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Simulation-report
Bansal, Hemant
Esslingen 27.06.2011
Introduction
1.
Introduction
Computational Fluid Dynamics, CFD has gained a very wide popularity in the recent times owing to its numerous applications and advantages. In addition to knowing the fundamentals of CFD it is very important to have the know-how of the commercial softwares code for CFD, as for indsutrial applications these commercial codes are widely used. The scope of the task here is to work with one of the CFD softwares STAR CCM+ was used in this case for simulations. A pipe with an orifice was considered, and internal fow thorugh the pipe was considered. The Scope of the task was to get familirized with various aspects of CFD commercial softwares, experiment with different setting conditions for models and analyse the simulation results.
Definition of problem
2.
Problem Description
2.1.
A fluid passing though an orifice constriction will experience a drop in pressure across the orifice. This change can be used to measure the flowrate of the fluid. Orifice plates are most commonly used for continuous measurement of fluid flow in pipes. The Present task involved setting up a CFD model for the given problem with different CFD parameters, Inlet and outlet conditions were already provided, flow was to be simulated at two different inlet conditions. For familirizing with the software it was stated to test different meshes and med refinement techniques. The following results should be analyzed Pressure, velocity and temperature contours in the pipe Streamlines at the mid section of pipe 2-D plots for axial velocity and static pressure along the pipe axis.
Definition of problem
Measuring the Reattachment length o In a sudden expansion an inlet pipe with small diameter, flow is unable to follow the sudden enlargement and will detach at the sudden expansion. After some length downstream, called the reattachment length, the flow attaches to the outlet pipe. This reattachment length is highly dependent on the inlet conditions of the flow and the expansion ratio.
3.
Pre processing of the model was using STAR CCM+ The CAD model of the pipe was available in STL format orifice.x_t. The model represented only quarter of the pipe as flow is symmetric inside the pipe. Hence the initial settings were made on the pipe to make detachg al its surfaces in order to assign them different properties and boundary conditions. Periodic Boundary Conditions: As discussed, because only quarter of pipe is analyzed here periodic boundary conditions should be assigned to the opposite walls so as to indicate the flow across them takes place with similar conditions.
General Settings and Boundary conditions: Fluid : Air Density: 1,205 kg/m3 Dynamic Viscosity: 1,845 E-05 Pa-s 3D simulation, Steady-state Incompressible, with segregated flow. Turbulent (k-epsilon) and heat transfer included.
Boundary Conditions Inlet temperature: 20 C Orifice wall Temperature: 300 C Static- Pressure outlet at down stream boundary: 0 Pa
3.1.
It was decided to conduct the Simualtions under various conditions listed in the table below, to familirize with the software and also to be able to analyze consequences of various paremeters of simulation.
Simulation Mesh Type No. Trimmed Mesh Trimmed Mesh Trimmed Mesh Tetrahedral Tetrahedral
Prism Layer
Volumetric Block around Orifice 10% of Base size 40% of Base size 20% of Base size 10% of Base size 20% of Base size
1 2 3 4 5
6 mm 6 mm 6 mm 6 mm 6 mm
3 15 15 3 6
4.
On the above mentioned conditions, simulation was carried out and the results are enclosed in this section. Simulation 1
Trimmed Mesh 10% of Base size
6 mm
Yes, 3
3 m/s
Fig 4.6 Reattachment length using Wall shear stress Reattacment Length measured from contour - 0,07m
Simulation 2
Trimmed Mesh 40% of Base size
6 mm
Yes, 3
15 m/s
Same simulation and post processing was done under the higher velocity of 15m/s. Here the volumetric Block was not meshed to a very fine , it was also kept coarse.
Simulation 3
Trimmed Mesh 20% of Base size
6 mm
Yes, 3
15 m/s
Same simulation and post processing was done under the higher velocity of 15m/s. The volumetric Block was meshed to a very fine value of 20%, i.e. a mesh size of 1.2 mm.
Simulation 4
Tetrahedral
6 mm
Yes, 3
3 m/s
Same simulation and post processing was done under the higher velocity of 15m/s. The volumetric Block was meshed to a very fine value of 20%, i.e. a mesh size of 1.2 mm.
Fig: 2D plot for axial velociy and Static Pressure Reattachment Length: 0,73 m
Simulation 5
20% of Base size
Tetrahedral
6 mm
Yes, 3
6 m/s
Same simulation and post processing was done under the higher velocity of 15m/s. Here the vaolumetric Block was not meshed to a very fine , it was also kept coarse.
Fig: 2D plot for axial velociy and Static Pressure Reattachment Length: 0,082m
5.
Different Mesh types were compared, and their influence on simulation accuracy and simulation time was studied. Pre processing was made to test different block mesh sizes to see their effect on the solution and how can the gradients be captured at critical sections. We can see from the contours as well as 2D plot their due to mesh refinement at the critical section, the velocity fluctuations were captured at fine spacing as well. Stream lines on the mid plane compare very well to the physical behaviour of the flow through an orifice. Effect of including heat transfer in the model also yielded interestif results as we can see from the temperature contours that temp effect should not be neglected. But further analysis is recommended here to include for thermal expansion as well as simulation correct convection behaviours. Working with different meshes in this case we cannot see major differences as the problem is not complex, and computing memory and space were not critical.