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Numerical Simulation of The Internal Flow Field of A New Main Nozzle in An Air-Jet Loom Based On Fluent
Numerical Simulation of The Internal Flow Field of A New Main Nozzle in An Air-Jet Loom Based On Fluent
Numerical Simulation of The Internal Flow Field of A New Main Nozzle in An Air-Jet Loom Based On Fluent
Abstract
In order to decrease the turbulence influence and the backflow during weft insertion in an air-jet loom, a new main
nozzle composed of two nozzle needles connected in series is designed. The internal flow fields of the commonly used
nozzle and the new nozzle are numerically studied by means of a three-dimensional model implemented by the com-
putational fluid dynamics technique. It is observed that the turbulence strength is effectively controlled with different air
supply pressures and the backflow phenomenon at the upstream passage generated by high supply pressures can be
eliminated when the supply pressure is reasonably distributed into two inlets of the new nozzle. The drag force exerted
on the weft yarn is calculated when the velocity distribution of the internal airflow is obtained, and results show that the
drag force can be improved. Also, the numerical simulation can give some guidelines for future prototyping and
experiments.
Keywords
air-jet loom, main nozzle, flow field, Fluent
The main nozzle is a key component in the weft inser- the shape, and the size. Zhu and Zhou4 analyzed the
tion system of an air-jet loom; it works as an ejector, structure, the velocity, and the static pressure charac-
sucking the weft yarn and driving it through the warp teristics of the airflow inside the main nozzle. Mohamed
shed. It is the first step for the weft yarn to be sucked and Salam5 and Salama et al.6 researched nozzles with
into the main nozzle. Therefore, the performance of the various geometries and the corresponding weft inser-
internal airflow, especially the centerline airflow, will tion behaviors through the tubes both in experiment
directly influence the efficiency of an air-jet loom and and theory. They also dispose the influence of air
the quality of the fabric. The airflow varies under dif- supply pressure and the presence of a yarn tube on
ferent air supply pressures, which may cause a stronger the performance of the main nozzle. Recently, more
turbulence area and generate backflow phenomenon. attention has been paid to the flow field analysis and
Studies on the research and optimization of the main structural optimization of the weft insertion system by
nozzle have been intermittently dealt with over the past our research group at Soochow University. Concretely,
few decades. Xue et al.1 and Liang et al.2 studied the Yuan7 built up a two-dimensional flow field model, and
internal flow field of the main nozzle by use of compu- simulated the flow field of weft insertion by the change
tational fluid dynamics (CFD) softwares; they obtained
the velocity distribution of the airflow along the axial
and radial direction, and observed the turbulence and
backflow phenomena. Belforte et al.3 also carried out a School of Mechanical and Electric Engineering, Soochow University, China
numerical simulation to determine which physical
Corresponding author:
model could predict a better behavior of the main Zhi-hua Feng, School of Mechanical and Electric Engineering, Soochow
nozzle, and they also discussed the influence on the University, 178 East Ganjiang Road, Suzhou, 215021, China.
drag force arising from the acceleration tube length, Email: zhfeng@suda.edu.cn
of parameters, such as the diameters, throat sectional models of the internal flow fields of the commonly used
areas, acceleration tube lengths of the main nozzle, and nozzle and the new nozzle are built up by use of the
air supply pressures. Guo8 modeled a three-dimen- three-dimensional software named Unigraphics NX
sional flow field, and investigated the main nozzles 8.5. Then the models are meshed by the professional
with different numbers of slots, diameters of the holes meshing software named ICEM CFD. Finally, the
for weft insertion, distances between the outlet of the numerical simulation is carried out using Fluent. In
needle and the slots and the air supply pressures. The order to evaluate the internal airflow performance,
advantage of different parameter combinations for the the drag force exerted on the weft is calculated. It is
structure of the main nozzle and the air supply pres- observed that the performance of the internal airflow of
sures was also analyzed. Lu9 provided a method to the new nozzle is optimized compared with that of the
control the velocity and pressure of the outlet of the commonly used nozzle. Naturally, these numerical
main nozzle by changing the throat area of the main simulation results can give some guidelines for future
nozzle. Xu et al.10 combined the numerical simulation prototyping and experiments.
of the airflow velocity and the density with the experi-
mental test of the drag force to obtain the friction coef-
ficients of different weft yarns. Dong et al.11 arrived at Structures and flow field models
the conclusion that the numerical simulation results for of the main nozzles
the flow field obtained by Fluent software are in good
agreement with those obtained experimentally.
The commonly used main nozzle
In this paper, a new main nozzle composed of two Structure of the commonly used main nozzle. Figure 1
nozzle needles connected in series is designed to address shows the structure of a commonly used nozzle. The
the need to control the turbulence strength and to elim- nozzle is composed of a body (1), a needle (2), a cylin-
inate the backflow phenomenon. The three-dimensional der (3) and an acceleration tube (4). Figure 2 shows the
Figure 3. Three-dimensional model and boundary condition of the flow field of the commonly used main nozzle.
Figure 5. Velocity distribution of the centerline of internal airflow under different air supply pressures of the commonly used main
nozzle.
Figure 6. Velocity contour under 0.2 MPa air supply pressure of the symmetric surface of the internal flow field of the commonly
used nozzle.
the new nozzle; when the air passes away from the needle passage (A) of the needle1. Since the air supply pressures
tip1, there is also a negative pressure area and a strong in inlet1 and inlet2 are adjustable, different airflow can
turbulence area, and a flow expansion also occurs. After be obtained. Thus, different pressure distribution can be
the air flows into the nozzle needle2, the interior flow chosen to obtain a suitable airflow to meet the different
passage (L) works as an acceleration area. After the air needs of the manufacturing process.
from inlet1 and inlet2 meets, the mixed air will be accel-
erated in the interior passage (M) of the acceleration Flow field model of the new main nozzle. Figure 9 shows the
tube, and the weft yarn is sucked into interior flow three-dimensional model and the boundary condition
Figure 9. Three-dimensional model and boundary condition of the flow field of the new main nozzle.
of the flow field of the new nozzle. The flow field of the Numerical simulation of two main nozzles
new nozzle is disposed like that of the commonly used
Simulation setting
nozzle. Figure 10 shows the finite element model of the
flow field of the new nozzle. There are about 754,895 To implement the simulation, some assumptions are
elements and 546,606 nodes. made as given below:
A-1 0.1
A-2 0.2
A-3 0.3
A-4 0.4
A-5 0.5
Figure 10. Finite element model of the flow field of the new
main nozzle.
Tables 2 and 3 for the commonly used main nozzle
and the new main nozzle, respectively.
Table 3. Air supply pressures for the new main nozzle Table 4. Simulation classification
Air supply pressure (MPa) Total supply pressure (MPa) Simulation type
Figure 11. Comparison among different conditions under 0.1 MPa total supply pressure.
Figure 12. Comparison among different conditions under 0.2 MPa total supply pressure.
Figure 13. Comparison among different conditions under 0.3 MPa total supply pressure.
and ‘‘D-2’’), and the airflow in type ‘‘E-1’’ plays better Figure 15 shows the comparison among different con-
than that in type ‘‘D-2’’ because the internal flow pas- ditions under 0.5 MPa total supply pressure. The max-
sage in needle2 works as an acceleration area, and the imum backflow velocity caused by the strong turbulence
accelerated airflow can decrease the turbulence strength area in the downstream area at point ‘‘S2’’ of the com-
in the downstream area at point ‘‘S3’’. Thus, this shows monly used nozzle and the new nozzle are about 400
that the preferred airflow may be obtained only in a and 370 m/s, respectively, whereas the maximum back-
proper air distribution method. flow velocity in some types of the new nozzle is about
Figure 14 shows the comparison among different 185 m/s, except types ‘‘B-5’’, ‘‘D-4’’, and ‘‘E-3’’.
conditions under 0.4 MPa total supply pressure. As Furthermore, there is no backflow phenomenon in the
the air supply pressure increases, the backflow phenom- upstream area at point ‘‘S1’’ in types ‘‘H-5’’ and ‘‘I-5’’.
enon is more serious, which does not happen in types The airflow in type ‘‘F-2’’ plays better than that in type
‘‘C-4’’, ‘‘H-4’’, and ‘‘I-4’’. There are three air distribu- ‘‘E-3’’, and the airflow in type ‘‘E-3’’ plays better than
tion methods (Types ‘‘D-3’’, ‘‘E-2’’, and ‘‘F-1’’): the that in type ‘‘D-4’’, which is similar to that in the types
airflow in type ‘‘F-1’’ plays better than that in type with 0.4 MPa air supply pressure. However, the airflow in
‘‘E-2’’ and the airflow in type ‘‘E-2’’ plays better than type ‘‘G-1’’ is not better than that in type ‘‘F-2’’, because
that in type ‘‘D-3’’. This is similar to the types under 0.3 the air supply pressure distributed to inlet1 has already
MPa total supply pressure. As the air supply pressure generated a stronger turbulence area, which influences the
of inlet1 is much higher than that of inlet2, the airflow airflow in the downstream area at point ‘‘S2’’.
may play much better, because the compressed air with
0.4 MPa supply pressure distributed to inlet1 does not
generate a stronger turbulence area to obviously influ- Drag force evaluation
ence the airflow in the whole upstream area at point
‘‘S2’’, and to seriously influence the airflow in the down- In order to evaluate the internal airflow performance,
stream area at point ‘‘S2’’. The maximum backflow vel- the drag force exerted on the weft is calculated. The
ocity caused by the strong turbulence area in the drag force Fdl exerted on one element of the weft
downstream area at point ‘‘S2’’ of the commonly used yarn is defined as
nozzle and the new nozzle are about 409 and 245 m/s,
respectively. However, the maximum backflow velocity
in some types of the new nozzle is about 151 m/s, except 1
Fdl ¼ Cf dðv uÞ2 dl ð1Þ
type ‘‘D-3’’. 2
Figure 14. Comparison among different conditions under 0.4 MPa total supply pressure.
Figure 15. Comparison among different conditions under 0.5 MPa total supply pressure.
Drag force
per meter
Figure 16. A model of an element connected by two points. (N/m)
Simulation Air supply
type pressure (Mpa) U¼0 U ¼ 80
where Cf is the friction coefficient between air and the A-1 0.1 14,010 3261
weft yarn element, d is the diameter of the weft yarn,
H-1 0.1 17,183 4840
is air density, v is air velocity, u is weft yarn velocity,
I-1 0.1 21,989 7189
and dl is the length of the element.
Physical parameters on a series of points, such as A-2 0.2 25,481 8768
and v, can be obtained from numerical simulation. C-2 0.2 33,440 13,077
Figure 16 shows a model of an element connected by H-2 0.2 32,334 13,177
two points. I-2 0.2 42,160 18,495
p is a constant, and d is a constant for a kind of weft A-3 0.3 32,923 10,085
in theory. Although Cf varies with the relative velocity C-3 0.3 40,483 15,611
between the air velocity and the weft yarn velocity, it E-1 0.3 38,178 16,017
only has a small influence on the final drag force H-3 0.3 43,408 19,021
according to Guo and Chen.12 Therefore, Cf is treated I-3 0.3 56,876 25,728
as a constant. In order to simplify the evaluation, it is A-4 0.4 37,208 6234
reasonable to treat Cf, p and d as 1, and the drag force
C-4 0.4 40,649 16,930
exerted on an element is defined as
E-2 0.4 40,463 15,772
0 1 F-1 0.4 47,548 19,110
Fdl ¼ ðv uÞ2 dl ð2Þ H-4 0.4 30,583 11,447
2
I-4 0.4 41,458 17,510
Physical parameters of the element, such as and v, A-5 0.5 42,060 4918
are disposed as C-5 0.5 46,036 18,927
E-3 0.5 36,118 8283
¼ 12 ða þ b Þ, v ¼ 12 ðva þ vb Þ ð3Þ F-2 0.5 51,662 19,571
G-1 0.5 33,019 10,674
In order to compare the air performance of the new H-5 0.5 32,508 10,685
nozzle with that of the commonly used nozzle fully, two I-5 0.5 47,583 20,053
kinds of flying status of weft yarn are taken into
consideration:
to compare with those of the commonly used nozzle
1. u ¼ 0, which means one side of the weft yarn is fixed; in Table 5. Considering Equation (1), it is observed
and that the air density and the air velocity v are the
2. u ¼ 80 m/s, which means the weft yarn maintains key factors increasing the drag force, whereas the air
normal flying status. velocity v plays a more important role. As a conse-
quence, when the air supply pressure is less than 0.3
A series of drag forces exerted on the weft elements MPa, the air velocity grows faster and so does the
can be obtained, considering that the length of the new drag force; however, when the air supply pressure is
nozzle is longer than that of the commonly used nozzle; more than 0.3 MPa, the air velocity varies towards a
therefore, total drag force can be defined as gentle gradient, and the air density grows faster, which
X results in the drag force increasing more gently. When
0
F¼ Fdl =l ð4Þ the drag forces in different types under different air
supply pressures are compared with each other, it is
where l is the total length of the main nozzle. Drag observed that a stronger turbulence area, which
force F of the new main nozzle and commonly used causes generation of the backflow phenomenon in the
nozzle under different total supply pressure is shown upstream area at point ‘‘S2’’, is generated under high air
in Table 5. supply pressure; it obviously influences the increase of
In order to describe the advantages of the new the total drag force. It also indicates that when the air is
nozzle, some better and special situations are chosen distributed reasonably into two inlets of the new nozzle,
Funding
This work was supported by the Priority Academic Program
Development of Jiangsu Higher Education Institutions.