The intersection marker method for 3D interface tracking of deformable surfaces in finite volumes

Currently, the majority of computational fluid dynamics (CFD) codes use the finite volume method to spatially discretise the computational domain, sometimes as an array of cubic control volumes. The Finite volume method works well with single‐phase flow simulations, but two‐phase flow simulations are more challenging because of the need to track the surface interface traversing and deforming within the 3D grid. Surface area and volume fraction details of each interface cell must be accurately accounted for, in order to calculate for the momentum exchange and rates of heat and mass transfer across the interface. To attain a higher accuracy in two‐phase flow CFD calculations, the intersection marker (ISM) method is developed. The ISM method is a hybrid Lagrangian–Eulerian front‐tracking algorithm that can model an arbitrary 3D surface within an array of cubic control volumes. The ISM method has a cell‐by‐cell remeshing capability that is volume conservative and is suitable for the tracking of complex interface deformation in transient two‐phase CFD simulations. Copyright © 2015 John Wiley & Sons, Ltd.     

3D two phase flows numerical simulations by SL‐VOF method

This paper describes the development of a semi‐Lagrangian computational method for simulating complex 3D two phase flows. The Navier–Stokes equations are solved separately in both fluids using a robust pseudo‐compressibility method able to deal with high density ratio. The interface tracking is achieved by the segment Lagrangian volume of fluid (SL‐VOF) method. The 2D SL‐VOF method using the concepts of VOF, piecewise linear interface calculation (PLIC) and Lagrangian advection of the interface is herein extended to 3D flows. Three different test cases of SL‐VOF 3D are presented for validation and comparison either with 2D flows or with other numerical methods. A good agreement is observed in each case. Copyright © 2004 John Wiley & Sons, Ltd.     

A cost‐effective curvature calculation approach for interfacial flows on unstructured meshes

We present a simple and cost‐effective curvature calculation approach for simulations of interfacial flows on structured and unstructured grids. The interface is defined using volume fractions, and the interface curvature is obtained as a function of the gradients of volume fractions. The gradient computation is based on a recently proposed gradient recovery method that mimicks the least squares approach without the need to solve a system of equations and is quite easy to implement on arbitrary polygonal meshes. The resulting interface curvature is used in a continuum surface force formulation within the framework of a well‐balanced finite‐volume algorithm to simulate multiphase flows dominated by surface tension. We show that the proposed curvature calculation is at least as accurate as some of the existing approaches on unstructured meshes while being straightforward to implement on any mesh topology. Numerical investigations also show that spurious currents in stationary problems that are dependent on the curvature calculation methodology are also acceptably low using the proposed approach. Studies on capillary waves and rising bubbles in viscous flows lend credence to the ability of the proposed method as an inexpensive, robust, and reasonably accurate approach for curvature calculation and numerical simulation of multiphase flows.     

An improved three-dimensional model for interface pressure calculations in free-surface flows

A three-dimensional method for the calculation of interface pressure in the computational modeling of free surfaces and interfaces is developed. The methodology is based on the calculation of the pressure force at the interfacial cell faces and is mainly designed for volume of fluid (VOF) interface capturing approach. The pressure forces at the interfacial cell faces are calculated according to the pressure imposed by each fluid on the portion of the cell face that is occupied by that fluid. Special formulations for the pressure in the interfacial cells are derived for different orientations of an interface. The present method, referred to as pressure calculation based on the interface location (PCIL), is applied to both static and dynamic cases. First, a three-dimensional motionless drop of liquid in an initially stagnant fluid with no gravity force is simulated as the static case and then two different small air bubbles in water are simulated as dynamic cases. A two-fluid, piecewise linear interface calculation VOF method is used for numerical simulation of the interfacial flow. For the static case, both the continuum surface force (CSF) and the continuum surface stress (CSS) methods are used for surface tension calculations. A wide range of Ohnesorge numbers and density and viscosity ratios of the two fluids are tested. It is shown that the presence of spurious currents (artificial velocities present in case of considerable capillary forces) is mainly due to the inaccurate calculation of pressure forces in the interfacial computational cells. The PCIL model reduces the spurious currents up to more than two orders of magnitude for the cases tested.

Also for the dynamic bubble rise case, it is shown that using the numerical solver employed here, without PCIL, the magnitude of spurious currents is so high that it is not possible to simulate this type of surface tension dominated flows, while using PCIL, we are able to simulate bubble rise and obtain results in close agreement with the experimental data.     

Multi‐material incompressible flow simulation using the moment‐of‐fluid method

This paper compares the numerical performance of the moment‐of‐fluid (MOF) interface reconstruction technique with Youngs, LVIRA, power diagram (PD), and Swartz interface reconstruction techniques in the context of a volume‐of‐fluid (VOF) based finite element projection method for the numerical simulation of variable‐density incompressible viscous flows. In pure advection tests with multiple materials MOF shows dramatic improvements in accuracy compared with the other methods. In incompressible flows where density differences determine the flow evolution, all the methods perform similarly for two material flows on structured grids. On unstructured grids, the second‐order MOF, LVIRA, and Swartz methods perform similarly and show improvement over the first‐order Youngs' and PD methods. For flow simulations with more than two materials, MOF shows increased accuracy in interface positions on coarse meshes. In most cases, the convergence and accuracy of the computed flow solution was not strongly affected by interface reconstruction method. Published in 2009 by John Wiley & Sons, Ltd.     

An accurate interface reconstruction method using piecewise circular arcs

A novel piecewise circular interface construction (PCIC) method for accurate reconstruction of interface in a two‐phase flow problem is proposed. This is under the framework of a fixed grid, volume of fluid approach applied on a two‐dimensional semistaggered structured grid. Fluid interface in each mixed cell is represented using a geometric template of piecewise circular arc. Data corresponding to arc center coordinates and radius are first predicted using curve fitting methods and corrected with the help of volume fraction constraints. Further corrections are carried out to achieve function (c0) continuity at cell boundaries. The proposed method does not require additional calculations for the determination of curvature (for calculation of surface tension force), since it is obtained as part of reconstruction process itself. For dynamic interface construction, simple analytical expressions are derived to construct edge matched flux polygons. Area of intersection of flux polygons with area covered by primary fluid is determined to effect geometric advection across a PCIC interface. Accuracy of this method is demonstrated by the reconstruction of standard static and dynamically evolving interface problems. Accuracy levels superior to most interface reconstruction methods using PLIC and schemes using higher order curves are established. Finally, the capability to handle a complex two‐phase flow problem simulation viz the four‐vortex flow field, where interface undergoes breakage and coalescence, is also demonstrated.     

A hybrid Lagrangian–Eulerian particle‐level set method for numerical simulations of two‐fluid turbulent flows

A coupled Lagrangian interface‐tracking and Eulerian level set (LS) method is developed and implemented for numerical simulations of two‐fluid flows. In this method, the interface is identified based on the locations of notional particles and the geometrical information concerning the interface and fluid properties, such as density and viscosity, are obtained from the LS function. The LS function maintains a signed distance function without an auxiliary equation via the particle‐based Lagrangian re‐initialization technique. To assess the new hybrid method, numerical simulations of several ‘standard interface‐moving’ problems and two‐fluid laminar and turbulent flows are conducted. The numerical results are evaluated by monitoring the mass conservation, the turbulence energy spectral density function and the consistency between Eulerian and Lagrangian components. The results of our analysis indicate that the hybrid particle‐level set method can handle interfaces with complex shape change, and can accurately predict the interface values without any significant (unphysical) mass loss or gain, even in a turbulent flow. The results obtained for isotropic turbulence by the new particle‐level set method are validated by comparison with those obtained by the ‘zero Mach number’, variable‐density method. For the cases with small thermal/mass diffusivity, both methods are found to generate similar results. Analysis of the vorticity and energy equations indicates that the destabilization effect of turbulence and the stability effect of surface tension on the interface motion are strongly dependent on the density and viscosity ratios of the fluids. Copyright © 2007 John Wiley & Sons, Ltd.     

Enhancement of the accuracy of the finite volume particle method for the simulation of incompressible flows

A finite volume particle (FVP) method for simulation of incompressible flows that provides enhanced accuracy is proposed. In this enhanced FVP method, a dummy neighbor particle is introduced for each particle in the calculation and used for the discretization of the gradient model and Laplacian model. The error‐compensating term produced by introducing the dummy neighbor particle enables higher order terms to be calculated. The proposed gradient model and Laplacian model are applied in both pressure and pressure gradient calculations. This enhanced FVP scheme provides more accurate simulations of incompressible flows. Several 2‐dimensional numerical simulations are given to confirm its enhanced performance.     

Numerical simulation of droplet ejection of thermal inkjet printheads

In this study, we present a method to predict the droplet ejection in thermal inkjet printheads including the growth and collapse of a vapor bubble and refill of the firing chamber. The three‐dimensional Navier–Stokes equations are solved using a finite‐volume approach with a fixed Cartesian mesh. The piecewise‐linear interface calculation‐based volume‐of‐fluid method is employed to track and reconstruct the ink–air interface. A geometrical computation based on Lagrangian advection is used to compute the mass flux and advance the interface. A simple and efficient model for the bubble dynamics is employed to model the effect of ink vapor on the adjacent ink liquid. To solve the surface tension‐dominated flow accurately, a hierarchical curvature‐estimation method is proposed to adapt to the local grid resolution. The numerical methods mentioned earlier have been implemented in an internal simulation code, CFD3. The numerical examples presented in the study show good performance of CFD3 in prediction of surface tension‐dominated free‐surface flows, for example, droplet ejection in thermal inkjet printing. Currently, CFD3 is used extensively for printhead development within Hewlett‐Packard. Copyright © 2015 John Wiley & Sons, Ltd.     

Numerical errors of the volume‐of‐fluid interface tracking algorithm

One of the important limitations of the interface tracking algorithms is that they can be used only as long as the local computational grid density allows surface tracking. In a dispersed flow, where the dimensions of the particular fluid parts are comparable or smaller than the grid spacing, several numerical and reconstruction errors become considerable. In this paper the analysis of the interface tracking errors is performed for the volume‐of‐fluid method with the least squares volume of fluid interface reconstruction algorithm. A few simple two‐fluid benchmarks are proposed for the investigation of the interface tracking grid dependence. The expression based on the gradient of the volume fraction variable is introduced for the estimation of the reconstruction correctness and can be used for the activation of an adaptive mesh refinement algorithm. Copyright © 2002 John Wiley & Sons, Ltd.     

Compressive advection and multi‐component methods for interface‐capturing

This paper develops methods for interface‐capturing in multiphase flows. The main novelties of these methods are as follows: (a) multi‐component modelling that embeds interface structures into the continuity equation; (b) a new family of triangle/tetrahedron finite elements, in particular, the P₁DG‐P₂(linear discontinuous between elements velocity and quadratic continuous pressure); (c) an interface‐capturing scheme based on compressive control volume advection methods and high‐order finite element interpolation methods; (d) a time stepping method that allows use of relatively large time step sizes; and (e) application of anisotropic mesh adaptivity to focus the numerical resolution around the interfaces and other areas of important dynamics. This modelling approach is applied to a series of pure advection problems with interfaces as well as to the simulation of the standard computational fluid dynamics benchmark test cases of a collapsing water column under gravitational forces (in two and three dimensions) and sloshing water in a tank. Two more test cases are undertaken in order to demonstrate the many‐material and compressibility modelling capabilities of the approach. Numerical simulations are performed on coarse unstructured meshes to demonstrate the potential of the methods described here to capture complex dynamics in multiphase flows. Copyright © 2015 John Wiley & Sons, Ltd.     

Pressure weighted upwinding for flow induced force predictions: application to iced surfaces

This paper addresses two main topics, namely the development of a pressure‐weighted upwinding method and its application to flow induced forces on iced cylinders. Although the near‐wall convective upwinding exhibits special applicability to iced surfaces, its capabilities extend more generally to other applications. By fully linking pressure and velocity at a sub‐element level near the wall, a higher order accuracy can be obtained. Also, a non‐physical de‐coupling between pressure and velocity can be prevented. The method is developed under the context of a control‐volume‐based finite element method for 2‐D, incompressible flows. Drag and lift coefficients are predicted, based on the pressure weighted upwinding near the wall. The numerical predictions are successfully compared against experimental data, including flow induced forces on iced cables. Copyright © 2004 John Wiley & Sons, Ltd.     

VOLUME-TRACKING METHODS FOR INTERFACIAL FLOW CALCULATIONS

A new algorithm for volume tracking which is based on the concept of flux-corrected transport (FCT) is introduced. It is applicable to incompressible 2D flow simulations on finite volume and difference meshes. The method requires no explicit interface reconstruction, is direction-split and can be extended to 3D and orthogonal curvilinear meshes in a straightforward manner. A comparison of the new scheme against well-known existing 2D finite volume techniques is undertaken. A series of progressively more difficult advection tests is used to test the accuracy of each scheme and it is seen that simple advection tests are inadequate indicators of the performance of volume-tracking methods. A straightforward methodology is presented that allows more rigorous estimates to be made of the error in volume advection and coupled volume and momentum advection in real flow situations. The volume advection schemes are put to a final test in the case of Rayleigh–Taylor instability. © 1997 by CSIRO.     

Developing implicit pressure‐weighted upwinding scheme to calculate steady and unsteady flows on unstructured grids

The finite‐volume methods normally utilize either simple or complicated mathematical expressions to interpolate the fluxes at the cell faces of their unstructured volumes. Alternatively, we benefit from the advantages of both finite‐volume and finite‐element methods and estimate the advection terms on the cell faces using an inclusive pressure‐weighted upwinding scheme extended on unstructured grids. The present pressure‐based method treats the steady and unsteady flows on a collocated grid arrangement. However, to avoid a non‐physical spurious pressure field pattern, two mass flux per volume expressions are derived at the cell interfaces. The dual advantages of using an unstructured‐based discretization and a pressure‐weighted upwinding scheme result in obtaining high accurate solutions with noticeable progress in the performance of the primitive method extended on the structured grids. The accuracy and performance of the extended formulations are demonstrated by solving different standard and benchmark problems. The results show that there are excellent agreements with both benchmark and analytical solutions as well as experimental data. Copyright © 2007 John Wiley & Sons, Ltd.     

Development of a hybrid particle‐mesh method for two‐phase flow simulations

A hybrid particle‐mesh method was developed for efficient and accurate simulations of two‐phase flows. In this method, the main component of the flow is solved using the constrained interpolated profile/multi‐moment finite volumemethod; the two‐phase interface is rendered using the finite volume particle (FVP) method. The effect of surface tension is evaluated using the continuum surface force model. Numerical particles in the FVP method are distributed only on the surface of the liquid in simulating the interface between liquid and gas; these particles are used to determine the density of each mesh grid. An artificial term was also introduced to mitigate particle clustering in the direction of maximum compression and sparse discretization errors in the stretched direction. This enables accurate interface tracking without diminishing numerical efficiency. Two benchmark simulations are used to demonstrate the validity of the method developed and its numerical stability. Copyright © 2016 John Wiley & Sons, Ltd.     

A discrete forcing method dedicated to moving bodies in two‐phase flow

The numerical simulation of interaction between structures and two‐phase flows is a major concern for many industrial applications. To address this challenge, the motion of structures has to be tracked accurately. In this work, a discrete forcing method based on a porous medium approach is proposed to follow a nondeformable rigid body with an imposed velocity by using a finite‐volume Navier‐Stokes solver code dedicated to multiphase flows and based on a two‐fluid approach. To deal with the action reaction principle at the solid wall interfaces in a conservative way, a porosity is introduced allowing to locate the solid and insuring no diffusion of the fluid‐structure interface. The volumetric fraction equilibrium is adapted to this novelty. Mass and momentum balance equations are formulated on a fixed Cartesian grid. Interface tracking is addressed in detail going from the definition of the porosity to the changes in the discretization of the momentum balance equation. This so‐called time‐ and space‐dependent porosity method is then validated by using analytical and elementary test cases.     

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.     

Parallel three‐dimensional simulation of the injection molding process

This paper describes the development of a parallel three‐dimensional unstructured non‐isothermal flow solver for the simulation of the injection molding process. The numerical model accounts for multiphase flow in which the melt and air regions are considered to be a continuous incompressible fluid with distinct physical properties. This aspect avoids the complex reconstruction of the interface. A collocated finite volume method is employed, which can switch between first‐ and second‐order accuracy in both space and time. The pressure implicit with splitting of operators algorithm is used to compute the transient flow variables and couple velocity and pressure. The temperature equation is solved using a transport equation with convection and diffusion terms. An upwind differencing scheme is used for the discretization of the convection term to enforce a bounded solution. In order to capture the sharp interface, a bounded compressive high‐resolution scheme is employed. Parallelization of the code is achieved using the PETSc framework and a single program multiple data message passing model. Predicted numerical solutions for several example problems are considered. The first case validates the solution algorithm for moderate Reynolds number flows using a structured mesh. The second case employs an unstructured hybrid mesh showing the capability of the solver to describe highly viscous flows closer to realistic injection molding conditions. The final case presents the non‐isothermal filling of a thick cavity using three mesh sizes and up to 80 processors to assess parallel performance. The proposed algorithm is shown to have good accuracy and scalability. Copyright © 2008 John Wiley & Sons, Ltd.     

Tracking accuracy of a semi‐Lagrangian method for advection–dispersion modelling in rivers

There is an increasing need to improve the computational efficiency of river water quality models because: (1) Monte‐Carlo‐type multi‐simulation methods, that return solutions with statistical distributions or confidence intervals, are becoming the norm, and (2) the systems modelled are increasingly large and complex. So far, most models are based on Eulerian numerical schemes for advection, but these do not meet the requirement of efficiency, being restricted to Courant numbers below unity. The alternative of using semi‐Lagrangian methods, consisting of modelling advection by the method of characteristics, is free from any inherent Courant number restriction. However, it is subject to errors of tracking that result in potential phase errors in the solutions. The aim of this article is primarily to understand and estimate these tracking errors, assuming the use of a cell‐based backward method of characteristics, and considering conditions that would prevail in practical applications in rivers. This is achieved separately for non‐uniform flows and unsteady flows, either via theoretical considerations or using numerical experiments. The main conclusion is that, tracking errors are expected to be negligible in practical applications in both unsteady flows and non‐uniform flows. Also, a very significant computational time saving compared to Eulerian schemes is achievable. Copyright © 2006 John Wiley & Sons, Ltd.     

Numerical study of flows with multiple free surfaces

This paper demonstrates that a numerical method based on the generalized simplified marker and cell (GENSMAC) flow solver and Youngs' volume of fluid (Y‐VOF) surface‐tracking technique is an effective tool for studying the basic mechanics of hydraulic engineering problems with multiple free surfaces and non‐hydrostatic pressure distributions. Two‐dimensional flow equations in a vertical plane are solved numerically for this purpose. The numerical results are compared with experimental data and earlier numerical results based on a higher‐order depth‐averaged flow model available in the literature. Two classical problems, (i) flow in a free overfall and (ii) flow past a floor slot, are considered. The numerical results correspond very well with the experimental data for both sub‐critical and supercritical flows. Copyright © 2001 John Wiley & Sons, Ltd.