Simulation of polymeric flows in the injection moulding process

Recent progress in the simulation of polymeric flows of two key problems in the injection moulding process, carried out by a team at Cornell University, is briefly described. For the filling of cooled thin cavities, the fluid is characterized by a power-law viscosity with exponential temperature dependence, and interaction between the transient thermal boundary-layer and the core flow in a domain with moving boundary is essential. The earlier procedure of Hieber and Shen is modified in two aspects: a boundary-integral formulation replaces the finite-element treatment of the pressure, and an ‘energy integral’ approach is used for the transient temperature. The second problem is the steady visco-elastic flow in the juncture region where sudden changes of the geometry and large strain rates occur. The constitutive equation is postulated according to the Leonov model. The main features in the numerical implementation are: integration along a streamline to determine the elastic deformation tensors for a given velocity field, and finite-element treatment (in time-dependent form) of the pressure and fields for given stresses. In an example where the contraction ratio is 7:1, results for nominal Deborah number exceeding 100 show no numerical instability. (However, for this problem, the true Weissenberg number, i.e. the ratio of local first-normal-stress difference to shear stress turns out to be generally O(10).) The predictions also correlate very well with experimental birefringence measurements.     

The axisymmetric contraction–expansion: the role of extensional rheology on vortex growth dynamics and the enhanced pressure drop

The flow of a polystyrene Boger fluid through axisymmetric contraction–expansions having various contraction ratios (2≤β≤8) and varying degrees of re-entrant corner curvatures are studied experimentally over a large range of Deborah numbers. The ideal elastic fluid is dilute, monodisperse and well characterized in both shear and transient uniaxial extension. A large enhanced pressure drop above that of a Newtonian fluid is observed independent of contraction ratio and re-entrant corner curvature. Streak images, laser Doppler velocimetry (LDV) and digital particle image velocimetry (DPIV) are used to investigate the flow kinematics upstream of the contraction plane. LDV is used to measure velocity fluctuation in the mean flow field and to characterize a global elastic flow instability which occurs at large Deborah numbers. For a contraction ratio of β=2, a steady elastic lip vortex is observed while for contraction ratios of 4≤β≤8, no lip vortex is observed and a corner vortex is seen. Rounding the re-entrant corner leads to shifts in the onset of the flow transitions at larger Deborah numbers, but does not qualitatively change the overall structure of the flow field. We describe a simple rescaling of the deformation rate which incorporates the effects of lip curvature and allows measurements of vortex size, enhanced pressure drop and critical Deborah number for the onset of elastic instability to be collapsed onto master curves. Transient extensional rheology measurements are utilized to explain the significant differences in vortex growth pathways (i.e. elastic corner vortex versus lip vortex growth) observed between the polystyrene Boger fluids used in this research and polyisobutylene and polyacrylamide Boger fluids used in previous contraction flow experiments. We show that the role of contraction ratio on vortex growth dynamics can be rationalized by considering the dimensionless ratio of the elastic normal stress difference in steady shear flow to those in transient uniaxial extension. It appears that the differences in this normal stress ratio for different fluids at a given Deborah number arise from variations in solvent quality or excluded volume effects.     

Non-Newtonian biomagnetic fluid flow through a stenosed bifurcated artery with a slip boundary condition

The effects of a velocity slip and an external magnetic field on the flow of biomagnetic fluid(blood) through a stenosed bifurcated artery are investigated by using ANSYS FLUENT. Blood is regarded as a non-Newtonian power-law fluid, and the magnetization and electrical conductivity are considered in the mathematical model.The no-slip condition is replaced by the first-order slip condition. The slip boundary condition and magnetic force are compiled in the solver by the user-defined function(UDF)...     

Investigation of thermal convection in water columns using particle image velocimetry

Particle image velocity measurements were applied on thermally driven convection at low Rayleigh numbers. In a model experiment using a water column heated from bottom and cooled from above, the velocity field was studied at different vertical temperature gradients. In the testing facility with high aspect ratio (about 19) representing a 1-m-long column with 5?cm diameter, occurrence of free convection was verified for destabilizing temperature gradients of 0.1–2?K/m. The PIV results revealed that significant flow exists already at low vertical temperature gradients. The velocity of the stable large-scale circulations increased linearly with temperature gradient (<1?K/m) from 8?×?10^?5 to 1?×?10^?3?m/s. At higher temperature gradients (1–2?K/m), a transition from quasi-stationary into time-dependent flow was observed, where convection cells changed position, number, and form temporarily. The motivation of this research was to gain more insight into density-driven convection in boreholes and groundwater monitoring wells.     

Effect of a small axisymmetric contraction on grid turbulence

Measurements downstream of a grid followed by a contraction with an area ratio of 1.36 have been made with a one-component vorticity probe. The velocity data indicate that there is indeed an improvement in isotropy of the large scales when such a contraction is used. In particular, the spectrum of u loses a significant amount of low frequency energy and its peak is shifted towards that of v. Although the v spectrum is less affected than the u spectrum, the relative magnitudes of the u and v spectra satisfy isotropy more closely with than without the contraction. In particular, isotropy is most closely approximated when the contraction is used in combination with a grid designed to minimise vortex shedding. The lateral vorticity spectrum is essentially unaffected, irrespective of the grid that is used or the magnitude of the wavenumber.     

Three-dimensional flow of Newtonian and Boger fluids in square–square contractions

The flow of a Newtonian fluid and a Boger fluid through sudden square–square contractions was investigated experimentally aiming to characterize the flow and provide quantitative data for benchmarking in a complex three-dimensional flow. Visualizations of the flow patterns were undertaken using streak-line photography, detailed velocity field measurements were conducted using particle image velocimetry (PIV) and pressure drop measurements were performed in various geometries with different contraction ratios. For the Newtonian fluid, the experimental results are compared with numerical simulations performed using a finite volume method, and excellent agreement is found for the range of Reynolds number tested (Re₂ ≤ 23). For the viscoelastic case, recirculations are still present upstream of the contraction but we also observe other complex flow patterns that are dependent on contraction ratio (CR) and Deborah number (De₂) for the range of conditions studied: CR = 2.4, 4, 8, 12 and De₂ ≤ 150. For low contraction ratios strong divergent flow is observed upstream of the contraction, whereas for high contraction ratios there is no upstream divergent flow, except in the vicinity of the re-entrant corner where a localized atypical divergent flow is observed. For all contraction ratios studied, at sufficiently high Deborah numbers, strong elastic vortex enhancement upstream of the contraction is observed, which leads to the onset of a periodic complex flow at higher flow rates. The vortices observed under steady flow are not closed, and fluid elasticity was found to modify the flow direction within the recirculations as compared to that found for Newtonian fluids. The entry pressure drop, quantified using a Couette correction, was found to increase with the Deborah number for the higher contraction ratios.     

Radiation effect on mixed convection from a horizontal surface in a porous medium

The effect of thermal radiation on the non-Darcy mixed convection flow over a non-isothermal horizontal surface immersed in a saturated porous medium has been studied. The wall temperature is assumed to have a power-law variation with the distance measured from the leading edge of the plate. The non-linear coupled parabolic partial differential equations governing the flow have been solved numerically using a finite-difference scheme. For some particular cases, the self-similar solution has also been obtained. The heat transfer is found to be strongly influenced by the radiative flux number, buoyancy parameter, variation of wall temperature, non-Darcy parameter and the nature of the free stream velocity.     

Variable viscosity and slip velocity effects on the flow and heat transfer of a power-law fluid over a non-linearly stretching surface with heat flux and thermal radiation

The flow and heat transfer of a non-Newtonian power-law fluid over a non-linearly stretching surface has been studied numerically under conditions of constant heat flux and thermal radiation and evaluated for the effect of wall slip. The governing partial differential equations are transformed into a set of coupled non-linear ordinary differential equations which are using appropriate boundary conditions for various physical parameters. The remaining set of ordinary differential equations is solved numerically by fourth-order Runge–Kutta method using the shooting technique. The effects of the viscosity, the slip velocity, the radiation parameter, power-law index, and the Prandtl number on the flow and temperature profiles are presented. Moreover, the local skin friction and Nusselt numbers are presented. Comparison of numerical results is made with the earlier published results under limiting cases.     

Investigation on effect of drag models on flow behavior of power-law fluid–solid two-phase flow in fluidized bed

In this study, a Eulerian-Eulerian two-fluid model combined with the kinetic theory of granular flow is adopted to simulate power-law fluid–solid two-phase flow in the fluidized bed. Two new power-law liquid–solid drag models are proposed based on the rheological equation of power-law fluid and pressure drop. One called model A is a modified drag model considering tortuosity of flow channel and ratio of the throat to pore, and the other called model B is a blending drag model combining drag coefficients of high and low particle concentrations. Predictions are compared with experimental data measured by Lali et al., where the computed porosities from model B are closer to the measured data than other models. Furthermore, the predicted pressure drop rises as liquid velocity increases, while it decreases with the increase of particle size. Simulation results indicate that the increases of consistency coefficient and flow behavior index lead to the decrease of drag coefficient, and particle concentration, granular temperature, granular pressure, and granular viscosity go down accordingly.     

Non-Newtonian flow in microporous structures under the electroviscous effect

Single phase non-Newtonian microporous flow combined with the electroviscous effect is investigated in the pore-scale under conditions of various rheological properties and electrokinetic parameters. The lattice Boltzmann method is employed to solve both the electric potential field and flow velocity field. The simulation of commonly used power-law non-Newtonian flow shows that the electroviscous effect on the flow depends on both the fluid rheological behavior and pore surface area ratio significantly. For the shear thinning fluid with power-law exponent n < 1, the fluid viscosity near the wall is smaller and the electrovicous effect plays a more important role compared to the Newtonian fluid and shear thickening fluid. The high pore surface area ratio in the porous structure increases the electroviscous force and the induced flow resistance becomes important even to the flow of Newtonian and shear thickening fluids.     

Flow characteristics and mixing performance of electrokinetically driven non-Newtonian fluid in contraction–expansion microchannel

A numerical investigation is performed into the flow characteristics and mixing performance of electrokinetically driven non-Newtonian fluid in a contraction–expansion microchannel. In the study, the rheological behavior of the fluid is characterized using a power-law model. The results show that the volumetric flow rate reduces as the flow behavior index increases, and thus an improved mixing performance is obtained. Furthermore, it is shown that for all considered values of the flow behavior index, the mixing performance can be enhanced by increasing the ratio of the main channel width to the contraction channel width, extending the length of the contraction channel, assigning a smaller value to the nondimensional Debye–Hückel parameter, and applying an appropriate electric field strength. Finally, it is shown that although the mixing efficiency reduces with a reducing flow behavior index, an acceptable mixing performance can still be obtained given an appropriate specification of the flow conditions and geometry parameters.     

Application of Fractal Grids in Industrial Low-Swirl Combustion

Fractal-grid-generated turbulence is a successful technique to significantly increase the reaction rate in the center of a low-swirl flame. Previous results (Verbeek et al. Combust. Flame 162(1), 129–143, 2015) are promising, but the experiments are only performed using natural gas at a single equivalence ratio and flow rate. In industry, the need arises to adapt gas turbines to a wider range of fuels, such as biogas and syngas. To simulate these other fuels, natural gas is enriched with up to 30 % hydrogen (molar based). By means of planar OH-LIF, the turbulent flame speed is assessed. It is shown that the beneficial effect of fractal-grid-generated turbulence remains upon hydrogen enrichment. The fractal grids enhance the combustion in an energy efficient way, irrespective of the hydrogen fraction. Moreover, the characteristic linear relation of the normalized local consumption speed versus the normalized rms velocity holds for the investigated range, with an increasing coefficient upon hydrogen enrichment. For industry, a wide operability range is essential to operate at part load, therefore the lean stability limit is investigated, as well. It is shown that fractal grids increase the lean stability limit, i.e., the adiabatic flame temperature at which blow off occurs, by 50 K, compared to a standard grid. Increasing the bulk flow significantly increases the lean stability limit and the difference between the two investigated grid types increases upon hydrogen enrichment. Hydrogen addition results in a decrease in the lean stability limit, regardless of the grid. A positive correlation was found between the adiabatic flame temperature at blow-off and the rms velocity at the flame brush. The outcome of the presented study provides, despite a slightly increased lean stability limit, a promising prospect for the application of fractal grids in industrial low-swirl combustion.     

An investigation on internal thermal flow of non-Newtonian fluid

In the present paper an unsteady thermal flow of non-Newtonian fluid is investigated which is of the fiow into axisymmetric mould cavity. In the second part an unsteady thermal flow of upper-convected Maxwell fluid is studied, For the flow into mould cavity the constitutive equation of power-law fluid is used as a rheological model of polymer fluid. The apparent viscosity is considered as a function of shear rate and temperature. A characteristic viscosity is introduced in order to avoid the nonlinearity due to the temperature dependence of the apparent viscosity. As the viscosity of the fluid is relatively high the flow of the thermal fluid can be considered as a flow of fully developed velocity field. However, the temperature field of the fluid fiow is considered as an unsteady one. The governing equations are constitutive equation, momentum equation of steady flow and energy conservation equation of non-steady form. The present system of equations has been solved numerically by the splitting differen     

A finite element analysis of the steady laminar entrance flow in a 90° curved tube

A standard Galerkin finite element penalty function method is used to approximate the solution of the three-dimensional Navier–Stokes equations for steady incompressible Newtonian entrance flow in a 90° curved tube (curvature ratio δ = 1/6) for a triple of Dean numbers (κ = 41, 122 and 204). The computational results for the intermediate Dean number (κ = 122) are compared with the results of laser–Doppler velocity measurements in an equivalent experimental model. For both the axial and secondary velocity components, fair agreement between the computational and experimental results is found.     

Magnetohydrodynamic stagnation-point flow of a power-law fluid towards a stretching surface

Steady two-dimensional stagnation-point flow of an electrically conducting power-law fluid over a stretching surface is investigated when the surface is stretched in its own plane with a velocity proportional to the distance from the stagnation-point. We have discussed the uniqueness of the solution except when the ratio of free stream velocity and stretching velocity is equal to 1. The effect of magnetic field on the flow characteristic is explored numerically and it is concluded that the velocity at a point decreases/increases with increase in the magnetic field when the free stream velocity is less/greater than the stretching velocity. It is further observed that for a given value of magnetic parameter M, the dimensionless shear stress coefficient |F^″(0)| increases with increase in power-law index n when the value of the ratio of free stream velocity and stretching velocity is close to 1 but not equal to 1. But when the value of this ratio further differs from 1, the variation of |F^″(0)| with n is non-monotonic.     

MHD flow and heat transfer of a power-law non-Newtonian nanofluid (Cu–H<Subscript>2</Subscript>O) over a vertical stretching sheet

A steady-state mixed convection boundary layer flow of an electrically conducting nanofluid (Cu–H₂O) obeying a power-law model in the presence of an alternating magnetic field due to a stretching vertical heated sheet is investigated numerically through the use of Wolfram Mathematica. The surface stretching velocity and the surface temperature are assumed to vary as linear functions of the distance from the origin. A similarity solution is presented, which depends on the nanoparticle volume fraction, power-law parameter, magnetic field parameter, buoyancy convection parameter, and modified Prandtl number.     

On thermal boundary layer of a non-Newtonian fluid on a power-law stretched surface of variable temperature with suction or injection

 Heat transfer characteristics of a non-Newtonian fluid on a power-law stretched surface of variable temperature with suction or injection were investigated. Similarity solutions of the laminar boundary layer equations describing heat transfer and fluid flow in a quiescent fluid were obtained and solved numerically. Velocity and temperature profiles as well as the Nusselt number, Nu, were studied for two thermal boundary conditions; uniform surface temperature and variable surface temperature, for different parameters; Prandtl number Pr, temperature exponent b, velocity exponent m, injection parameter d and power-law index n. It was found that decreasing injection parameter d, and power-law index n and increasing Prandtl number Pr and surface temperature exponent b enhance the heat transfer coefficient. Received on 27 April 2000     

Application of the PITM Method Using Inlet Synthetic Turbulence Generation for the Simulation of the Turbulent Flow in a Small Axisymmetric Contraction

We investigate the turbulence modeling of second moment closure used both in RANS and PITM methodologies from a fundamental point of view and its capacity to predict the flow in a low turbulence wind tunnel of small axisymmetric contraction designed by Uberoi and Wallis. This flow presents a complex phenomenon in physics of fluid turbulence. The anisotropy ratio of the turbulent stresses τ ₁₁/τ ₂₂ initially close to 1.4 returns to unity through the contraction, but surprisingly, this ratio gradually increases to its pre-contraction value in the uniform section downstream the contraction. This point constitutes the interesting paradox of the Uberoi and Wallis experiment. We perform numerical simulations of the turbulent flow in this wind tunnel using both a Reynolds stress model developed in RANS modeling and a subfilter scale stress model derived from the partially integrated transport modeling method. With the aim of reproducing the experimental grid turbulence resulting from the effects of the square-mesh biplane grid on the uniform wind tunnel stream, we develop a new analytical spectral method of generation of pseudo-random velocity fields in a cubic box. These velocity fields are then introduced in the channel using a matching numerical technique. Both RANS and PITM simulations are performed on several meshes to study the effects of the contraction on the mean velocity and turbulence. As a result, it is found that the RANS computation using the Reynolds stress model fails to reproduce the increase of anisotropy in the centerline of the channel after passing the contraction. In the contrary, the PITM simulation predicts fairly well this turbulent flow according to the experimental data, and especially, the “return to anisotropy” in the straight section of the channel downstream the contraction. This work shows that the PITM method used in conjunction with an analytical synthetic turbulence generation as inflow is well suited for simulating this flow, while allowing a drastic reduction of the computational resources.     

Forced Convection Heat Transfer on a Flat Plate Embedded in Porous Media for Power-Law Fluids

The effect of the presence of an isotropic solid matrix on the forced convection heat transfer rate from a flat plate to power-law non- Newtonian fluid-saturated porous medium, has been investigated. Numerical results are presented for the distribution of velocity and temperature profiles within the boundary layer. The effects of the flow index, first-order and second-order resistance on the velocity, and temperature profiles are discussed. The missing wall values of the velocity and thermal functions are tabulated.     

Electroviscous effects in steady fully developed flow of a power-law liquid through a cylindrical microchannel

Electroviscous effects in steady, fully developed, pressure-driven flow of power-law liquids through a uniform cylindrical microchannel have been investigated numerically by solving the Poisson–Boltzmann and the momentum equations using a finite difference method. The pipe wall is considered to have uniform surface charge density and the liquid is assumed to be a symmetric 1:1 electrolyte solution. Electroviscous resistance reduces the velocity adjacent to the wall, relative to the velocity on the axis. The effect is shown to be greater when the liquid is shear-thinning, and less when it is shear-thickening, than it is for Newtonian flow. For overlapping electrical double layers and elevated surface charge density, the electroviscous reduction in the near-wall velocity can form an almost stationary (zero shear) layer there when the liquid is shear-thinning. In that case, the liquid behaves approximately as if it is flowing through a channel of reduced diameter. The induced axial electrical field shows only a weak dependence on the power-law index with the dependence being greatest for shear-thinning liquids. This field exhibits a local maximum as surface charge density increases from zero, even though the corresponding electrokinetic resistance increases monotonically. The magnitude of the electroviscous effect on the apparent viscosity, as measured by the ratio of the apparent and physical consistency indices, decreases monotonically as the power-law index increases. Thus, overall, the electroviscous effect is stronger in shear-thinning, and weaker in shear-thickening liquids, than it is when the liquid is Newtonian.