Computational simulation of fluid dynamics in a tubular stirred reactor

The flow and concentration fields in a new style tubular stirred reactor were simulated by simulating the fluids dynamics(CFD), in which FLUENT software was used and the standard k-ε model and multiple reference frame(MRF) were adopted. The various values of initial rotating speed and inlet flow rate were adopted. Simulations were validated with experimental residence time distribution(RTD) determination. It is shown that the fluid flow is very turbulent and the flow pattern approaches to the plug flow. The velocity increases from shaft to the end of impeller, and the gradient is enlarged by increasing the rotating speed. Comparison between RTD curves shows that agitation can improve the performance of reactor. As the flow rate increases, the mean residence time decreases proportionally, and the variance of RTD lessens as well. When rotating speed increases to a certain value, the variance of RTD is enlarged by increasing rotating speed, but the mean residence time has no obvious change.     

Evaluations of spark distribution and wire vibration in wire EDM by high-speed observation

In fine wire EDM using thin wire electrode, uniform distribution of spark location is necessary to achieve stable machining performance. However, it is difficult to precisely evaluate the distribution of spark location by the conventional branched electric current method when the workpiece is thin. A new evaluation method by using a high-speed video camera is proposed. The locations of spark are measured by analyzing the recorded images. Then the effects of machining parameters, such as servo voltage, pulse interval time, wire running speed and others on the distribution of spark location are investigated. The possibility of evaluating the wire vibration is also discussed.     

等离子喷涂层片形成过程流体动力学模拟

建立了等离子喷涂层片形成过程的流动、传热和凝固耦合的三维数学模型,基于计算流体力学软件Fluent,运用有限体积法（FVM）离散控制方程,流体体积跟踪法（VOF）追踪熔滴自由表面,模拟了镍熔滴撞击基底表面形成层片的流体动力学过程,并对结果可视化输出.结果表明,撞击开始时刻,压力在撞击点出现最大值,熔滴内部压力场呈＂蘑菇云＂状,撞击压力分布从撞击点向熔滴上部递减;熔滴撞击后沿径向铺展,速度矢量场出现两个对称漩涡,在基底导热和熔体流动传热综合作用下,铺展熔滴内部温度场呈＂驼峰＂状分布;熔滴铺展速度最大值滞后最大撞击压力0.03μs出现.     

Computational fluid dynamic modeling of gas flow characteristics in a high-velocity oxy-fuel thermal spray system

A computational fluid dynamics (CFD) model is developed to predict gas dynamic behavior in a high-velocity oxy-fuel (HVOF) thermal spray gun in which premixed oxygen and propylene are burnt in a 12 mm combustion chamber linked to a parallel-sided nozzle. The CFD analysis is applied to investigate axisymmetric, steady-state, turbulent, compressible, and chemically combusting flow both within the gun and in a free jet region between the gun and the substrate to be coated. The combustion of oxygen and propylene is modeled using a single-step, finite-rate chemistry model that also allows for dissociation of the reaction products. Results are presented to show the effect of (1) fuel-to-oxygen gas ratio and (2) total gas flow rate on the gas dynamic behavior. Along the centerline, the maximum temperature reached is insensitive to the gas ratio but depends on the total flow. However, the value attained (∼2500 K) is significantly lower than the maximum temperature (∼3200 K) of the annular flame in the combustion chamber. By contrast, the centerline gas velocity depends on both total flow and gas ratio, the highest axial gas velocity being attained with the higher flow and most fuel-rich mixture. The gas Mach number increases through the gun and reaches a maximum value of approximately 1.6 around 5 mm downstream from the nozzle exit. The numerical calculations also show that the residual oxygen level is principally dependent on the fuel-to-oxygen ratio and decreases by approximately fivefold as the ratio is varied from 90 to 69% of the stoichiometric requirement. The CFD model is also used to investigate the effect of changes in combustion chamber size and geometry on gas dynamics, and the results are compared with the nominal 12 mm chamber baseline calculations.     

Numerical analysis of the effect of arc spray gun configuration parameters on the external gas flow

The objective of present study is to investigate the effect of different gun configuration parameters on the external gas flow by using a CFD model, and to optimize the design of an arc spray gun based on the modeling results. A converging nozzle and a converging/diverging nozzle for arc spraying were compared by calculating their flow distributions using a two-dimensional (2D) axially symmetrical model. Other parameters such as location of the intersection position and angle between the two wires were also analyzed in a three-dimensional (3D) model. The results show that the converging/diverging nozzle is more favorable for droplet atomization, moving the intersection position from the nozzle outside to the nozzle exit and using a moderate intersection angle are better for improving the flow dynamics properties. Consequently, an innovative design to upgrade the original HAS-01 type gun was put forward, and the modified design was experimentally compared with the original one by measuring the in-flight droplet size and velocity.     

Simulation model of debris and bubble movement in consecutive-pulse discharge of electrical discharge machining

Debris concentration and bubble volume fraction in the bottom gap between the electrode and workpiece affect the state of consecutive-pulse discharge and the efficiency of electrical discharge machining (EDM). Thus, the mechanisms of debris and bubble movement during consecutive-pulse discharge should be elucidated. However, these mechanisms have not been fully understood because of debris and bubble movement in the machining gap are difficult to simulate and observe. This study proposes a three-dimensional model of flow field with liquid, gas, and solid phases for machining gap in EDM. The mechanisms of debris and bubble movement in the machining gap during consecutive-pulse discharge were analyzed through the model. Debris and bubble movement in consecutive-pulse discharge was observed through experiments. The results showed that the proposed simulation model is feasible. The bubble expansion is the main way that the bubbles exclude from machining gap. Much debris moves outside the machining gap following the excluded bubbles, which is the main way that the debris excludes from machining gap. The bubble expansion becomes strong with the increase of the discharge current and pulse-on time.     

Erosion Behavior of NiCoCrFeNb0.45 Eutectic High-Entropy Alloy in Liquid-Solid Two-Phase Flow

The metal components exposed to the high-velocity liquid-solid ? ow can be rapidly eroded by the accelerated particles.With an excellent combination of strength and toughness, the NiCoCrFeNb _0.45 eutectic high-entropy alloy (EHEA) has emerged as a promising material to resist erosion damage. In this study, the erosion behavior of NiCoCrFeNb _0.45 EHEA in high-velocity multiphase ? ow is investigated through the coupling analysis of material properties, multiphase ? ow, a...     

Computer fluid dynamics analysis for efficient spraying of oil mist in finish-turning of Inconel 718

A compressible turbulence analysis of the flow of oil mist in MQL finish-turning of Inconel 718 was conducted using a finite volume method for optimizing the spraying conditions of oil mist and reducing the oil consumption. First, a domain of the analysis including a rotating workpiece and a single point cutting tool with a spraying nozzle was discretized, and then, changes in the velocity, pressure and vorticity of compressed air, and mass flow rate of oil mist near the cutting edge were calculated for three types of spraying nozzles. It was found that when the distance from the outlet of a nozzle to the tool tip was decreased using cover-type nozzles, mass flow rate of oil mist to near the cutting edge increased drastically. Among the three types of nozzles, the mass flow rate was the largest for a cover-type nozzle for oblique spraying. These results were consistent with the performance of the nozzles in cutting experiments. Finally, the flight of an oil droplet and the lubrication mechanism in MQL machining were investigated using analysis results.     

Fundamental geometry analysis of wire electrical discharge machining in corner cutting

Fundamental geometry properties of wire electrical discharge machining (WEDM) process in corner cutting is studied. The concept of discharge-angle is introduced, and its mathematical expression is derived by analytical geometry. A model to estimate the metal removal rate (MRR) in geometrical cutting is developed by considering wire deflection with transformed exponential trajectory of wire centre. The computed MRR is compared with measured sparking frequency of the process since they are equivalent to each other for an iso-energy type machine. A very good agreement is obtained. Both of the discharge-angle and MRR drop drastically to a minimum value depending on the corner angle being cut as the guides arrive at the corner apex, and then recover to the same level of straight-path cutting sluggishly. Hence the observed phenomenon of increased gap-voltage and decreased sparking frequency in corner cutting can be physically interpreted. In addition, the variation of the machining load caused by the change of MRR, which was taken as unknown disturbance in the past, can be predicted and used for control purpose.     

轴流式血泵流场CFD仿真

在轴流式血泵的研发过程中,动脉局部流场中可能产生流动剪切率非常低的区域,因此有必要考虑血液的非牛顿特性。建立了轴流式血泵模型,通过CFD仿真分析得到血泵转速和流量的变化对血泵出入口压力分布和速度分布的影响,并采用水和甘油(2∶1)的混合流体替代血液,对设计的血泵进行驱动实验,测量了轴流式血泵输出流量和压力参数。结果表明:所设计的血泵在规律上和仿真是相符的。     

Thermal fluid dynamics of liquid bridge transfer in laser wire deposition 3D printing

ABSTRACT

Liquid bridge transfer mode is most favourable deposition pattern in laser wire deposition. However, the thermal fluid dynamics has not been well understood. In this paper, we systematically investigated the fluid dynamics during liquid bridge transfer in the printing process. We developed a novel three-dimensional heat transfer and fluid flow model by considering the effect of wire feeding. The results showed that for typical process parameters the Weber number (We) of the fluid on the liquid bridge is on the order of O(10⁰～10¹). A dimensionless slenderness number (Sl), was roughly estimated at the range of 3.17～4.57 for maintaining the liquid bridge. This study provides the fluid mechanics insights of the metal transfer mechanisms in 3D printing process.     

基于CFD的冷却台风场数值计算与优化

为了解决热处理工艺中风冷处理阶段冷却台出风不均匀问题,基于CFD对冷却台进行了优化设计,并对冷却台风场进行了数值仿真,得出不加挡风板以及不同高度组合、角度组合工况下出风口的最大、最小风速,平均风速以及风速标准差。根据仿真所得结果,分析了高度和角度对风速均匀性的影响,得出了挡风板最佳高度和角度。结果表明:在冷却台风道中设置挡风板有助于提高出风均匀性;高度对出风均匀性影响较大,角度影响较小。     

Computational fluid dynamics analysis of a wire-feed, high-velocity oxygen fuel (HVOF) thermal spray torch

The fluid and particle dynamics of a high-velocity oxygen fuel (HVOF) thermal spray torch are analyzed using computational and experimental techniques. Three-dimensional computational fluid dynamics (CFD) results are presented for a curved aircap used for coating interior surfaces such as engine cylinder bores. The device analyzed is similar to the Metco diamond jet rotating wire (DJRW) torch. The feed gases are injected through an axisymmetric nozzle into the curved aircap. Premixed propylene and oxygen are introduced from an annulus in the nozzle, while cooling air is injected between the nozzle and the interior wall of the aircap. The combustion process is modeled using a single-step, finite-rate chemistry model with a total of nine gas species which includes dissociation of combustion products. A continually fed steel wire passes through the center of the nozzle, and melting occurs at a conical tip near the exit of the aircap. Wire melting is simulated computationally by injecting liquid steel particles into the flow field near the tip of the wire. Experimental particle velocity measurements during wire feed were also taken using a laser two-focus (L2F) velocimeter system. Flow fields inside and outside the aircap are presented, and particle velocity predictions are compared with experimental measurements outside of the aircap. This work was performed at Sandia National Laboratories, which is operated by Lockheed Martin for the U.S. Department of Energy under contract DE-AC04-94AL85000.     

A New High-Efficiency Experimental Design for Optimizing Various Flow Velocities Testing in Extremely Aggressive Formation Water

Compared to the traditional one-by-one method, a new high-efficiency method is used to characterize large numbers of regulations varying samples.Accordingly, bump-shaped electrodes are designed using the computational fluid dynamics model, and the effect of the height and placement of these electrodes is discussed.The experimental feasibility is certified by weight loss measurement.Results indicate that flow velocities of different bump-shaped electrode surfaces are significant differences.Thus, each surface can be analyzed independently; the thickness loss of each electrode surface is consistent with that using one-by-one method, which can effectively improve the experimental efficiency 12 times.     

Analysis of submerged arc welding process by three-dimensional computational fluid dynamics simulations

The effect of torch angle and current polarities on the convection heat transfer in single wire submerged arc welding is analyzed. To develop arc models such as arc heat flux, arc pressure and electromagnetic force, this study adopts the Abel inversion method with CCD camera images for direct and alternating current polarities. The heat transfer by molten slag from the flux consumption is considered as an additional boundary heat source in the numerical simulation. The variation of arc forces, the direction of droplet flight with polarity and the torch angle significantly affect the molten pool flow and the resultant weld beads. The simulated weld pool profiles are validated with corresponding experimental results and found to be in good agreement.     

鸽形扑翼机构设计及翅翼周围流场分析北大核心

为研究扑翼飞行器运动机构扑动原理和翅翼周围流场变化规律,设计鸽形扑翼飞行器扑翼机构并分析翅翼周围流场。运用四杆机构图解法计算出符合扑翼运动要求的曲柄摇杆机构参数,并对相关参数进行优化。基于计算流体力学对扑翼飞行的流场进行数值模拟计算;利用Fluent软件分析得到翅翼周围流场速度云图、湍动能云图以及升力、推力特性曲线。结果表明:鸽形扑翼飞行会引起翅翼流场流动速度发生变化,进而导致空气流动状态由层流变为湍流,湍流动能为扑翼飞行提供气动力。     

基于STAR-CCM的混合电动汽车电池冷却系统设计数值仿真研究(英文)

电池组是混合动力电池汽车(HEV)的重要能量供给装置,而电池组的性能几乎全部取决于其内部温度的影响。因此,设计电池组的冷却系统对于防止内部温度过高和保证相对活性反应的进行有重要的意义。基于商用数值仿真软件STAR-CCM建立了HEV电池组温度分布的模型,并且用数值分析的方法设计出了冷却系统的进口和散热口的最佳分布位置。     

A computational fluid dynamic analysis of gas and particle flow in flame spraying

The flame spraying process, which is a common industrial thermal spraying application, has been analyzed by means of three-dimensional computational fluid dynamics (CFD) simulations. The process used at the Volvo Aero Corporation for the coating of fan and compressor housings has been modeled. The process uses the Metco 6P torch (Metco, Westbury, NY), which ejects a mixture of acetylene and oxygen at high speed through a ring of 16 orifices to form the flame. A stream of argon gas flowing through an orifice in the center of the ring carries a powder of nickel-covered bentonite through the flame to the spray substrate. The torch is cooled by a flow of air through an outer ring of 9 orifices. The simulation emulated reality closely by including the individual inlets for fuel, cooling air, and injected particles. The gas combustion was simulated as a turbulent, multicomponent chemically reacting flow. The standard, two-equation k-ε turbulence model was used. The chemical reaction rates appeared as source terms in the species transport equations. They were computed from the contributions of the Arrhenius rate expressions and the Magnussen and Hjertager eddy dissipation model. The first simulations included several intermediate chemical substances whose predicted concentration agreed favorably with measurements. Later, more simplified simulations incorporated only the global chemical reaction involving the initial and the final products, with corrections to the thermal properties being made to account for the missing intermediaries. The gas velocity and temperature fields predicted by the later simulations compared satisfactorily to those predicted by the earlier, more elaborate, ones. Therefore, the final simulations, which incorporated injected particles, were conducted employing the simplified model with only the global reaction. An in-house finite difference code was developed to calculate particle properties. Allowance was made for elliptical shapes, phase changes, and internal heat transfer with regard to the composite material. The particle velocities and temperatures predicted by the final simulations compared fairly well with experimental results obtained with the optical DPV2000 system.     

Effect of flow velocity on corrosion behavior of AZ91D magnesium alloy at elbow of loop system

A loop system was used to investigate the effect of flow velocity on corrosion behavior of AZ91D magnesium alloy at an elbow of loop system based on array electrode technology by polarization, computational fluid dynamics (CFD) simulation and surface analysis. The experimental results showed that the corrosion rate increased with increasing flow velocity, and a critical flow velocity could exist in the corrosion of AZ91D magnesium alloy. When flow velocity exceeded the critical flow velocity, fluid hydrodynamics was dominant in the corrosion of AZ91D magnesium alloy. On the contrary, the electrochemical factors were dominant.