Comparative numerical study of two concentrated fiber suspension models

We consider two rheological models for concentrated fiber suspensions. In both models the equations for orientation and flow are fully coupled, i.e., the orientation influences the flow via a constitutive relation for the viscosity and the orientation of the fibers is determined by the flow field. The orientation state of the fibers is characterized by the Advani–Tucker orientation tensor. We are investigating suspensions of fibers in which the kinetic energies of the fibers are large compared to the thermal energies, i.e., the influence of Brownian motion may be neglected. The first model is the Folgar–Tucker model with backcoupling to the flow (FT model). The second model is an extension of Folgar–Tucker, which models phenomenologically the topological exclusion interaction in dense suspensions (FTMS model). As test cases for the simulation are considered channel flow, 8:1 contraction flow and flow around a cylinder.     

Fiber suspension flow in a tapered channel: The effect of flow/fiber coupling

A numerical model for predicting the flow and orientation state of semi-dilute, rigid fiber suspensions in a tapered channel is presented. The effect of the two-way flow/fiber coupling is investigated for low Reynolds number flow using the constitutive model of Shaqfeh and Fredrickson. An orientation distribution function is used to describe the local orientation state of the suspension and evolves according to a Fokker–Plank type equation. The planar orientation distribution function is determined along streamlines of the flow and is coupled with the fluid momentum equations through a fourth-order orientation tensor. The coupling term accounts for the two-way interaction and momentum exchange between the fluid and fiber phases. The fibers are free to interact through long range hydrodynamic fiber–fiber interactions which are modeled using a rotary diffusion coefficient, an approach outlined by Folgar and Tucker. Numerical predictions are made for two different orientation states at the inlet to the contraction, namely a fully random and a partially aligned fiber orientation state. Results from these numerical predictions show that the streamlines of the flow are altered and that velocity profiles change from Jeffery–Hamel, to something resembling a plug flow when the fiber phase is considered in the fluid momentum equations. This phenomenon was found when the suspension enters the channel in either a pre-aligned, or in a fully random orientation state. When the suspension enters the channel in an aligned orientation state, fiber orientation is shown to be only marginally changed when the two-way coupling is included. However, significant differences between coupled and uncoupled predictions of fiber orientation were found when the suspension enters the channel in a random orientation state. In this case, the suspension was shown to align much more quickly when the mutual coupling was accounted for and profiles of the orientation anisotropy were considerably different both qualitatively and quantitatively.     

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.     

Orientation distribution of fibers and rheological property in fiber suspensions flowing in a turbulent boundary layer

A model relating the translational and rotational transport of orientation distribution function （ODF） of fibers to the gradient of mean ODF and the dispersion coefficients is proposed to derive the mean equation for the ODE Then the ODF of fibers is predicted by numerically solving the mean equation for the ODF together with the equations of turbulent boundary layer flow. Finally the shear stress and first normal stress difference of fiber suspensions are obtained. The results, some of which agree with the available relevant experimental data, show that the most fibers tend to orient to the flow direction. The fiber aspect ratio and Reynolds number have significant and negligible effects on the orientation dis- tribution of fibers, respectively. The additional normal stress due to the presence of fibers is anisotropic. The shear stress of fiber suspension is larger than that of Newtonian solvent, and the first normal stress difference is much less than the shear stress. Both the additional shear stress and the first normal stress difference increase with increasing the fiber concentration and decreasing fiber aspect ratio.     

Structure and rheology of fiber-laden membranes via integration of nematodynamics and membranodynamics

This paper presents a study of the structure and dynamics of rigid fiber-laden deformable curved fluid membranes based on an viscoelastic model that integrates the statics of anisotropic membranes, the planar nematodynamics of fibers and the dynamics of isotropic membranes. Fiber-laden membranes arise frequently in biological systems, such as the plant cell wall and in protein–lipid bilayers. Based on the membrane's force and torque balance equations and the fiber's balance of molecular fields, a viscoelastic anisotropic model that provides the governing equations for the membrane's velocity and curvature and the fiber structure (fiber orientation and order) is found. A Helmholtz free energy that incorporates the tension/bending/and torsion membrane elasticity, the Landau–de Gennes fiber ordering, and fiber order-membrane curvature interactions is used to derive elastic moments, torques, and stresses. The corresponding viscous stresses and moments include the Boussinesq–Scriven contributions as well as bending, torsion, and rotational dissipation. A spectral decomposition leads to the main viscoelastic material functions for anisotropic fluid membranes. Applications of the rheological model to cylindrical growth and cylindrical axial stretching show that competing curvo-phobic, curvo-philic interactions under extensional flow predict transitions between axial and azimuthal fiber arrangements, of interest to cellulose fiber orientation in plant morphogenesis.     

EFFECTS OF TENSOR CLOSURE MODELS AND 3-D ORIENTATION ON THE STABILITY OF FIBER SUSPENSIONS IN A CHANNEL FLOW

IntroductionFlowoffibresuspensionshasbeenveryfamiliarinmanyindustrialfields.Fibreadditivesplayanimportantroleindragreductioninmanytypesofflow[1- 3].Inthesuspensions,somebehavioroftheflowmaybealteredbythefibres.Oneoftheimportantexamplesisthehydrodynamicsta…     

Direct simulation of flexible fibers

A numerical simulation of multiple flexible fibers in suspension in Newtonian simple shear flow is presented. The method used is similar to those of previous recent simulation works by Fan et al. [J. Non-Newtonian Fluid Mech. 74 (1998) 113] and Yamane et al. [J. Non-Newtonian Fluid Mech. 54 (1994) 405], however, the method has been modified to allow a small amount of bending and torsion in the fibers. A restoring moment acts to straighten the fibers as they interact in the flow.It is demonstrated that this simulation can be used to extract basic rheological information about the suspension including fiber orientations and suspension viscosity. The viscosity of semi-concentrated to concentrated flexible fiber suspensions are shown to increase by a magnitude of the order 7–10% greater than the equivalent rigid fiber suspension tested. This is in qualitative agreement with previous experimental work by Goto et al. [Rheologica Acta 25 (1986) 119] and Blakeney [J. Colloid Interface Sci. 22 (1966) 324]. The implication is that any constitutive relation involving particulate suspensions described by orientation vectors may quantitatively underestimate suspension viscosity, particularly for fibers of large aspect ratio, or low Young’s modulus, whereby the tendency to flex is greater [Rheologica Acta 25 (1986) 119]. If particulate deformation were accounted for (by whatever means) in the existing constitutive relationship, predictions of bulk suspension parameters such as viscosity should be noticeably improved. A method is developed to modify an existing rigid-fiber viscosity to an equivalent flexible fiber viscosity, hence improving viscosity prediction ability.     

A method for direct simulation of flexible fiber suspensions using lattice Boltzmann equation with external boundary force

The computational method presented here can be used to study the effect of volume fraction and particle deformation on the rheology and microstructure of deformable fibers suspended in Newtonian fluid. In this method, the flow is computed on a fixed regular ‘lattice’ using the lattice Boltzmann method, where each solid particle is mapped onto a Lagrangian frame moving continuously through the domain. Instead of the standard bounce-back method, an external boundary force is used to impose the no-slip boundary condition at the fluid–solid interface for stationary or moving boundaries. The motion and orientation of the fiber are obtained from Newtonian dynamics equations. Although the external boundary force method is general, in this application it is used in conjunction with a flexible fiber model, which calculates the flexible fiber deformation by the real material properties. The methodology is validated by comparing with experimental and theoretical results.     

Structure and properties of sheared fiber suspensions with mechanical contacts

The properties of fiber suspensions are highly sensitive to the suspension microstructure. In dilute or semi-dilute suspensions, nL²d≪1, the fibers' orientation distribution is controlled by hydrodynamic interactions among the fibers. However, direct mechanical contacts among the fibers play an important role in semi-concentrated suspensions, nL²d=O(1). Here, n is the number of fibers per unit volume, L is the fiber length and d is the fiber diameter. We have performed dynamic simulations of fiber suspensions including contact forces that prevent any two fibers from passing through one another. Collisions between the fibers cause them to flip more frequently in the shear flow, leading to a spread of the orientation distribution away from the flow direction. Both this increased orientational dispersion and the direct stress transmitted through the contacts enhance the shear viscosity of the suspension significantly. The contacts also give rise to normal stress differences. The results of the simulation are compared with experiments and the relative importance of contacts and hydrodynamic interactions is discussed.     

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.     

Evaluation of steerable filter for detection of fibers in flowing suspensions

Steerable filters are concluded to be useful in order to determine the orientation of fibers captured in digital images. The fiber orientation is a key variable in the study of flowing fiber suspensions. Here, digital image analysis based on a filter within the class of steerable filters is evaluated for suitability of finding the position and orientation of fibers suspended in flowing suspensions. In sharp images with small noise levels, the steerable filter succeeds in determining the orientation of artificially generated fibers with well-defined angles. The influence of reduced image quality on the orientation has been quantified. The effect of unsharpness and noise is studied and the results show that the error in orientation is less than 1° for moderate levels. Images from two flow cases, one laminar shear flow and one turbulent, are also analyzed. The fiber orientation distribution is determined in the flow-vorticity plane. For the laminar case a comparison is made to a robust, but computationally more expensive, method involving convolutions with an oriented elliptic filter. A good agreement is found when comparing the resulting fiber orientation distributions obtained with the two methods. For the turbulent case, it is demonstrated that correct results are obtained and that the method can handle overlapping fibers.     

The flow of fiber suspensions in complex geometries

A continuum theory for dilute suspensions of large-aspect-ratio particles is applied to the flow of fiber suspensions through contractions. The theory, which incorporates the statistical orientation distribution function into the stress equation, predicts that the flow of dilute suspensions will differ qualitatively from the flow of the suspending fluid. The theory is in excellent agreement with experiments on the flow of suspensions of chopped-glass fibers through axisymmetric contractions, where substantial enlargement of the recirculating corner vortex is observed at volume fractions of 0.1% and less.     

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.     

Well-posedness of the problem of fiber suspension flows

The well-posedness of the equations governing the flow of fiber suspensions is studied. The fluid is assumed to be Newtonian and incompressible, and the presence of fibers is accounted for through the use of second- and fourth-order orientation tensors, which model the effects of the orientation of fibers in an averaged sense. The fourth-order orientation tensor is expressed in terms of the second-order tensor through various closure relations. It is shown that the linear closure relation leads to anomalous behavior, in that the rest state of the fluid is unstable, in the sense of Liapounov, for certain ranges of the fiber particle number. No such anomalies arise in the case of quadratic and hybrid closure relations. For the quadratic closure relation, it is shown that a unique solution exists locally in time for small data.     

The stress-microstructure relationship in an evolving mixing layer of fiber suspensions

The equations for fiber suspensions in an evolving mixing layer were solved by the spectral method, and the trajectory and orientation of fibers were calculated based on the slender body theory. The calculated spatial and orientation distributions of fibers are consistent with the experimental ones that were performed in this paper. The relationship between the microstructure of fibers and additional stress was examined. The results show that the spatial and orientation distributions of fibers are heterogeneous because of the influence of coherent vortices in the flow, which leads to the heterogeneity of the additional stress. The degree of heterogeneity increases with the increasing of St number and fiber aspect ratio. The fibers in the flow make the momentum loss thickness of the mixing layer thicker and accelerate the vorticity dispersion.The project supported by the Doctoral Program of Higher Education in China (20030335001)     

Orientation tensors in simple flows of dilute suspensions of non-Brownian rigid ellipsoids,comparison of analytical and approximate solutions

General analytical solutions are obtained for the planar orientation structure of rigid ellipsoid of revolutions subjected to an arbitrary homogeneous flow in a Newtonian fluid. Both finite and infinite aspect ratio particles are considered. The orientation structure is described in terms of two-dimensional, time-dependent tensors that are commonly employed in constitutive equations for anisotropic fluids such as fiber suspensions. The effect of particle aspect ratio on the evolution of orientation structure is studied in simple shear and planar elongational flows. With the availability of analytical solutions, accuracies of quadratic closure approximations used for nonhomogeneous flows are analyzed, avoiding numerical integration of orientation distribution function. In general, fourth-order orientation evolution equations with sixth-order quadratic closure approximations yield more accurate representations compared to the commonly used second-order evolution equations with fourth-order quadratic closure approximations. However, quadratic closure approximations of any order are found to give correct maximum orientation angle (i.e., preferred direction) results for all particle aspect ratios and flow cases.     

Shear rheometry and visualization of glass fiber suspensions

The nonlinear rheological behavior of short glass fiber suspensions has been investigated in this work by rotational rheometry and flow visualization. A Newtonian and a Boger fluid (BF) were used as suspending media. The suspensions exhibited shear thinning in the semidilute regime and weaker shear thinning in the transition to the concentrated one. Normal stresses and relative viscosity were higher for the BF suspensions than for the Newtonian ones presumably due to enhanced hydrodynamic interactions resulting from BF elasticity. In addition, relative viscosity of the suspensions increased rapidly with fiber content, suggesting that the rheological behavior in the concentrated regime is dominated by mechanical contacts between fibers. Visualization of individual fibers and their interactions under flow allowed the detection of aggregates, which arise from adhesive contacts. The orientation states of the fibers were quantified by a second order tensor and fast Fourier transforms of the flow field images. Fully oriented states occurred for shear rates around 20 s^− 1. Finally, the energy required to orient the fibers was higher in step forward than in reversal flow experiments due to a change in the spatial distribution of fibers, from isotropic to planar oriented, during the forward experiments.     

Structure and orientation dynamics of sepiolite fibers–poly(ethylene oxide) aqueous suspensions under extensional and shear flow,probed by in situ SAXS

The structure and orientation dynamics of sepiolite clay fibers about 1,000 nm long and 10 nm thick, suspended in an aqueous poly(ehtylene oxide) matrix of 10⁵ g/mol molecular mass, have been studied under control extensional and shear flow. A new extensional flow cell developed at the “Laboratoire de Rhéologie” and the combined rheology and small angle X-ray scattering (Rheo-SAXS) setup available at the European Synchrotron Radiation Facility have allowed access to in situ and time-resolved fiber orientations and structure properties in the volume of suspensions under flow. In the volume fractions and shear rate domains for which the suspensions exhibit shear-thinning properties, two regimes of orientation separated by a critical strain rate have been identified under extensional flow.     

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.     

Isothermal extrusion of non-dilute fiber suspensions

The extrusion of a rod-like fiber suspension is a Newtonian solvent, as a first step to the fast and inexpensive production of composite materials, is investigated. The analysis is carried out by means of an integral constitutive equation for a non-dilute suspension, streamlined finite element for liquid with memory, and Newton iteration of nonlinear integro-differential equations. The predictions show substantial differences between dilute and nondilute fiber suspension regarding the processing conditions (pressure drop, velocity distribution, die-swell) and the resulting fiber orientation. Nondilute fiber suspensions exhibit substantial shear-thinning and negligible elasticity as evidenced by the small die-swell, and fiber concentration viscosity-thickening as evidenced by the large pressure drop. The fiber orientation is computed by solving the orientation distribution function along selected streamlines of the complex velocity field. It is shown that the fiber orientation far downstream can be made independent of the random fiber orientation at the inlet.