Modified Pressure Loss Model for T-junctions of Engine Exhaust Manifold

The T-junction model of engine exhaust manifolds significantly influences the simulation precision of the pressure wave and mass flow rate in the intake and exhaust manifolds of diesel engines. Current studies have focused on constant pressure models, constant static pressure models and pressure loss models. However, low model precision is a common disadvantage when simulating engine exhaust manifolds, particularly for turbocharged systems. To study the performance of junction flow, a cold wind tunnel experiment with high velocities at the junction of a diesel exhaust manifold is performed, and the variation in the pressure loss in the T-junction under different flow conditions is obtained. Despite the trend of the calculated total pressure loss coefficient, which is obtained by using the original pressure loss model and is the same as that obtained from the experimental results, large differences exist between the calculated and experimental values. Furthermore, the deviation becomes larger as the flow velocity increases. By improving the Vazsonyi formula considering the flow velocity and introducing the distribution function, a modified pressure loss model is established, which is suitable for a higher velocity range. Then, the new model is adopted to solve one-dimensional, unsteady flow in a D6114 turbocharged diesel engine. The calculated values are compared with the measured data, and the result shows that the simulation accuracy of the pressure wave before the turbine is improved by 4.3% with the modified pressure loss model because gas compressibility is considered when the flow velocities are high. The research results provide valuable information for further junction flow research, particularly the correction of the boundary condition in one-dimensional simulation models.     

NUMERICAL SIMULATION FOR AIR AND AIR-PM FLOW IN WALL FLOW DIESEL PARTICULATE FILTERS

Numerical simulations are performed both for the single airflow and air-PM two-phase flow in wall flow diesel particulate filters (DPF) for the first time. The calculation domain is divided into two regions. In the inlet and outlet flow channels, the simulations are performed for the steady and laminar flow; In the porous filtration walls, the calculation model for flow in porous media is used. The Lagrange two-phase flow model is used to calculate the air-PM flow in DPF, for the dispersed phase (PM), its flow tracks are obtained by the integrating of the Lagrange kinetic equation. The calculated velocity, pressure distribution and PM flow tracks in DPF are obtained, which exhibits the main flow characteristics in wall flow DPF and will be help for the optimal design and performance prediction of wall flow DPF.     

NUMERICAL ANALYSIS OF GASEOUS FLOW IN MICRO-CHANNELS

The algorithm of gaseous flow in bi-dimensional micro-channels is set up and the corre sponding program based on micro-flow theory is presented. Gaseous flow in micro-channels is numerically analyzed and the pressure drop along the duct as well as the velocity profile in the micro-channels is obtained. The numerical results agreed well with the experimental results in the references. Moreover, the effects of Kn, σv and Re on the velocity profiles are analyzed. It is found that for Kn>0.001, with increasing Kn number, the slip velocity on the wall boundary increases; the tangential momentum coefficient σv affects the slip velocity greatly. The slip velocity increases with decreasing σv In the slip flow regime and for low Re numbers, the slip velocity is little influenced by the Re number.     

Experimental Acoustic Determination of the Void Fraction in Two-Phase Flow in Horizontal Pipelines

In multi-phase flows, the phases can flow and arranged in different spatial configurations in the pipe, which called flow patterns. This type of flow is found in the oil, chemical and nuclear industries. For example, in the production and transport of oil and gas, the identification of the flow patterns are essential for answering those questions which are related to the economic return of the field, such as, measuring the volumetric flow, determining the pressure drop along the flow lines, production management and supervision. In offshore production, these factors are very important. This paper presents a new method for measuring the void fraction in horizontal pipelines, taking the air as gas in water-air two-phase flow. Through acoustic analysis of the frequency response of the pipe, the method gets the parameters to changes in runoff regime, in an experimental arrangement constructed on a small scale. The main advantages are the non-intrusive characteristic and easy to implement. The paper is composed of a qualitative experimental evaluation and transducers （microphone） which are used to analyze variations in the response accompanying variations in void and flow pattern changes. Changes are imposed and controlled by a two-phase flow experimental simulation rig, including a measurement cell constituted of an external casing that can isolate the measurement from the environmental background noise fitted with acoustic pressure transducers radially arranged, and the impact of a monitored excitation mechanism. The signals which captured by the microphones are processed and analyzed by checking their frequency contents changes according to the amount of air in the mixture.     

NUMERICAL ANALYSIS ON THREE- DIMENSIONAL FLOW FIELD OF TURBINE IN TORQUE CONVERTER

Three-dimensional flow field of turbine in torque converter is simulated by numerical calculation in order to improve the performance of torque converter. Calculation model of a torque converter is presented based on the mixing-plane technology. In the calculation of flow field,the 3D N-S equations are separated by finite-volume method and solved by semi-implicit method for pressure-linked equations(SIMPLE). Based on flow field calculation,the flow field of turbine is simulated. The velocity and pressure in the flow field of turbine are analyzed. The external performance of the torque converter is also calculated. Results of flow simulation show that there are secondary flow,off flow and velocity gradient in turbine passage. The validity of numerical simulation is verified by comparing the results of numerical simulation with experiment data.     

Mathematical model and experiment validation of fluid torque by shear stress under influence of fluid temperature in hydro-viscous clutch

The current design of hydro-viscous clutch（HVC） in tracked vehicle fan transmission mainly focuses on high-speed and high power. However, the fluid torque under the influence of fluid temperature can not be predicted accurately by conventional mathematical model or experimental research. In order to validate the fluid torque of HVC by taking the viscosity-temperature characteristic of fluid into account, the test rig is designed. The outlet oil temperature is measured and fitted with different rotation speed, oil film thickness, oil flow rate, and inlet oil temperature. Meanwhile, the film torque can be obtained. Based on Navier-Stokes equations and the continuity equation, the mathematical model of fluid torque is proposed in cylindrical coordinate. Iterative method is employed to solve the equations. The radial and tangential speed distribution, radial pressure distribution and theoretical flow rate are determined and analyzed. The models of equivalent radius and fluid torque of friction pairs are introduced. The experimental and theoretical results indicate that tangential speed distribution is mainly determined by the relative rotating speed between the friction plate and the separator disc. However, the radial speed distribution and pressure distribution are dominated by pressure difference at the lower rotating speed. The oil film fills the clearance and the film torque increases with increasing rotating speed. However, when the speed reaches a certain value, the centrifugal force will play an important role on the fluid distribution. The pressure is negative at the outer radius when inlet flow rate is less than theoretical flow, so the film starts to shrink which decreases the film torque sharply. The theoretical fluid torque has good agreement with the experimental data. This research proposes a new fluid torque mathematical model which may predict the film torque under the influence of temperature more accurately.     

COMPUTATIONAL FLUID DYNAMICS RESEARCH ON PRESSURE LOSS OF CROSS-FLOW PERFORATED MUFFLER

The pressure loss of cross-flow perforated muffler has been computed with the procedure of physical modeling,simulation and data processing. Three-dimensional computational fluid dynam-ics (CFD) has been used to investigate the relations of porosities,flow velocity and diameter of the holes with the pressure loss. Accordingly,some preliminary results have been obtained that pressure loss increases with porosity descent as nearly a hyperbolic trend,rising flow velocity of the input makes the pressure loss increasing with parabola trend,diameter of holes affects little about pressure loss of the muffler. Otherwise,the holes on the perforated pipes make the air flow gently and meanly,which decreases the air impact to the wall and pipes in the muffler. A practical perforated muffler is used to illustrate the available of this method for pressure loss computation,and the comparison shows that the computation results with the method of CFD has reference value for muffler design.     

Application of computational fluid dynamics and fluid structure interaction techniques for calculating the 3D transient flow of journal bearings coupled with rotor systems

Journal bearings are important parts to keep the high dynamic performance of rotor machinery. Some methods have already been proposed to analysis the flow field of journal bearings, and in most of these methods simplified physical model and classic Reynolds equation are always applied. While the application of the general computational fluid dynamics (CFD)-fluid structure interaction (FSI) techniques is more beneficial for analysis of the fluid field in a journal bearing when more detailed solutions are needed. This paper deals with the quasi-coupling calculation of transient fluid dynamics of oil film in journal bearings and rotor dynamics with CFD-FSI techniques. The fluid dynamics of oil film is calculated by applying the so-called ’’dynamic mesh’’ technique. A new mesh movement approach is presented while the dynamic mesh models provided by FLUENT are not suitable for the transient oil flow in journal bearings. The proposed mesh movement approach is based on the structured mesh. When the journal moves, the movement distance of every grid in the flow field of bearing can be calculated, and then the update of the volume mesh can be handled automatically by user defined function (UDF). The journal displacement at each time step is obtained by solving the moving equations of the rotor-bearing system under the known oil film force condition. A case study is carried out to calculate the locus of the journal center and pressure distribution of the journal in order to prove the feasibility of this method. The calculating results indicate that the proposed method can predict the transient flow field of a journal bearing in a rotor-bearing system where more realistic models are involved. The presented calculation method provides a basis for studying the nonlinear dynamic behavior of a general rotor-bearing system.     

Single-phase computational fluid dynamics applicability for the study of three-dimensional flow in 5′ 5 rod bundles with spacer grids

Spacer grids play an important role in pressurized water reactor(PWR) fuel assembly in that they have significant influence on the thermal-hydraulic characteristics of the reactor core.But so far,the numerical studies are performed without regarding dimple and spring of spacer grids,just considering mixing vane.Moreover,these studies use k-ε turbulence model without considering the suitability of the other turbulence models upon the different spacer grids flow.A study is carried out to understand the 3-D single-phase flow in AFA-2G 5×5 rod bundles with spacer grids based on numerical method.In order to investigate the suitability of different turbulence models,k-ε model and k-ω model,the influence of different parts of spacer grid on the fluid flow is also predicted.By using second-order upwind scheme,hybrid grids technique,and improved SIMPLEC algorithm,the Reynolds averaged mass conservation and momentum conservation equations are solved,and the pressure and velocity field of flow are obtained.The numerical simulation results are compared with experiment results and the agreement is satisfactory.The simulation results show the influences of the spring,dimple and mixing vane,and the different characteristics of the k-ε model and k-ω model.Comparing with the experiment results,the simulation results suggest that the k-ω model is suitable for the simulation of the rod bundle flow with spacer grids;the spring and dimple are the main causes of the pressure loss in the spacer grid channel.The friction coefficient of the channel with spring and dimple is 1.5 times the coefficient of the channel with the vane.These results are beneficial to enhance the simulation ability of spacer grids flow and optimization design ability of spaces grid.     

THREE-DIMENSIONAL COUPLED IMPELLER-VOLUTE SIMULATION OF FLOW IN CENTRIFUGAL PUMP AND PERFORMANCE PREDICTION

A three-dimensional turbulent flow through an entire centrifugal pump is simulated using κ-ε turbulence model modified by rotation and curvature, SIMPLEC method and body-fitted coordinate. The velocity and pressure fields are obtained for the pump under various working conditions, which is used to predict the head and hydraulic efficiency of the pump, and the results correspond well with the measured values. The calculation results indicate that the pressure is higher on the pressure side than that on the suction side of the blade; The relative velocity on the suction side gradually decreases from the impeller inlet to the outlet, while increases on the pressure side, it finally results in the lower relative velocity on the suction side and the higher one on the pressure side at the impeller outlet; The impeller flow field is asymmetric, i.e. the velocity and pressure fields are totally different among all channels in the impeller; In the volute, the static pressure gradually increases with the flow route, and a large pressure gratitude occurs in the tongue; Secondary flow exists in the rear part of the spiral.     

Numerical Simulation and Experimental Research on Microstructural Evolution During Compact Hot Extrusion of Heavy Caliber Thick-Wall Pipe

Compact hot extrusion(CHE) process of heavy caliber thick-wall pipe is a new material-saving production process. In order to reveal the optimum hot extrusion parameters in CHE process, the e ects of the extrusion parameters on the microstructural evolution are investigated systematically. The metadynamic recrystallization(MDRX) kinetic models and grain size models of as-cast P91 steel are established for the first time according to the hot compression tests performed on the Gleeble-3500 thermal-simulation machine. Then a thermal-mechanical and micro-macro coupled hot extrusion finite element(FE) model is established and further developed in DEFORM software. The results indicated that the grain size of the extruded pipe increases with the increasing of initial temperature and extrusion speed, decreases when extrusion ratio increases. Moreover, the grain size is more sensitive to the initial temperature and the extrusion ratio. The optimum hot extrusion parameters are including that, the initial extrusion temperature of 1250 °C, the extrusion ratio of 9 and the extrusion speed of 50 mm/s. Furthermore, in order to verify the simulation precisions, hot extrusion experiment verification on the heavy caliber thick-wall pipe is carried out on the 500 MN vertical hot extrusion equipment. The load–displacement curve of the extrusion process and the grain sizes of the middle part extruded pipe are in good accuracy with the simulation results, which confirms that the hot extrusion FE models of as-cast P91 steel could estimate the hot extrusion behaviors. The proposed hot extrusion FE model can be used to guide the industrial production research of CHE process.     

Thermal Fluid-Solid Interaction Model and Experimental Validation for Hydrostatic Mechanical Face Seals

Hydrostatic mechanical face seals for reactor coolant pumps are very important for the safety and reliability of pressurized-water reactor power plants.More accurate models on the operating mechanism of the seals are needed to help improve their performance.The thermal fluid–solid interaction（TFSI）mechanism of the hydrostatic seal is investigated in this study.Numerical models of the flow field and seal assembly are developed.Based on the mechanism for the continuity condition of the physical quantities at the fluid–solid interface,an on-line numerical TFSI model for the hydrostatic mechanical seal is proposed using an iterative coupling method.Dynamic mesh technology is adopted to adapt to the changing boundary shape.Experiments were performed on a test rig using a full-size test seal to obtain the leakage rate as a function of the differential pressure.The effectiveness and accuracy of the TFSI model were verified by comparing the simulation results and experimental data.Using the TFSI model,the behavior of the seal is presented,including mechanical and thermal deformation,and the temperature field.The influences of the rotating speed and differential pressure of the sealing device on the temperature field,which occur widely in the actual use of the seal,are studied.This research proposes an on-line and assembly-based TFSI model for hydrostatic mechanical face seals,and the model is validated by full-sized experiments.     

STRUCTURE DESIGN OF THE BEIJING SPECTROMETER Ⅲ BEAM PIPE

The Beijing spectrometer Ⅲ （BESⅢ） beam pipe is in the center of the BESⅢ, which is the detector of the upgrade project of Beijing electron and positron collider （BEPC Ⅱ）. Electrons and positrons collide in the BESⅢ beam pipe. According to the demands of the BEPC Ⅱ, a key program of Chinese Academy of Sciences, the BESⅢ beam pipe is designed based on the finite elements analysis. The BESIII beam pipe is installed in the inner cylinder of the BESⅢ drift chamber. As a vacuum tube, the BESIII beam pipe is designed as 1 000 mm in length, 63 mm in inner diameter and 114 mm in outer diameter, respectively. The BESIII beam pipe consists of a central beryllium pipe cooled by EDM-1, the oil No.1 for electric discharge machining, and two extended copper pipes cooled by deionized water （DW）. The three parts are jointed by vacuum welding. Factors taken into account in the design are as follows. ① The wall thickness of the central beryllium pipe should be designed as small as possible to reduce the multi-scattering and improve the particle momentum resolution. And the wall thickness of the extended copper pipe should be designed as large as possible to protect the detectors from the backgrounds. ②The BESⅢ beam pipe must be sufficiently cooled to avoid the damage and prevents its influence to the BESⅢ drift chamber （DC） operation. The inner surface temperature of the DC inner cylinder must be maintained at 293±2 K. ③ The magnetic permeability of the materials used in the BESⅢ beam pipe must be less than 1.05 H/m to avoid large magnetic field distortions. ④ The static pressure of the vacuum chamber of the BESⅢ beam pipe must be less than 800 μPa. The simulating results show that the designed structure of the BESⅢ beam pipe satisfies the requirements mentioned above. The structure design scheme is evaluated and adonted hv the headouarters of BEPCⅡ.     

In uence of Endwall Boundary Layer Suction on the Flow Fields of a Critically Loaded Di usion Cascade

Boundary layer suction is an e ective method used to delay separations in axial compressors. Most studies on bound?ary layer suction have focused on improving the performance of compressors,whereas few studies investigated the influence on details of the flow fields,especially vortexes in compressors. CFD method is validated with experi?mental data firstly. Three single?slot and one double?slot endwall boundary layer suction schemes are designed and investigated. In addition to the investigation of aerodynamic performance of the cascades with and without suction,variations in corner open separation,passage vortex,and concentration shedding vortex,which are rarely seen for the flow controlled blades in published literatures,are analyzed. Then,flow models,which are the ultimate aim,of both baseline and aspirated cascades are established. Results show that single?slot endwall suction scheme adjacent to the suction surface can e ectively remove the corner open separation. With suction mass flow rate of 0.85%,the overall loss coe cient and endwall loss coe cient of the cascade are reduced by 25.2% and 48.6%,respectively. Besides,this scheme increases the static pressure rise coe cient of the cascade by 3.2% and the flow turning angle of up to 3.3° at 90% span. The concentration shedding vortex decreases,whereas the passage vortex increases. For single?slot suction schemes near the middle pitchwise of the passage,the concentration shedding vortex increases and the passage vortex is divided into two smaller passage vortexes,which converge into a single?passage vortex near the trailing edge section of the cascade. For the double?slot suction scheme,triple?passage vortexes are presented in the blade passage. Some new vortex structures are discovered,and the novel flow models of aspirated compressor cascade are proposed,which are important to improve the design of multi?stage aspirated compressors.     

Numerical Research on Performance Prediction for Centrifugal Pumps

Performance prediction for centrifugal pumps is now mainly based on numerical calculation and most of the studies merely focus on one model. Therefore, the research results are not representative. To make an improvement of numerical calculation method and performance prediction for centrifugal pumps, performance of six centrifugal pump models at design flow rate and off design flow rates, whose specific speed are different, were simulated by using commercial code FLUENT. The standard k-ε turbulence model and SIMPLEC algorithm were chosen in FLUENT. The simulation was steady and moving reference frame was used to consider the impeller-volute interaction. Also, how to dispose the gap between impeller and volute was presented and the effect of grid number was considered. The characteristic prediction model for centrifugal pumps is established according to the simulation results. The head and efficiency of the six models at different flow rates are predicted and the prediction results are compared with the experiment results in detail. The comparison indicates that the precision of head and efficiency prediction are all less than 5%. The flow analysis indicates that flow change has an important effect on the location and area of low pressure region behind the blade inlet and the direction of velocity at impeller inlet. The study shows that using FLUENT simulation results to predict performance of centrifugal pumps is feasible and accurate. The method can be applied in engineering practice.     

COMPUTATIONAL FLUID DYNAMICS （CFD） SIMULATIONS OF DRAG REDUCTION WITH PERIODIC MICRO-STRUCTURED WALL

Computational fluid dynamics（CFD） simulations are adopted to investigate rectangular microchannel flows with various periodic micro-structured wall by introducing velocity slip boundary condition at low Reynolds number. The purpose of the current study is to numerically find out the effects of periodic micro-structured wall on the flow resistance in rectangular microchannel with the different spacings between microridges ranging from 15 to 60 pm. The simulative results indicate that pressure drop with different spacing between microridges increases linearly with flow velocity and decreases monotonically with slip velocity; Pressure drop reduction also increases with the spacing between microridges at the same condition of slip velocity and flow velocity. The results of numerical simulation are compared with theoretical predictions and experimental results in the literatures. It is found that there is qualitative agreement between them.     

THERMAL ANALYSIS OF FRICTIONAL DISK IN SPEEDING WET CLUTCH

Multi-frictional disks are employed to transmit the torque in speeding wet clutch, and the oil thickness within frictional disks could be adjusted for practical output speeding. As oil combined with a-hydrocarbon or polyester is getting widely used as lubricant and the speeding wet clutch works within hydrodynamic lubrication, mixture lubrication, boundary lubrication and contact situation, established the thermal analysis model for investigating the behavior of frictional disks in speeding wet clutch, which covers the power-law fluid model, Patir-Cheng average flow model,GT asperity contact-model, oil film inertia and heat effects, mean energy equation, and heat conduction equation. The formulas in the model are deduced. The numeral calculation and analysis for hydrodynamic lubrication and mixture lubrication are executed. Relationships and variations among transmitting torque, mean push pressure, output speed, and load are presented. Thermal effect should be considered during the hydrodynamic lubricat     

Numerical and Experimental Investigation of High-efficiency Axial-flow Pump

The experimental investigation of axial-flow pump has been rapidly developed to meet the needs of South-to-North Water Diversion Project of China. Owing to the boundary conditions of hub, blade tip clearance, much of the physical phenomena and laws involved in this complex flow field can’t be fully determined. The flow characteristics of the high efficiency axial-flow pump have been simulated by RNG k –ε turbulence model and SIMPLEC arithmetic based on FLUENT software. Numerical results indicate that the data from the prediction show agreement with the experimental results, static pressure on pressure side of blades increases slightly at circumferential direction with radius increasing, and keep almost constant at the same radial while increasing gradually from inlet to exit on the suction side along flow direction at design conditions. The static pressure, total pressure and velocity at inlet, impeller outlet and vane outlet were measured by a five-hole probe, and a contrastive experiment was done to investigate the influence of hub leakage. The experimental results show that inlet flow is almost axial and the prerotation is very small at various conditions. The meridional velocity and circulation distribution are almost identical at impeller outlet at design conditions due to steady flow and high efficiency. The residual circulation exits at downstream of the guide vane, and the circumferential velocity component increases linearly from hub to tip at small flow rate conditions. Hub leakage in adjustable blades results in the decrease of the meridional velocity and circulation at blade exit near hub. The results of numerical simulation and experiments supply important flow structure information for the high-efficiency axial-flow pump.     

Configuration Selection for Reconfigurable Manufacturing Systems by Means of Characteristic State Space

The configuration selection for reconfigurable manufacturing systems(RMS) have been tackled in a number of studies by using analytical or simulation models. The simulation models are usually based on fewer assumptions than the analytical models and therefore are more wildly used in modeling complex RMS. But in the absence of an efficient gradient analysis method of the objective function, it is time-consuming in solving large-scale problems by using a simulation model coupled with a meta-heuristics algorithm. In this paper, a new approach by means of characteristic state space is presented to improve the efficiency of the configuration selection for an RMS. First, a characteristic state equation is set up to represent the input and the output resources of each basic activity in an RMS. A production process model in terms of matrix equations is established by iterating the equations of basic activities according to the resource flows. This model introduces the production process into a characteristic state space for further analysis. Second, the properties of the characteristic state space are presented. On the basis of these properties, the configuration selection in an RMS is considered as a path-planning problem, and the gradient of the objective function is computed. Modified simulated annealing(SA) is also presented, in which neighborhood generation is guided by the gradient to accelerate convergence and reduce the run time of the optimization procedure. Finally, several case studies on the configuration selection for some actual reconfigurable assembly job-shops are presented and compared to the classical SA. The comparison shows relatively positive results. This study provides a more efficient configuration selection approach by using the gradient of the objective function and presents the relevant theories on which it is based.