Simulation of coating flows with slip effects

This work is concerned with the numerical prediction of wire coating flows. Both annular tube‐tooling and pressure‐tooling type extrusion–drag flows are investigated for viscous fluids. The effects of slip at die walls are analysed and free surfaces are computed. Flow conditions around the die exit are considered, contrasting imposition of no‐slip and various instances of slip models for die wall conditions. Numerical solutions are computed by means of a time marching Taylor–Galerkin/pressure–correction finite element scheme, that demonstrates how slip conditions on die walls mitigate stress singularities at the die exit. For pressure‐tooling and with appropriate handling of slip, reduction in shear rate at the die exit may be achieved. Maximum shear rates for tube‐tooling are about one quarter of those encountered in pressure‐tooling. Equivalently, extension rates peak at land entry, and tube‐tooling values are one third of those observed for pressure‐tooling. With slip and tube‐tooling, peak shear values at die exit may be almost completely eliminated. Nevertheless, in contrast to the pressure‐tooling scenario, this produces larger peak shear rates upstream within the land region than would otherwise be the case for no‐slip. Copyright © 2000 John Wiley & Sons, Ltd.     

Solving viscoelastic free surface flows of a second‐order fluid using a marker‐and‐cell approach

This work is concerned with the numerical simulation of two‐dimensional viscoelastic free surface flows of a second‐order fluid. The governing equations are solved by a finite difference technique based on the marker‐and‐cell philosophy. A staggered grid is employed and marker particles are used to represent the fluid free surface. Full details for the approximation of the free surface stress conditions are given. The resultant code is validated and convergence is demonstrated. Numerical simulations of the extrudate swell and flow through a planar 4:1 contraction for various values of the Deborah number are presented. Copyright © 2006 John Wiley & Sons, Ltd.     

Finite element solution of three‐dimensional turbulent flows applied to mold‐filling problems

This paper presents a finite element solution algorithm for three‐dimensional isothermal turbulent flows for mold‐filling applications. The problems of interest present unusual challenges for both the physical modelling and the solution algorithm. High‐Reynolds number transient turbulent flows with free surfaces have to be computed on complex three‐dimensional geometries. In this work, a segregated algorithm is used to solve the Navier–Stokes, turbulence and front‐tracking equations. The streamline–upwind/Petrov–Galerkin method is used to obtain stable solutions to convection‐dominated problems. Turbulence is modelled using either a one‐equation turbulence model or the κ–ε two‐equation model with wall functions. Turbulence equations are solved for the natural logarithm of the turbulence variables. The change of dependent variables allows for a robust solution algorithm and good predictions even on coarse meshes. This is very important in the case of large three‐dimensional applications for which highly refined meshes result in untreatable large numbers of elements. The position of the flow front in the mold cavity is computed using a level set approach. Finally, equations are integrated in time using an implicit Euler scheme. The methodology presents the robustness and cost effectiveness needed to tackle complex industrial applications. Copyright © 2000 John Wiley & Sons, Ltd.     

Simulation of pressure‐tooling wire‐coating flow with Phan‐Thien/Tanner models

Annular pressure‐tooling extrusion is simulated for a low density polymer melt using a Taylor–Petrov–Galerkin finite element scheme. This represents industrial‐scale wire‐coating. Viscoelastic fluids are modeled via three forms of Phan‐Thien/Tanner (PTT) constitutive laws employed for short‐die and full specification pressure‐tooling. Effects of variation in Weissenberg number (We) and polymeric viscosity are investigated. Particular attention is paid to mesh refinement to predict accurate results. The impact of variation in shear‐thinning and strain‐softening properties is considered upon the modelling predictions. For the short‐die flow, the influence of the lack of strain softening is identified. For the full‐die flow and more severe deformation rates, the linear PTT model failed to converge. In contrast, the exponential PTT model is found to be more stable numerically and to adequately reflect the material response. Comparing short‐die and full‐die pressure‐tooling results, shear rates increase 10‐fold, while strain rates increase one hundred times. Copyright © 2002 John Wiley & Sons, Ltd.     

Time‐related element‐free Taylor–Galerkin method with non‐splitting decoupling process for incompressible steady flow

The time‐related element‐free Taylor–Galerkin method with non‐splitting decoupling process (EFTG‐NSD) is proposed for the simulation of steady flows. The goal of the present paper is twofold. One is to raise the efficiency of the time‐related methods for solving steady flow problems, and the other is to obtain a good stability. The EFTG‐NSD method, which uses the time‐related Navier–Stokes equations to describe steady flows, does not care about the intermediate process and obtains solution of steady flows through time marching. Different from the classical time‐related fractional step methods, the EFTG‐NSD method decouples the Navier–Stokes equations without any operator‐splitting and correction. Because the elimination of correction at each iteration step reduces the computation cost, the EFTG‐NSD method possesses higher computation efficiency. In addition, the EFTG‐NSD method has a good stability due to the use of the Taylor–Galerkin formula in time and space discretization. Furthermore, the method combining element‐free Galerkin method with Taylor–Galerkin method is an important supplement of the element‐free Galerkin method for solving flow problems. Copyright © 2011 John Wiley & Sons, Ltd.     

A two‐dimensional vertical non‐hydrostatic σ model with an implicit method for free‐surface flows

An implicit finite difference model in the σ co‐ordinate system is developed for non‐hydrostatic, two‐dimensional vertical plane free‐surface flows. To accurately simulate interaction of free‐surface flows with uneven bottoms, the unsteady Navier–Stokes equations and the free‐surface boundary condition are solved simultaneously in a regular transformed σ domain using a fully implicit method in two steps. First, the vertical velocity and pressure are expressed as functions of horizontal velocity. Second, substituting these relationship into the horizontal momentum equation provides a block tri‐diagonal matrix system with the unknown of horizontal velocity, which can be solved by a direct matrix solver without iteration. A new treatment of non‐hydrostatic pressure condition at the top‐layer cell is developed and found to be important for resolving the phase of wave propagation. Additional terms introduced by the σ co‐ordinate transformation are discretized appropriately in order to obtain accurate and stable numerical results. The developed model has been validated by several tests involving free‐surface flows with strong vertical accelerations and non‐linear waves interacting with uneven bottoms. Comparisons among numerical results, analytical solutions and experimental data show the capability of the model to simulate free‐surface flow problems. Copyright © 2004 John Wiley & Sons, Ltd.     

An adaptive numerical scheme for solving incompressible 2‐phase and free‐surface flows

In this paper, we present a numerical scheme for solving 2‐phase or free‐surface flows. Here, the interface/free surface is modeled using the level‐set formulation, and the underlying mesh is adapted at each iteration of the flow solver. This adaptation allows us to obtain a precise approximation for the interface/free‐surface location. In addition, it enables us to solve the time‐discretized fluid equation only in the fluid domain in the case of free‐surface problems. Fluids here are considered incompressible. Therefore, their motion is described by the incompressible Navier‐Stokes equation, which is temporally discretized using the method of characteristics and is solved at each time iteration by a first‐order Lagrange‐Galerkin method. The level‐set function representing the interface/free surface satisfies an advection equation that is also solved using the method of characteristics. The algorithm is completed by some intermediate steps like the construction of a convenient initial level‐set function (redistancing) as well as the construction of a convenient flow for the level‐set advection equation. Numerical results are presented for both bifluid and free‐surface problems.     

An implicit two‐dimensional non‐hydrostatic model for free‐surface flows

An implicit finite volume model in sigma coordinate system is developed to simulate two‐dimensional (2D) vertical free surface flows, deploying a non‐hydrostatic pressure distribution. The algorithm is based on a projection method which solves the complete 2D Navier–Stokes equations in two steps. First the pressure term in the momentum equations is excluded and the resultant advection–diffusion equations are solved. In the second step the continuity and the momentum equation with only the pressure terms are solved to give a block tri‐diagonal system of equation with pressure as the unknown. This system can be solved by a direct matrix solver without iteration. A new implicit treatment of non‐hydrostatic pressure, similar to the lower layers is applied to the top layer which makes the model free of any hydrostatic pressure assumption all through the water column. This treatment enables the model to evaluate both free surface elevation and wave celerity more accurately. A series of numerical tests including free‐surface flows with significant vertical accelerations and nonlinear behaviour in shoaling zone are performed. Comparison between numerical results, analytical solutions and experimental data demonstrates a satisfactory performance. Copyright © 2006 John Wiley & Sons, Ltd.     

A new positive‐definite regularization of incompressible Navier–Stokes equations discretized with Q1/P0 finite element

A new regularization method is proposed for the Galerkin approximation of the incompressible Navier–Stokes equations with Q1/P0 element, by newly introducing a square‐type linear form into the variational divergence‐free constraint regularized with the global pressure jump (GPJ) method. The addition of the square‐type linear form is intended to eliminate the hydrostatic pressure mode appearing in confined flows, and to make the discretized matrix positive definite and then non‐singular without the pressure pegging trick. Effects of the free parameters for the regularization on the solutions are numerically examined with a 2‐D driven cavity flow problem. Furthermore, the convergences in the conjugate gradient iteration for the solution of the pressure Poisson equation are compared among the mixed method, the GPJ method and the present method for both leaky and non‐leaky 3‐D driven cavity flows. Finally, the non‐leaky 3‐D cavity flows at different Re numbers are solved to compare with the literature data and to demonstrate the accuracy of the proposed method. Copyright © 2003 John Wiley & Sons, Ltd.     

An implicit numerical algorithm for solving non‐hydrostatic free‐surface flow problems

Details are given of the development of a two‐dimensional vertical numerical model for simulating unsteady free‐surface flows, using a non‐hydrostatic pressure distribution. In this model, the Reynolds equations and the kinematic free‐surface boundary condition are solved simultaneously, so that the water surface elevation can be integrated into the solution and solved for, together with the velocity and pressure fields. An efficient numerical algorithm has been developed, deploying implicit parameters similar to those used in the Crank–Nicholson method, and generating a block tri‐diagonal algebraic system of equations. The model has been applied to simulate a range of unsteady flow problems involving relatively strong vertical accelerations. The results show that the numerical algorithm described is able to produce accurate predictions and is also easy to apply. Copyright © 2001 John Wiley & Sons, Ltd.     

3D free‐surface flow computation using a RANSE/Fourier–Kochin coupling

A coupling method for numerical calculations of steady free‐surface flows around a body is presented. The fluid domain in the neighbourhood of the hull is divided into two overlapping zones. Viscous effects are taken in account near the hull using Reynolds‐averaged Navier–Stokes equations (RANSE), whereas potential flow provides the flow away from the hull. In the internal domain, RANSE are solved by a fully coupled velocity, pressure and free‐surface elevation method. In the external domain, potential‐flow theory with linearized free‐surface condition is used to provide boundary conditions to the RANSE solver. The Fourier–Kochin method based on the Fourier–Kochin formulation, which defines the velocity field in a potential‐flow region in terms of the velocity distribution at a boundary surface, is used for that purpose. Moreover, the free‐surface Green function satisfying this linearized free‐surface condition is used. Calculations have been successfully performed for steady ship‐waves past a serie 60 and then have demonstrated abilities of the present coupling algorithm. Copyright © 2003 John Wiley & Sons, Ltd.     

A fully hydrodynamic model for three‐dimensional,free‐surface flows

The hydrostatic pressure assumption has been widely used in studying water movements in rivers, lakes, estuaries, and oceans. While this assumption is valid in many cases and has been successfully used in numerous studies, there are many cases where this assumption is questionable. This paper presents a three‐dimensional, hydrodynamic model for free‐surface flows without using the hydrostatic pressure assumption. The model includes two predictor–corrector steps. In the first predictor–corrector step, the model uses hydrostatic pressure at the previous time step as an initial estimate of the total pressure field at the new time step. Based on the estimated pressure field, an intermediate velocity field is calculated, which is then corrected by adding the non‐hydrostatic component of the pressure to the estimated pressure field. A Poisson equation for non‐hydrostatic pressure is solved before the second intermediate velocity field is calculated. The final velocity field is found after the free surface at the new time step is computed by solving a free‐surface correction equation. The numerical method was validated with several analytical solutions and laboratory experiments. Model results agree reasonably well with analytical solutions and laboratory results. Model simulations suggest that the numerical method presented is suitable for fully hydrodynamic simulations of three‐dimensional, free‐surface flows. Copyright © 2003 John Wiley & Sons, Ltd.     

A direct reinitialization approach of level‐set/splitting finite element method for simulating incompressible two‐phase flows

Computation of a moving interface by the level‐set (LS) method typically requires reinitialization of LS function. An inaccurate execution of reinitialization results in incorrect free surface capturing and thus errors such as mass gain/loss so that an accurate and robust reinitialization process in the LS method is essential for the simulation of free surface flows. In the present study, we pursue further development of the reinitialization process, which directly corrects the LS function after advection is carried out by using the normal vector to the interface instead of solving the reinitialization equation of hyperbolic type. The Taylor–Galerkin method is adopted to discretize the advection equation of the LS function and the P1P1 splitting finite element method is applied to solve the Navier–Stokes equation. The proposed algorithm is validated with the well‐known benchmark problems, i.e. stretching of a circular fluid element, time‐reversed single‐vortex, solitary wave propagation, broken dam flow and filling of a container. The simulation results of these flows are in good agreement with previously existing experimental and numerical results. Copyright © 2010 John Wiley & Sons, Ltd.     

CFD simulation of two‐ and three‐dimensional free‐surface flow

The paper describes the implementation of moving‐mesh and free‐surface capabilities within a 3‐d finite‐volume Reynolds‐averaged‐Navier–Stokes solver, using surface‐conforming multi‐block structured meshes. The free‐surface kinematic condition can be applied in two ways: enforcing zero net mass flux or solving the kinematic equation by a finite‐difference method. The free surface is best defined by intermediate control points rather than the mesh vertices. Application of the dynamic boundary condition to the piezometric pressure at these points provides a hydrostatic restoring force which helps to eliminate any unnatural free‐surface undulations. The implementation of time‐marching methods on moving grids are described in some detail and it is shown that a second‐order scheme must be applied in both scalar‐transport and free‐surface equations if flows driven by free‐surface height variations are to be computed without significant wave attenuation using a modest number of time steps. Computations of five flows of theoretical and practical interest—forced motion in a pump, linear waves in a tank, quasi‐1d flow over a ramp, solitary wave interaction with a submerged obstacle and 3‐d flow about a surface‐penetrating cylinder—are described to illustrate the capabilities of our code and methods. Copyright © 2003 John Wiley & Sons, Ltd.     

A semi‐implicit finite difference method for non‐hydrostatic,free‐surface flows

In this paper a semi‐implicit finite difference model for non‐hydrostatic, free‐surface flows is analyzed and discussed. It is shown that the present algorithm is generally more accurate than recently developed models for quasi‐hydrostatic flows. The governing equations are the free‐surface Navier–Stokes equations defined on a general, irregular domain of arbitrary scale. The momentum equations, the incompressibility condition and the equation for the free‐surface are integrated by a semi‐implicit algorithm in such a fashion that the resulting numerical solution is mass conservative and unconditionally stable with respect to the gravity wave speed, wind stress, vertical viscosity and bottom friction. Copyright © 1999 John Wiley & Sons, Ltd.     

Three‐dimensional numerical modelling of free surface flows with non‐hydrostatic pressure

A three‐dimensional numerical model is developed for incompressible free surface flows. The model is based on the unsteady Reynolds‐averaged Navier–Stokes equations with a non‐hydrostatic pressure distribution being incorporated in the model. The governing equations are solved in the conventional sigma co‐ordinate system, with a semi‐implicit time discretization. A fractional step method is used to enable the pressure to be decomposed into its hydrostatic and hydrodynamic components. At every time step one five‐diagonal system of equations is solved to compute the water elevations and then the hydrodynamic pressure is determined from a pressure Poisson equation. The model is applied to three examples to simulate unsteady free surface flows where non‐hydrostatic pressures have a considerable effect on the velocity field. Emphasis is focused on applying the model to wave problems. Two of the examples are about modelling small amplitude waves where the hydrostatic approximation and long wave theory are not valid. The other example is the wind‐induced circulation in a closed basin. The numerical solutions are compared with the available analytical solutions for small amplitude wave theory and very good agreement is obtained. Copyright © 2002 John Wiley & Sons, Ltd.     

Computation of two‐dimensional flows past ram‐air parachutes

Computational results for flow past a two‐dimensional model of a ram‐air parachute with leading edge cut are presented. Both laminar (Re=10⁴) and turbulent (Re=10⁶) flows are computed. A well‐proven stabilized finite element method (FEM), which has been applied to various flow problems earlier, is utilized to solve the incompressible Navier–Stokes equations in the primitive variables formulation. The Baldwin–Lomax model is employed for turbulence closure. Turbulent flow computations past a Clarck‐Y airfoil without a leading edge cut, for α=7.5°, result in an attached flow. The leading edge cut causes the flow to become unsteady and leads to a significant loss in lift and an increase in drag. The flow inside the parafoil cell remains almost stagnant, resulting in a high value of pressure, which is responsible for giving the parafoil its shape. The value of the lift‐to‐drag ratio obtained with the present computations is in good agreement with those reported in the literature. The effect of the size and location of the leading edge cut is studied. It is found that the flow on the upper surface of the parafoil is fairly insensitive to the configuration of the cut. However, the flow quality on the lower surface improves as the leading edge cut becomes smaller. The lift‐to‐drag ratio for various configurations of the leading edge cut varies between 3.4 and 5.8. It is observed that even though the time histories of the aerodynamic coefficients from the laminar and turbulent flow computations are quite different, their time‐averaged values are quite similar. Copyright © 2001 John Wiley & Sons, Ltd.     

Time‐dependent finite element simulations of a shear‐thinning viscoelastic fluid with application to blood flow

A new finite element method is developed to simulate time‐dependent viscoelastic shear‐thinning flows characterized by the generalized Oldroyd‐B model. The focus of the algorithm is improved stability through a free‐energy dissipative scheme by using low‐order piecewise‐constant finite element approximations for stress. The algorithm is further modified by incorporating a pressure‐projection method, a DG‐upwinding scheme, a symmetric interior penalty DG method to solve the elliptic pressure‐update equation and a geometric multigrid preconditioner. The improved stability and cost to accuracy is compared when using higher order discontinuous bilinear approximation, where in addition, we consider the influence of a slope limiter for these elements. The algorithm is applied to the 2D start‐up‐driven cavity problem, and the stability of the free energy is illustrated and compared between element choices. An application of the model to modelling blood in small arterioles and channels is considered by simulating pulsatile blood flow through a stenotic arteriole. The individual influences of viscoelasticity and shear‐thinning within the generalized Oldroyd‐B model are investigated by comparing results to the Newtonian, generalized Newtonian and Oldroyd‐B models. Copyright © 2014 John Wiley & Sons, Ltd.     

Computations of two passing‐by high‐speed trains by a relaxation overset‐grid algorithm

This paper presents a relaxation algorithm, which is based on the overset grid technology, an unsteady three‐dimensional Navier–Stokes flow solver, and an inner‐ and outer‐relaxation method, for simulation of the unsteady flows of moving high‐speed trains. The flow solutions on the overlapped grids can be accurately updated by introducing a grid tracking technique and the inner‐ and outer‐relaxation method. To evaluate the capability and solution accuracy of the present algorithm, the computational static pressure distribution of a single stationary TGV high‐speed train inside a long tunnel is investigated numerically, and is compared with the experimental data from low‐speed wind tunnel test. Further, the unsteady flows of two TGV high‐speed trains passing by each other inside a long tunnel and at the tunnel entrance are simulated. A series of time histories of pressure distributions and aerodynamic loads acting on the train and tunnel surfaces are depicted for detailed discussions. Copyright © 2004 John Wiley & Sons, Ltd.     

A semi‐implicit numerical method for the free‐surface Navier–Stokes equations

Semi‐implicit methods are known for being the basis of simple, efficient, accurate, and stable numerical algorithms for simulating a large variety of geophysical free‐surface flows. Geophysical flows are typically characterized by having a small vertical scale as compared with their horizontal extents. Hence, the hydrostatic approximation often applies, and the free surface can be conveniently represented by a single‐valued function of the horizontal coordinates. In the present investigation, semi‐implicit methods are extended to complex free‐surface flows that are governed by the full incompressible Navier–Stokes equations and are delimited by solid boundaries and arbitrarily shaped free‐surfaces. The primary dependent variables are the velocity components and the pressure. Finite difference equations for momentum, and a finite volume discretization for continuity, are derived in such a fashion that, after simple manipulation, the resulting pressure equation yields a well‐posed piecewise linear system from which both the pressure and the fluid volume within each computational cell are naturally derived. This system is efficiently solved by a nested Newton type iterative scheme, and the resulting fluid volumes are assured to be nonnegative and bounded from above by the available cell volumes. The time step size is not restricted by stability conditions dictated by surface wave speed, but can be freely chosen just to achieve the desired accuracy. Several examples illustrate the model applicability to a large range of complex free‐surface flows and demonstrate the effectiveness of the proposed algorithm. Copyright © 2013 John Wiley & Sons, Ltd.