikkelsen (1998) for another category of sand particles, which tell us that the electrostatic force is one of main factors that have to be considered in the research of mechanism of wind-blown sand saltation.     

Simulation of topological chaos in laminar flows

In the present study the immersed boundary method is used for numerical simulation of Stokes-flow mixing driven by stirrers moving in a such way that trajectories of the stirrers form a "braid" in the augmented phase space. It is demonstrated that topologically more complex flow can be a more effective blender than its topologically simpler counterpart with the same energy dissipation rate. Positions of elliptic periodic points are detected and it is demonstrated that the total area of unmixed islands is negligible in comparison with the area of the cavity. Matrix representation of a mixing protocol provides a good estimation for the stretching rate.     

等离子体对含硼两相流扩散燃烧特性的影响

为排除来流空气对含硼燃气的掺混效应, 研究等离子体对含硼富燃料推进剂在补燃室二次燃烧过程的影响, 建立了含硼两相流平行进气扩散燃烧物理模型. 利用高速摄影仪拍摄了含硼燃气在补燃室二次燃烧的火焰图像, 分析了该物理模型的扩散燃烧特性和硼颗粒的二次点火距离. 采用硼颗粒的King点火模型、有限速度/涡耗散模型、颗粒轨道模型和RNG k-ε模型以及等离子体模型, 模拟了一定条件下等离子体对含硼两相流扩散燃烧过程的影响. 结果表明, 依据含硼燃气二次燃烧图像得到的硼颗粒二次点火距离, 与数值模拟结果基本一致, 保证了该物理模型和计算方法的可靠性. 含硼两相流经过等离子体区域后, 硼颗粒在运动轨迹上颗粒温度明显增加, 颗粒直径明显减小, B₂O₃的质量分数分布区域明显扩增, 70%的硼颗粒在到达补燃室2/3尺寸前燃烧效率已达到100%, 硼颗粒充分燃烧释放出更多热量导致中心流线区域温度增加近1/2, 可见等离子体可以明显强化含硼两相流的燃烧过程, 提高硼颗粒的燃烧效率.     

空间发展湍流气粒两相平面混合层的大涡模拟与统计

本文对空间发展的湍流气固两相平面混合层流动进行了大涡模拟研究,其中气相亚网格尺度（SGS）使用结构函数模型,气相控制方程组采用SIMPLE方法求解,固体颗粒运动用拉格朗日方法计算。计算结果正确重现了流体涡结构的卷起、合并和破碎过程,以及小尺寸颗粒在涡边缘（低涡度区）的局部富集现象。对直径分别为42μm、72μm和135μm分别进行了模拟,并将统计结果和实验测量结果（Hishida　et　al[1]）比较,表明两者的平均速度吻合很好,但颗粒数密度和脉动速度存在较明显的差异,因此有必要对亚网格应力和颗粒之间的耦合作用以及拟序结构的三维性对颗粒运动的影响开展深入研究。     

Dispersion and alignment of carbon nanotubes in polycarbonate

Dispersion and alignment of carbon nanotubes in thermoplastic polymers such as polycarbonate have been studied. Dispersion was accomplished by mixing in a conical twin-screw extruder and alignment was carried out using a fiber-spinning apparatus. The effects of mixing time and fiber draw rates on dispersion and alignment were investigated. Uniform dispersions were produced with relatively short residence times in the extruder. Excellent alignment of carbon nanotubes in nanocomposite filaments was obtained when the fiber draw rate was greater than 70 m/min. The ability to closely control the dispersion and alignment of carbon nanotubes in polymers is expected to lead to the development of nanocomposites with desirable electronic and structural properties. Received: 7 January 2002 / Accepted: 11 April 2002 / Published online: 10 September 2002 RID="*" ID="*"Corresponding author. Fax: +1-508/233-5521, E-mail: Michael.Sennett@natick.army.mil     

Modelling of lifted turbulent diffusion flames in a channel mixing layer by the flame hole dynamics

The partial quenching structure of turbulent diffusion flames in a turbulent mixing layer is investigated by the method of flame hole dynamics as an effort to develop a prediction model for the turbulent flame lift off. The essence of the flame hole dynamics is derivation of the random walk mapping, from the flame-edge theory, which governs expansion or contraction of the quenching holes initially created by the local quenching events. The numerical simulation for the flame hole dynamics is carried out in two stages. First, a direct numerical simulation is performed for a constant-density fuel–air channel mixing layer to obtain the background turbulent flow and mixing fields, from which a time series of two-dimensional scalar-dissipation-rate array is extracted. Subsequently, a Lagrangian simulation of the flame hole random walk mapping, projected to the scalar dissipation rate array, yields a temporally evolving turbulent extinction process and its statistics on partial quenching characteristics. In particular, the probability of encountering the reacting state, while conditioned with the instantaneous scalar dissipation rate, is examined to reveal that the conditional probability has a sharp transition across the crossover scalar dissipation rate, at which the flame edge changes its direction of propagation. This statistical characteristic implies that the flame edge propagation instead of the local quenching event is the main mechanism controlling the partial quenching events in turbulent flames. In addition, the conditional probability can be approximated by a heavyside function across the crossover scalar dissipation rate.     

入流激励下可压缩剪切层中Kelvin-Helmholtz涡的响应特性

通过直接数值求解Navier-Stokes方程,研究了入流激励下可压缩剪切层中Kelvin-Helmholtz(KH)涡结构的响应特性,结果清晰地展示了KH涡的独特演化方式.基于流动可视化数据,采用两点相关性分析获得了流场拟序结构的空间尺寸和结构角分布.通过分析不同激励频率下涡结构的动态特性,揭示了入流激励下可压缩剪切层中KH涡结构的独特演化机理.研究结果表明,低频入流激励(f=5 k Hz)下KH涡尺寸在远场区域达到饱和后呈现锁频状态,KH涡量厚度稳定在12-14 mm之间;与自由剪切层涡结构通过配对合并的方式实现生长的机理不同,低频入流激励下剪切层的发展是通过中间涡核顺时针吞噬KH不稳定波诱导的一串外围小涡结构来实现生长.此外,针对高频激励(f=20 k Hz)下的剪切层流动,研究了涡结构特性和入流激励参数之间的定量关系,发现均匀分布涡结构的尺寸近似等于对流速度与入流激励频率之比.     

离心压缩机级内三维粘性流动数值分析

本文介绍了用时间推进法进行离心压缩机级内全三维粘性流场的计算方法．该方法是作者在已完成的求解孤立叶排Ｎ－Ｓ方程的计算程序的基础上发展的，通过使用周向非均匀的叶排间隙混合平面概念来考虑离心叶轮与扩压器之间的相互影响，并依据质量守恒原则，对下游的进口气流角进行了修正，以保证了上下游叶排在相容的流动特性下工作．完成了离心压缩机级（包括叶轮与扩压器）三维粘性定常流场的计算及性能预测．应用本文所发展的程序，对某高炉鼓风机的叶轮及其叶片扩压器进行了计算．     

使用确定应力模型研究离心压气机叶片相互作用

离心压气机叶轮和扩压器叶片间空隙很小,在无叶区和半有叶区的流动非定常特性十分明显。特别是离心叶轮出口通常的射流／尾迹流动使得有叶扩压器进口在时间、空间两个尺度上都存在十分强烈的不均匀性。叶轮和扩压器叶片间的相互作用,历来都被认为是影响离心压气机效率和稳定工作范围的重要因素。本文引入确定应力模型和改进的计算域延伸方法,计算了Ｋｒａｉｎ离心压气机组的流场,着重分析了叶轮出口无叶区、半无叶区等叶片间相互作用最强烈的区域的复杂流动现象。     

超声速转子叶片非定常引射器流场特性数值模拟

采用计算流体力学方法,结合适当的边界条件,对超声速转子叶片非定常引射器进行了模拟。从结果可以看出:此类引射器内流态复杂,主气流出口斜激波干扰现象明显,叶片设计参数对引射器性能影响很大。叶片尾部的膨胀波有效诱导了被引射气流,在短距离内增强了气流混合,湍流效应对引射器性能的影响较小;叶片可维持自旋转,提升叶片转速可增强引射效率。最后,对引射器内的流动机理进行了探讨。     

旋转气固两相流动与分离数值模拟

针对旋转气固两相流分离及其应用问题,研究旋转气固两相流中尘粒的运动特性及分离效率,提出了分离效率的计算式.考虑尘粒间碰撞与并聚、喷水对尘粒间碰撞与并聚的影响,数值模拟研究旋转分离器内气固两相流场、尘粒运动特性及分离效率.研究结果表明分离器结构对流场和压力场有显著影响,且尘粒并聚有利于提高分离效率.     

单链表在离子发动机光学系统粒子模拟中的应用

 目前离子发动机光学系统数值模拟大多采用PIC方法，由于该方法需要跟踪单个粒子的运动，因此需要存储每个粒子的位置信息与运动信息。传统的粒子模拟程序中，保存粒子信息大多采用数组的方式，但是采用这种方式存在弊端，例如对粒子总数变化的自适应不好。基于此开发了一种使用链式存储结构的粒子模拟程序，该程序使用带头节点的单向链表存储粒子信息。使用基于链式存储结构的PIC方法对离子发动机光学系统进行了粒子模拟，验证了链式粒子信息存储方法在粒子模拟中的可用性。模拟表明：（1）在粒子模拟中采用链式存储结构存储粒子信息，无需预先指定最大粒子总数，程序可自适应粒子总数的变化，因此无需进行试算，节省了计算时间；（2）在粒子模拟中采用链式存储结构，由于不存在内存资源的浪费，因而可显著提高程序的存储效率与计算效率。     

受碾区域内颗粒轴向流动特性的离散元模拟

为探讨受碾状态颗粒的稳定流动, 在碾辊轴与筛筒组成的受碾区域内, 建立了轴向运动的颗粒流离散元物理模型. 研究结果表明: 受碾区域内各颗粒沿轴向运动能力的差异造成了颗粒流密度不均匀; 颗粒与筛筒间的静摩擦系数影响颗粒轴向流动的形态、速率及集散程度, 受碾区域内单层颗粒的轴向均方偏差与流动时间的平方正相关, 属于“super”扩散; 整体分析受碾区域发现, 颗粒的轴向平均速度沿轴向坐标逐渐增大, 而颗粒的三轴合成平均速度沿轴向坐标逐渐降低; 受碾区域内各轴向位置处颗粒运动的剧烈程度不同, 沿轴向坐标颗粒的波动速度平方呈现先增大后降低而后又增大的趋势; 单颗粒的碰撞总能量损失能谱也表明了颗粒运动程度不同, 即轴向流动时在受碾区域的前半段碰撞剧烈, 能量损失多, 在后半段碰撞程度弱, 能量损失较少. 通过对受碾区域内颗粒流动的数值模拟分析, 明晰了颗粒在受碾条件下稳定流动特性, 有益于碾磨工业对产品品质控制及设备参数优化的研究.     

高焓横向射流尾迹区掺混燃烧的数值特性

尾迹区作为横向射流流场的重要结构受到广泛关注,其掺混和燃烧特性对近壁面区域的流场特性有重要影响.文章在对仿真充分验证的基础上,采用Reynolds平均模拟方法对Ma=8飞行条件下高焓横向射流尾迹区中的掺混和燃烧特性进行了数值研究.探究了冷热流场尾迹区中的氢气掺混特性,冷态流场尾迹区中的激波结构对氢气分布产生一定影响,热态流场尾迹区中存在多种氢气掺混路径.V形回流区中的高浓度氢气对燃烧产生了一定的阻碍作用.定量测量了尾迹区中的火焰结构,尾迹区火焰的顶点位置随高度增加向下游线性移动,受射流主流影响,尾迹区火焰的展向宽度在距离壁面一定高度后开始增大.对冷热流场中的主要参数进行了对比,燃烧消耗了氢气使温度升高,但是尾迹区中的流动速度没有明显增加,燃烧放出的热量没有完全转化为流体的动能.