Computational Fluid Dynamics Air Flow through the Pipe with Orifice

CFD laboratory Prof. Dr.-Ing. Muris Torlak Anderson de Oliveira 00739606

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Target
Simulate via STAR CCM+, from company CD-adapco, the air flow through a pipe with an orifice according to the given boundary conditions and provide the appropriate and requested analysis.

Loading the 3D model in the CFD program

The 3D model orifice.x_t was given and the simulation process inside STAR CCM+ started through File New Simulation and Run Mode Serial. In order to complete the 3D loading process the file was imported via File Import Import Surface Mesh as it is shown in the Figure 1. The imported 3D part appearance, displayed in the monitor, is illustrated the Figure 2.

Figure 1 Importing the surface mesh

Figure 2 3D part loaded in the program

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Splitting the model and distinguishing the surfaces

After finishing the loading process, the model was split by patches which, afterwards, were used to define the boundary conditions on each surface. In addition, it was applied a functionality to distinguish the color of the surfaces. These steps are shown in the Figure 3 and Figure 4.

Figure 3 Split by patches

Figure 4 Color mode to distinguish the parts

The Figure 5 illustrates the application of the color mode function.

Figure 5 Application of the color mode functionality

Meshing definition and creation

Figure 6 demonstrates the meshing parameters which were applied, as follows: Trimmer and Prism Layer Mesh.

Figure 6 Meshing parameters definition The reference value for the base size was changed to 2mm as it is shown in the Figure 7

Figure 7 Meshing base size changed to 2mm

Finally the mesh was created according to the parameters which were set-up above and the Figure 8 Mesh Scene illustrates the appearance of the part after meshing in the monitor.

Figure 8 Mesh scene Below are some information about the mesh that was generated. Extrusion mesh contains: 1718 cells 6179 faces 7336 edges 2876 vertices ---------------------------------------Prism Layer Extrusion Completed: CPU Time: 0.17, Wall Time: 0.17, Memory: 8.99 MB ---------------------------------------Assembling core mesh and prismatic mesh. Converting mesh into finite volume representation in Region CDF Orifice - task 1 Volume Meshing Pipeline Completed: CPU Time: 8.55, Wall Time: 8.55, Memory: 4.60 MB Cells: 5041 Faces: 13234 Vertices: 6335

Selecting the physics model

All the settings of the physics model were defined as it is shown in the Figure 9.

Figure 9 Physics model settings The air properties, i.e. density and dynamic viscosity, were introduced in the physics model, these properties are illustrated through Figure 10 and Figure 11.

Figure 10 Air density: 1.205 kg/m3

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Figure 11 Dynamic viscosity: 1.845x10-5 Pa s

Applying the boundary conditions in the regions

Regarding to the boundary conditions, the following values were implemented in the model and it is shown by each figure respectively.
inlet velocity: 3 m/s Figure 12; inlet temperature: 20C Figure 13; orifice wall temperature: 300C Figure 14; static-pressure outlet at the downstream boundary: 0 Pa periodic side boundaries Figure 16.

Figure 15 and

Figure 12 Inlet velocity: 3 m/s

Figure 13 Inlet temperature: 20C

Figure 14 Orifice wall temperature: 300C

Figure 15 Static-pressure outlet at the downstream boundary: 0 Pa

Figure 16 Periodic side boundaries

Running the simulation and post-processing

After generating of the mesh, setting the physics and, least but not least, defining the boundary conditions, the simulation was performed and the following results were obtained:
streamlines in the mid-plane along the pipe Figure 17 streamlines velocity Figure 18; reattachment length distance between the orifice plate and the wall point behind the orifice plate where the flow attaches to the wall Figure 19; 2D plots: o axial velocity Figure 20; o static pressure Figure 21; o residual history Figure 22; contour plots in radial plane inside the pipe: o velocity magnitude Figure 23; o axial velocity Figure 24 o pressure Figure 25 and o temperature Figure 26.

Figure 17 Streamlines in the pipe mid-plane

Figure 18 Streamlines velocity in z axle direction

Figure 19 Reattachment length

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The length of the reattachment was taken through the wall shear stress plot in the z direction combined with picking the lowest pressure value. The message below was used to get the measurement. **cell probe entity: Walls 2 cellId: 550 field: Wall Shear Stress [k] value: 1.274904e-03 (Pa) position: (0.01268597260734075, 1.4999790024471105E-4, 0.11674378043616723) (m) Thus the pressure nearest to zero was found and its coordinate points, yielding to the reattachment length of 0.117m where the pressure was 1.3x10-3 Pa, assumed as zero in this analysis.

Figure 20 Axial velocity plot

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Figure 21 Static pressure plot

Figure 22 Residual history plot

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Figure 24 Velocity magnitude Figure 23 Velocity magnitude

Figure 24 Axial velocity

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o velocity: magnitude Figure 23; o axial velocity Figure 24 o pressure Figure 25 and o temperature Figure 26.

Figure 25 Temperature

Comparison between results applying different mesh types

In order to compare the meshes it was created two section planes, the first before and second one after the orifice. Their distances were 0.0145m and 0.0200m from the inlet as it is illustrated in the Figure 26 and Figure 27.
0.0145m Inlet 0.02m

Figure 26 Planes section details

Figure 27 Planes section overview

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Two tables were built-up to show the differences between the two meshes in both planes, i.e. before and after the orifice, with respect to the mesh type, axial velocity, pressure and temperature. All the boundary conditions were kept the same. Table 1: Plane 1 0.0145m, before the orifice
Mesh definition: trimmer; prism layer mesher and base size 2mm Mesh definition: polyhedral mesher; surface mesher; prism layer mesher and base size 5mm

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Table 1: Plane 1 0.0145m, before the orifice

Mesh definition: trimmer; prism layer mesher and base size 2mm Mesh definition: polyhedral mesher; surface mesher; prism layer mesher and base size 5mm

Table 2: Plane 2 0.02m, after the orifice

Mesh definition: trimmer; prism layer mesher and base size 2mm Mesh definition: polyhedral mesher; surface mesher; prism layer mesher and base size 5mm

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Table 2: Plane 2 0.02m, after the orifice

Mesh definition: trimmer; prism layer mesher and base size 2mm Mesh definition: polyhedral mesher; surface mesher; prism layer mesher and base size 5mm

Conclusion
There were no relevant differences, in the planes before and after the orifice, comparing the results of the axial velocity and pressure. Regarding to the comparison of the temperature on planes and in the meshes, it is recommended to perform further analysis, by an experienced professional, in order to verify whether the temperature on the wall could really achieve 235C or not. In addition to that, a multiphysic simulation would also be valuable to evaluate the influence of the temperature with respect to: thermal expansion which could lead to increase the volume and strength that could decrease depending of the material chosen.

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