Computational Fluid Dynamics

Computational Fluid Dynamics

SHEGESH.M.NAIR G. SANDEEP
B-Tech – 3/4 B-Tech – 3/4

Mechanical Engineering Mechanical Engineering

Email : shagy_jan8@yahoo.co.in Email:

Ph no: 9866747535 Ph no: 9948872122

MAHAVEER INSTITUTE OF SCIENCE AND TECHNOLOGY,

BANDLAGUDA, HYDERABAD .

CONTENTS

1. INTRODUCTION

2. HISTORY

3. PREDICTIONS

4. CFD PROCESS

• PRE PROCESSING

• SOLVING

• POST PROCESSING

5. BENEFITS

• INSIGHT

6. APPLICATIONS

• FEM

• SPH

• DIE CASTING
• DEM

7. USES

8. BIBLIOGRAPHY

Abstract

Computational Fluid Dynamics , a computational technology that enables us to study the

dynamics of things that flow. Using C FD, we can build a computational model that represents a
system or device that you want to study. Then we apply the fluid flow physics and chemistry to this
virtual prototype, and the software will output a prediction of the fluid dynamics and related physical
phenomena. Therefore, C FD is a sophisticated computationally based design and analysis technique.
C FD software gives us the power to simulate flows of gases and liquids, heat and mass transfer,
moving bodies, multiphase physics, chemical reaction, fluid-structure interaction and acoustics
through computer modeling. Using C FD software, we can build a ' virtual prototype ' of the
system or device that we wish to analyze and then apply real-world physics and chemistry to the
model, and the software will provide us with images and data, which predict the performance of the
design.

This Paper deals with the factors responsible for the advent of C FD, what actually C FD is, the
process it involves, the predictions it makes in the process, its applications, uses. It provides us with
a brief explanation of C FD's application in the field of high pressure die casting, it also gives us an
idea about how far the C FD can be trusted.

INTRODUCTION

A Working Definition of Computational Fluid Dynamics :

· Computational - having to do with mathematics, computing

· Fluid Dynamics - the dynamics of things that flow

Computational Fluid Dynamics (C FD) is one of the branches of fluid mechanics that uses
numerical methods and algorithms to solve and analyze problems that involve fluid flows.
C omputers are used to perform the millions of calculations required to simulate the interaction of
fluids and gases with the complex surfaces used in engineering. However, even with simplified
equations and high-speed super computers, only approximate solutions can be achieved in many
cases. More accurate codes that can accurately and quickly simulate even complex scenarios such
as supersonic or turbulent flows are an ongoing area of research. Validation of such codes is
often performed using a wind tunnel .

Fluid flow is:

· Breathing, drinking, digesting, washing, swimming, smoking.

· Laundering clothes, and hanging them out to dry.

· Heating or ventilating a room; extinguishing a fire with water.

· Burning gasoline in an automobile engine to create power and pollution.

· Making soup, creating plastics from petroleum.

· Flying an airplane, parachuting, surfing, sailing.

· Soldering, making steel, electrolysing water.

What actually CFD is :-

CFD is predicting what will happen, quantitatively, when fluids flow, often with the complications of:

· simultaneous flow of heat ,

· Mass transfer (eg perspiration, dissolution),

· Phase change (eg melting, freezing, boiling),

· Chemical reaction (eg combustion, rusting),

· Mechanical movement (eg of pistons, fans, rudders),

· Stresses in and displacement of immersed or surrounding solids.

History :
The development of C omputational Fluid Dynamics began with the advent of digital computers in the
early 1950's. Finite Difference Methods (FDM) and Finite Elementary Methods (FEM), which
are basically used as tools in solving partial differential equations in general and C FD in particular ,
have different origins. In 1910, at the royal society of London , Richardson presented a paper on
the first FDM solution for the stress analysis of a masonry dam. In contrast, the first FEM work was
published in Aeronautical science journal by Turner , Clough, Martin and Topp for applications to
aircraft stress analysis in 1956. Since then both methods have been developed extensively in fluid
dynamics, heat transfer and related areas.

Its early beginnings were in the 1960's.

· Its first successes came to prominence in the 1970's.

· The creation of the C FD-service industry started in the 1980's.

· The industry expanded significantly in the 1990's.

· Expansion continued in the Second Millennium as C FD packages devloped easier connexions with
those for C AD and solid-stress analysis.

· A significant change of the near future is likely to involve the use of pay-as-you go remote
computing, via Internet.

The way CFD makes predictions :-

C FD uses a computer to solve the relevant science-based mathematical equations, using
information about the circumstances in question.

Its components are therefore:

· the human being who states the problem,

· scientific knowledge expressed mathematically ,

· the computer code (ie software) which embodies this knowledge and expresses the stated
problem in scientific terms,

· the computer hardware which performs the calculations dictated by the software,

· the human being who inspects and interprets their results.

The CFD Process :

Schematic of a CFD simulation process on a generic Formula 1 Motor Racing Car: CAD,
grid and CFD prediction

There are essentially three stages to every C FD simulation process:

• preprocessing

• solving

• postprocessing

Preprocessing :
This is the first step in building and analyzing a flow model. It includes building the model within a
computer-aided design (CAD) package, creating and applying a suitable computational mesh,
and entering the flow boundary conditions and fluid materials properties. We supply our customers
with preprocessing tools such as GAMBIT , TGrid and G/Turbo as standard. But, we also have
very good filters to nearly every other third -party preprocessing tool available in the market today.

C AD geometries are easily imported and adapted for C FD solutions in GAMBIT, Fluent's own
preprocessor. 3D solid modeling options in GAMBIT allow for straightforward geometry construction
as well as high quality geometry translation. Among a wide range of geometry tools, Boolean
operators provide a simple way of getting from a C AD solid to a fluid domain. A state-of-the-art set
of cleanup and conditioning tools prepares the model for meshing. GAMBIT's unique curvature and
proximity based "size function" produces a correct and smooth C FD-type mesh throughout the
model. Together with our boundary layer technology, a number of volumetric meshing schemes
produce the right mesh for your application. Parametric variations are also inherent to the process.
Fluent's solvers also couple with leading third-party meshing tools such as ANSA , Harpoon ,
Sculptor and YAMS , extending your capability to effectively create the mesh you need.

Solving :

Typical FLUENT CFD simulation interface of an automotive cylinder

The C FD solver does the flow calculations and produces the results. We provide four general-
purpose products :FLUENT , Flo Wizard , FIDAP , and POLYFLOW . . FLUENT is used in most
industries. FloWizard is the first general-purpose rapid flow modeling tool for design and process
engineers built by Fluent. POLYFLOW (and FIDAP) are also used in a wide range of fields, with
emphasis on the materials processing industries.

The FLUENT C FD code has extensive interactivity, so you can make changes to the analysis at any
time during the process. This saves you time and enables you to refine your designs more
efficiently. Our graphical user interface (GUI) is intuitive, which helps to shorten the learning
curve and make the modeling process faster. It is also easy to customize physics and interface
functions to your specific needs. In addition, FLUENT's adaptive and dynamic mesh capability is
unique among C FD vendors and works with a wide range of physical models. This capability makes
it possible and simple to model complex moving objects in relation to flow.

We provide the broadest range of rigorous physical models that have been validated against
industrial scale applications, so you can accurately simulate real-world conditions, including:

· multiphase flows,

· reacting flows

· rotating equipment

· moving and deforming objects

· turbulence

· radiation

· acoustics, and

· dynamic meshing

The FLUENT solver has repeatedly proven to be fast and reliable for a wide range of C FD
applications. The speed to solution is faster because our suite of software enables you to stay within
one interface from geometry building through the solution process, to post processing and final
output. FLUENT's performance has been tried and proven on a variety of multi-platform clusters.
Our parallel computing capability is flexible and enables you to solve larger problems faster.

Postprocessing :
This is the final step in C FD analysis, and it involves the organization and interpretation of the
predicted flow data and the production of C FD images and animations. All of Fluent's software
products include full postprocessing capabilities. Our postprocessing tools enable you to provide
several levels of reporting, so you can satisfy the needs and interests of all the stakeholders in your
design process. Quantitative data analysis can be as sophisticated as you require. High-resolution
images and animations help you to tell your story in a quick and impactful manner.

Fluent's C FD data exports to third-party postprocessor and visualization tools such as

Ensight, Fieldview and TechPlot as well as to VRML formats. In addition, FLUENT C FD solutions are
easily coupled with structural codes such as ABAQUS , MSC and ANSYS , as well as to other
engineering process simulation tools.

The Benefits of CFD :-

There are three compelling reasons to use C FD software: insight , foresight , and efficiency .

Insight :
If you have a device or system design which is difficult to prototype or test through

Here we can see C FD insight into the effect of breathing different sized particles in a human
airway

The foresight you gain from C FD helps you to design better and faster, save money, meet
environmental regulations and ensure industry compliance. C FD analysis leads to shorter design
cycles and your products get to market faster. In addition, equipment improvements are built and
installed with minimal downtime. C FD is a tool for compressing the design and development cycle
allowing for rapid prototyping.

Foresight :

Simulation of flow over a male elite swimmer gliding under water C ourtesy of Speedo International
Ltd.

Because C FD is a tool for predicting what will happen under a given set of circumstances, it can
quickly answer many 'what if?' questions. You provide a set of boundary conditions, and the
software gives you outcomes. In a short time, you can predict how your design will perform, and
test many variations until you arrive at an optimal result. All of this can be done before physical
prototyping and testing.

Efficiency :

Turbulent mixing inside a rotating impeller mixing vessel. By analyzing this mixer with C FD we can
improve its productivity and efficiency.

The foresight you gain from C FD helps you to design better and faster, save money, meet
environmental regulations and ensure industry compliance. C FD analysis leads to shorter design
cycles and your products get to market faster. In addition, equipment improvements are built and
installed with minimal downtime. C FD is a tool for compressing the design and development cycle
allowing for rapid prototyping.

Applications :-

CFD finds its applications in the following aspects :

1. Finite Element Methods (FEM)

· Turbulent flow over a car

· Convective cooling of heated plates

· Differentially heated room

· Water slide

· Heart Valve

· Visco elastic flow around a sphere

· Turbulent flow in a tundish

2. Discrete Element Method (DEM)

· Ball Mill

· SAG Mill

· Vibrating screen

· C ylindrical Hoppers

3. Smoothed Particle Hydrodynamics (SPH)

· High Pressure die casting in a channel

· Heat and Mass transfer in an electric arc furnace

· High Pressure die casting

High pressure die casting into a 2D channel :

High pressure die casting (HPDC ) is used extensively to fabricate complex-shaped objects using
light metals. Liquid metal is injected at high speeds under very high pressure. The resulting flow is
extremely complicated, with substantial droplet and fragment formation. HPDC dynamics are not
well understood; numerical simulation using SPH can lead to an increased knowledge of the HPDC
process.

The flow of liquid metal in a channel of width 2 mm has been computed using two-dimensional SPH
simulations. The Reynolds number - based on the velocity through the gate of 50 m/s , and the
gate width of 1 mm - is Re = 100 . For this example, the liquid is assumed to be isothermal, and
the air initially in the mould is neglected.

The filling of the channel is observed in the plots below, which are coloured according to local
velocity magnitude. It can be seen that the liquid metal enters and is forced upwards by the right
wall without contacting the left one. The jet then collides head-on with the top wall and fragments.
Most of the fluid moves to the right and forms an irregular horizontal jet. The rest is forced back
down along the left side of the mould as a spray of droplets and is likely to trap air in the central
gap in the vertical section between the upward and downward jets. This takes quite some time to fill
with what would be partially solidified irregularly shaped fragments and would be expected to
produce fine scale porosity and mechanical strength problems. Flakiness of the front surface of such
castings is actually observed here.

Velocity contours of the liquid metal at different times

Meanwhile, the jet travels along the upper part of the short horizontal section to the next bend
where it is deflected downwards, again with the formation of fragments. Similar behaviour is
observed for the filling of each of the mould sections. During the filling of the end vertical section,
multiple recirculations appear. Once filled, there is a back flow and the lower part of the horizontal
section fills. The region near the lower wall of the top right section is the last to fill. Bubbles are
frequently observed here in real castings.

Uses of CFD :-

Knowing how fluids will flow, and what will be their

quantitative effects on the solids with which they are in
contact, assists:
· building-services engineers and architects to provide comfortable and safe human
environments;

· power-plant designers to attain maximum efficiency, and reduce release of pollutants;

· chemical engineers to maximize the yields from their reactors and processing equipment;

· land-, air - and marine-vehicle designers to achieve maximum performance, at least cost;

· risk-and-hazard analysts, and safety engineers, to predict how much damage to structures,
equipment, human beings, animals and vegetation will be caused by fires, explosions and blast
waves.

CFD-based flow simulations enable :

· metropolitan authorities need to determine where pollutant-emitting industrial plant may be safely
located, and under what conditions motor-vehicle access must be restricted so as to preserve air
quality;

· meteorologists and oceanographers to foretell winds and water currents; - hydrologists and others
concerned with ground-water to forecast the effects of changes to ground-surface cover, of the
creation of dams and aquaducts on the quantity and quality of water supplies;

· petroleum engineers to design optimum oil-recovery strategies, and the equipment for putting
them into practice;

Can CFD be trusted?

C FD-based predictions are never 100%-reliable, because:

· the input data may involve too much guess-work or imprecision;

· the available computer power may be too small for high numerical accuracy (this is often the
case);

· the scientific knowledge base may be inadequate (so is this).

The reliability is greater:

- for laminar flows rather than turbulent ones

- for single-phase flows rather than multi-phase flows;

- for chemically-inert rather than chemically-reactive materials;

- for single chemical reactions rather than multiple ones;

- for simple fluids rather than those of complex composition.

Therefore, coal-fired furnaces represent an extreme of uncertainty; but C FD is nevertheless used

increasingly in their design because the uncertainties resulting from its non-use is even greater.

Bibliography :
1. C omputational Fluid Dynamics by Eduardo. Ramos

2. P.W. C leary and J. Ha, SPH modelling of isothermal high pressure die casting , Proceedings of the
13th Australasian Fluid Mechanics C onference ( Melbourne , 1998).

C reated by Department of C SE