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.     

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.     

Characteristics of fiber suspension flow in a rectangular channel

Velocity profile of fiber suspension flow in a rectangular channel is measured by pulsed ultrasonic Doppler velocimetry (PUDV), and the effect of fiber concentration and Reynolds number on the shape of the velocity profile is investigated. Five types of flow behavior are observed when fiber concentration increases or flow rate decreases progressively. The turbulent velocity profiles of fiber suspension can be described by a correlation with fiber concentration, nl³, and Reynolds number, Re as the main parameters. The presence of fiber in the suspension will reduce the turbulence intensity and thus reduce the turbulent momentum transfer. On the other hand, fibers in the suspension have the tendency to form fiber networks, which will increase the momentum transfer. The relative contribution of these two types of momentum flux will determine the final shape of the velocity profile.     

An anisotropic rotary diffusion model for fiber orientation in short- and long-fiber thermoplastics

The Folgar–Tucker model, which is widely-used to predict fiber orientation in injection-molded composites, accounts for fiber–fiber interactions using isotropic rotary diffusion. However, this model does not match all aspects of experimental fiber orientation data, especially for composites with long discontinuous fibers. This paper develops a fiber orientation model that incorporates anisotropic rotary diffusion. From kinetic theory we derive the evolution equation for the second-order orientation tensor, correcting some errors in earlier treatments. The diffusivity is assumed to depend on a second-order space tensor, which is taken to be a function of the orientation state and the rate of deformation. Model parameters are selected by matching the experimental steady-state orientation in simple shear flow, and by requiring stable steady states and physically realizable solutions. Also, concentrated fiber suspensions align more slowly with respect to strain than models based on Jeffery's equation, and we incorporate this behavior in an objective way. The final model is suitable for use in mold filling and other flow simulations, and it gives improved predictions of fiber orientation for injection molded long-fiber composites.     

Investigation of the rheological properties of short glass fiber-filled polypropylene in extensional flow

The behavior of short glass fiber–polypropylene suspensions in extensional flow was investigated using three different commercial instruments: the SER wind-up drums geometry (Extensional Rheology System) with a strain-controlled rotational rheometer, a Meissner-type rheometer (RME), and the Rheotens. Results from uniaxial tensile testing have been compared with data previously obtained using a planar slit die with a hyperbolic entrance. The effect of three initial fiber orientations was investigated: planar random, fully aligned in the stretching flow direction and perpendicular to it. The elongational viscosity increased with fiber content and was larger for fibers initially oriented in the stretching direction. The behavior at low elongational rates showed differences among the various experimental setups, which are partly explained by preshearing history and nonhomogenous strain rates. However, at moderate and high rates, the results are comparable, and the behavior is strain thinning. Finally, a new constitutive equation for fibers suspended into a fluid obeying the Carreau model is used to predict the elongational viscosity, and the predictions are in good agreement with the experimental data.     

Numerical prediction of fiber motion in a branching channel flow of fiber suspensions

Fiber orientation and dispersion in the dilute fiber suspension that flows through a T-shaped branching channel are simulated numerically based on the slender-body theory. The simulated results are consistent qualitatively with the experimental data available in the literature. The results show that the spatial distribution of fibers is dependent on the fiber aspect ratio, but has no relation with the volume fraction of fiber. The content ratio of fibers near the upper wall increases monotonically with an increasing Re number, and the situation is reverse for the region near the bottom wall. The orientation of fibers depends on Re number, however, the function of fiber volume fraction and aspect ratio is negligible. The fibers near the wall and in the central region of the channel align along the flow direction at all times, but the fibers in the other parts of the channel tend to align along the flow direction only in the downstream region.The project supported by the National Natural Science Foundation of China (10372090) and Doctoral Program of Higher Education in China (20030335001)The English text was polished by Ron Marshall     

Fiber orientation kinetics of a concentrated short glass fiber suspension in startup of simple shear flow

The common approach for simulating the evolution of fiber orientation during flow in concentrated suspensions is to use an empirically modified form of Jeffery's equation referred to as the Folgar–Tucker (F-T) model. Direct measurements of fiber orientation were performed in the startup of shear flow for a 30 wt% short glass fiber-filled polybutylene terephthalate (PBT-30); a matrix that behaves similar to a Newtonian fluid. Comparison between predictions based on the F-T model and the experimental fiber orientation show that the model over predicts the rate of fiber reorientation. Rheological measurements of the stress growth functions show that the stress overshoot phenomenon approaches a steady state at a similar strain as the fiber microstructure, at roughly 50 units. However, fiber orientation measurements suggest that a steady state is not reached as the fiber orientation continues to slowly evolve, even up to 200 strain units. The addition of a “slip” parameter to the F-T model improved the model predictions of the fiber orientation and rheological stress growth functions.     

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     

On the orientation probability distribution of flexible fibres in a contracting channel flow

The development of fibre orientation distribution in a plane contracting channel flow is investigated with combining experiments and modelling. A dilute suspension of flexible wood fibres is used in the experiments. The salient feature of the suspension is the flexibility of the fibres. To model the fibre orientation probability distribution (FOPD) a diffusion–convection equation is used. The effect of random motion, in this case turbulence, is considered with translational and rotational diffusion coefficients. In addition to providing the inlet conditions, experiments are used to determine the rotational diffusion coefficient for the model. The work addresses the problems related to the above mentioned modelling method and combines the experiments and modelling in order to understand the mechanisms affecting the development of fibre orientation.     

Finite-length effects on dynamical behavior of rod-like particles in wall-bounded turbulent flow

Combined Particle Image Velocimetry (PIV) and Particle Tracking Velocimetry (PTV) measurements have been performed in dilute suspensions of rod-like particles in wall turbulence. PIV results for the turbulence field in the water table flow apparatus compared favorably with data from Direct Numerical Simulations (DNS) of channel flow turbulence and the universality of near-wall turbulence justified comparisons with DNS of fiber-laden channel flow. In order to examine any shape effects on the dynamical behavior of elongated particles in wall-bounded turbulent flow, fibers with three different lengths but the same diameter were used. In the logarithmic part of the wall-layer, the translational fiber velocity was practically unaffected by the fiber length l. In the buffer layer, however, the fiber dynamics turned out to be severely constrained by the distance z to the wall. The short fibers accumulated preferentially in low-speed areas and adhered to the local fluid speed. The longer fibers (l/z > 1) exhibited a bi-modal probability distribution for the fiber velocity, which reflected an almost equal likelihood for a long fiber to reside in an ejection or in a sweep. It was also observed that in the buffer region, high-speed long fibers were almost randomly oriented whereas for all size cases the slowly moving fibers preferentially oriented in the streamwise direction. These phenomena have not been observed in DNS studies of fiber suspension flows and suggested l/z to be an essential parameter in a new generation of wall-collision models to be used in numerical studies.     

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.     

Dynamics of short fiber suspensions in bounded shear flow

We have studied the dynamics of non-colloidal short fiber suspensions in bounded shear flow using the Stokesian dynamics simulation. Such particles make up the microstructure of many suspensions for which the macroscopic dynamics are not well understood. The effect of wall on the fiber dynamics is the main focus of this work. For a single fiber undergoing simple shear flow between plane parallel walls the period of rotation was compared with the Jeffrey’s orbit. A fiber placed close to the wall shows significant deviation from Jeffrey’s orbit. The fiber moving near a solid wall in bounded shear flow follows a pole-vaulting motion, and its centroid location from the wall is also periodic. Simulations were also carried out to study the effect of fiber–fiber interactions on the viscosity of concentrated suspensions.     

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.     

Numerical study of concentrated fluid–particle suspension flow in a wavy channel

The particle migration effects and fluid–particle interactions occurring in the flow of highly concentrated fluid–particle suspension in a spatially modulated channel have been investigated numerically using a finite volume method. The mathematical model is based on the momentum and continuity equations for the suspension flow and a constitutive equation accounting for the effects of shear‐induced particle migration in concentrated suspensions. The model couples a Newtonian stress/shear rate relationship with a shear‐induced migration model of the suspended particles in which the local effective viscosity is dependent on the local volume fraction of solids. The numerical procedure employs finite volume method and the formulation is based on diffuse‐flux model. Semi‐implicit method for pressure linked equations has been used to solve the resulting governing equations along with appropriate boundary conditions. The numerical results are validated with the analytical expressions for concentrated suspension flow in a plane channel. The results demonstrate strong particle migration towards the centre of the channel and an increasing blunting of velocity profiles with increase in initial particle concentration. In the case of a stenosed channel, the particle concentration is lowest at the site of maximum constriction, whereas a strong accumulation of particles is observed in the recirculation zone downstream of the stenosis. The numerical procedure applied to investigate the effects of concentrated suspension flow in a wavy passage shows that the solid particles migrate from regions of high shear rate to low shear rate with low velocities and this phenomenon is strongly influenced by Reynolds numbers and initial particle concentration. Copyright © 2008 John Wiley & Sons, Ltd.     

An algebraic closure for the DNS of fiber-induced turbulent drag reduction in a channel flow

An algebraic closure for the non-Newtonian Navier–Stokes equations is presented which accounts for the effect of a dilute fiber suspension. The model is intended to be used in simulations of turbulent drag reduction by fiber additives, and can be considered as a computationally efficient alternative to the existing rheological models for fiber suspensions in turbulent wall-bounded flows. It is based on the assumption that the suspended elongated particles are aligned with the local velocity fluctuation vector. The model is proved to be Galilean invariant. One-way coupled simulations and comparison with a direct solution of the underlying Fokker–Planck equation show a considerable improvement over an existing and comparable model. Finally, two-way coupled simulations demonstrate that the model predicts flow statistics that are in very good agreement with those obtained by the moment approximation approach. Interestingly, the model is realistic in terms of the polymer concentration. Using the proposed model, the cost of simulating a drag-reduced flow in terms of CPU-time is slightly more than that of a Newtonian flow.     

Investigation of closure approximations for fiber orientation distribution in contracting turbulent flow

We have investigated the orientation state of a dilute fiber suspension flow in a planar contraction at high Reynolds numbers in turbulent flow. High speed imaging is used to directly measure the orientation distribution function at different downstream positions along the contraction centerline. The results from the direct measurement of the orientation distribution are used to evaluate the existing closure models. The results show that the fitted orthotropic and natural closure approximations give almost identical results with the best agreement to the orientation distribution in the contraction flow considered here.     

Constitutive equations for fiber suspensions in viscoelastic media

The kinetic theory of elastic dumbells with a friction factor that depends on the fiber orientation is used to obtain constitutive equations for fiber suspensions in a polymer matrix. We followed the approach of Fan (X.J. Fan, in P. Moldenaers and R. Keunings (Eds.), Theoretical and Applied Rheology, Proceedings XIth International Congress on Rheology, Brussels, Elsevier, Amsterdam, 1992, pp. 850–852), and derived equations for polymer solutions based on the FENE-P, FENE-CR, and Giesekus models. Start-up and steady-state free shear flows are studied to explore the effects of the fiber-polymer coupling as well as the fiber volume fraction. Predictions based on different types of closure approximations for the fourth-order fiber orientation tensor are also discussed.     

A model long-discontinuous-fiber filled thermoplastic melt in extensional flow

The shear cell model works for dilute fiber filled systems in extensional flow. This research investigates the suitability of the idea for highly aligned fibers in a concentrated suspension. A model fiber-filled polymer system made from nylon fibers in low-density polyethylene provided a means of controlling the material parameters. Two systems, with fiber aspect ratios of 20 and 100, containing 50% 0.5 mm fibers by volume are investigated. The thickness of the polymer layer, i.e. with fibers this size, allows bulk viscosity data to be compared with the data from the filled fluid. A weaving process created the discontinuous fiber/polyethylene preforms with high alignment of the fibers and with control of the fiber to fiber overlap. Testing the polyethylene in simple shear and extending the nylon/polyethylene provided the data needed to check the micro mechanics. A cone and plate rheometer and a capillary instrument produced the viscosity/strain rate data that characterized the specific polyethylene used in the composite. A furnace inset placed in an Instron hydraulic test machine allowed extension of the filled system at strain rates from 0.002 to 0.4 s⁻¹. The shear experiments show that the low-density polyethylene is a simple shear-thinning melt that provides a good model fluid. The extension of the filled systems shows an increase of the apparent extensional viscosity from that of neat polyethylene. Apparent viscosity rises two to three orders of magnitude for the systems investigated. The micromechanics allowed the conversion of the extensional data from the two filled systems to the shear viscosity of the polymer surrounding the fibers. The calculated polyethylene viscosity compares well with the data from the standard rheometers. The shear cell approach may be applied to highly aligned, high fiber-volume-fraction suspensions when the viscosity of the polymer is known at the scale of the film surrounding each fiber.     

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.