Kaiserslautern - Fachbereich Maschinenbau und Verfahrenstechnik
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Faculty / Organisational entity
A Consistent Large Eddy Approach for Lattice Boltzmann Methods and its Application to Complex Flows
(2015)
Lattice Boltzmann Methods have shown to be promising tools for solving fluid flow problems. This is related to the advantages of these methods, which are among others, the simplicity in handling complex geometries and the high efficiency in calculating transient flows. Lattice Boltzmann Methods are mesoscopic methods, based on discrete particle dynamics. This is in contrast to conventional Computational Fluid Dynamics methods, which are based on the solution of the continuum equations. Calculations of turbulent flows in engineering depend in general on modeling, since resolving of all turbulent scales is and will be in near future far beyond the computational possibilities. One of the most auspicious modeling approaches is the large eddy simulation, in which the large, inhomogeneous turbulence structures are directly computed and the smaller, more homogeneous structures are modeled.
In this thesis, a consistent large eddy approach for the Lattice Boltzmann Method is introduced. This large eddy model includes, besides a subgrid scale model, appropriate boundary conditions for wall resolved and wall modeled calculations. It also provides conditions for turbulent domain inlets. For the case of wall modeled simulations, a two layer wall model is derived in the Lattice Boltzmann context. Turbulent inlet conditions are achieved by means of a synthetic turbulence technique within the Lattice Boltzmann Method.
The proposed approach is implemented in the Lattice Boltzmann based CFD package SAM-Lattice, which has been created in the course of this work. SAM-Lattice is feasible of the calculation of incompressible or weakly compressible, isothermal flows of engineering interest in complex three dimensional domains. Special design targets of SAM-Lattice are high automatization and high performance.
Validation of the suggested large eddy Lattice Boltzmann scheme is performed for pump intake flows, which have not yet been treated by LBM. Even though, this numerical method is very suitable for this kind of vortical flows in complicated domains. In general, applications of LBM to hydrodynamic engineering problems are rare. The results of the pump intake validation cases reveal that the proposed numerical approach is able to represent qualitatively and quantitatively the very complex flows in the intakes. The findings provided in this thesis can serve as the basis for a broader application of LBM in hydrodynamic engineering problems.
The growing computational power enables the establishment of the Population Balance Equation (PBE)
to model the steady state and dynamic behavior of multiphase flow unit operations. Accordingly, the twophase
flow
behavior inside liquid-liquid extraction equipment is characterized by different factors. These
factors include: interactions among droplets (breakage and coalescence), different time scales due to the
size distribution of the dispersed phase, and micro time scales of the interphase diffusional mass transfer
process. As a result of this, the general PBE has no well known analytical solution and therefore robust
numerical solution methods with low computational cost are highly admired.
In this work, the Sectional Quadrature Method of Moments (SQMOM) (Attarakih, M. M., Drumm, C.,
Bart, H.-J. (2009). Solution of the population balance equation using the Sectional Quadrature Method of
Moments (SQMOM). Chem. Eng. Sci. 64, 742-752) is extended to take into account the continuous flow
systems in spatial domain. In this regard, the SQMOM is extended to solve the spatially distributed
nonhomogeneous bivariate PBE to model the hydrodynamics and physical/reactive mass transfer
behavior of liquid-liquid extraction equipment. Based on the extended SQMOM, two different steady
state and dynamic simulation algorithms for hydrodynamics and mass transfer behavior of liquid-liquid
extraction equipment are developed and efficiently implemented. At the steady state modeling level, a
Spatially-Mixed SQMOM (SM-SQMOM) algorithm is developed and successfully implemented in a onedimensional
physical spatial domain. The integral spatial numerical flux is closed using the mean mass
droplet diameter based on the One Primary and One Secondary Particle Method (OPOSPM which is the
simplest case of the SQMOM). On the other hand the hydrodynamics integral source terms are closed
using the analytical Two-Equal Weight Quadrature (TEqWQ). To avoid the numerical solution of the
droplet rise velocity, an analytical solution based on the algebraic velocity model is derived for the
particular case of unit velocity exponent appearing in the droplet swarm model. In addition to this, the
source term due to mass transport is closed using OPOSPM. The resulting system of ordinary differential
equations with respect to space is solved using the MATLAB adaptive Runge–Kutta method (ODE45). At
the dynamic modeling level, the SQMOM is extended to a one-dimensional physical spatial domain and
resolved using the finite volume method. To close the mathematical model, the required quadrature nodes
and weights are calculated using the analytical solution based on the Two Unequal Weights Quadrature
(TUEWQ) formula. By applying the finite volume method to the spatial domain, a semi-discreet ordinary
differential equation system is obtained and solved. Both steady state and dynamic algorithms are
extensively validated at analytical, numerical, and experimental levels. At the numerical level, the
predictions of both algorithms are validated using the extended fixed pivot technique as implemented in
PPBLab software (Attarakih, M., Alzyod, S., Abu-Khader, M., Bart, H.-J. (2012). PPBLAB: A new
multivariate population balance environment for particulate system modeling and simulation. Procedia
Eng. 42, pp. 144-562). At the experimental validation level, the extended SQMOM is successfully used
to model the steady state hydrodynamics and physical and reactive mass transfer behavior of agitated
liquid-liquid extraction columns under different operating conditions. In this regard, both models are
found efficient and able to follow liquid extraction column behavior during column scale-up, where three
column diameters were investigated (DN32, DN80, and DN150). To shed more light on the local
interactions among the contacted phases, a reduced coupled PBE and CFD framework is used to model
the hydrodynamic behavior of pulsed sieve plate columns. In this regard, OPOSPM is utilized and
implemented in FLUENT 18.2 commercial software as a special case of the SQMOM. The dropletdroplet
interactions
(breakage
and
coalescence)
are
taken
into
account
using
OPOSPM,
while
the
required
information
about
the
velocity
field
and
energy
dissipation
is
calculated
by
the
CFD
model.
In
addition
to
this,
the proposed coupled OPOSPM-CFD framework is extended to include the mass transfer. The
proposed framework is numerically tested and the results are compared with the published experimental
data. The required breakage and coalescence parameters to perform the 2D-CFD simulation are estimated
using PPBLab software, where a 1D-CFD simulation using a multi-sectional gird is performed. A very
good agreement is obtained at the experimental and the numerical validation levels.
The present thesis describes the development and the evaluation of a design procedure of inducer with arbitrary meridional and blade shape. This special type of pump impeller, which is usually mounted upstream of a main pump impeller, is employed in many applications demanding the realization of low NPSH values. An inducer basically increases suction performance by producing mostly a small pressure rise while allowing for a greater degree of cavitation, that is the formation of vapor bubbles, at its inlet than a conventional pump impeller. This is achieved by specially designed blade channels promoting the collapse of the produced vapor bubbles.
The main focus of the present thesis is the description of the design method, which enables the generation of the three-dimensional blade geometry. The method is based on a parametric representation of the geometry considering the particular requirements for inducers and the publicly available design practice. Within this approach the sequence of design steps is adapted from the classical design process of mixed flow and radial impellers. As a consequence leading and trailing edge blade angles are determined based on simplifications and certain empirical assumptions for multiple blade sections and are used to design the blade camber curves. Along the camber curves the blade profile is generated following a thickness distribution that has to be prescribed. A special feature of the newly developed method is that arbitrary shaped, asymmetric thickness distributions can be realized.
Due to the detailed description of the design and calculation steps a fully comprehensible procedure is outlined, which covers the development of inducer bladings from an initial set of duty parameters to the final three-dimensional blade geometry.
The components involved in the design procedure are tested by designing two exemplary inducers and they are assessed by comparison with numerical simulations. Functioning of these inducers in the real application is finally demonstrated with water tests.
The main result of this dissertation is a design software for inducers allowing for the design of three-dimensional, asymmetrically profiled bladings. The developed software is free of commercial third-party libraries. As a consequence a program is available that can be modified and extended as desired. As potential future development goals inducers with splitter and tandem blades as well as an integrated design of inducer and impeller are proposed.
This work deals with the simulation of the micro-cutting process of titanium. For this
purpose, a suitable crystal-plastic material model is developed and efficient implemen-
tations are investigated to simulate the micro-cutting process. Several challenges arise
for the material model. On the one hand, the low symmetry hexagonal close-packed
crystal structure of titanium has to be considered. On the other hand, large defor-
mations and strains occur during the machining process. Another important part is
the algorithm for the determination of the active slip systems, which has a significant
influence on the stability of the simulation. In order to obtain a robust implemen-
tation, different aspects, such as the algorithm for the determination of the active
slip systems, the method for mesh separation between chip and workpiece as well as
the hardening process are investigated, and different approaches are compared. The
developed crystal-plastic material model and the selected implementations are first
validated and investigated using illustrative examples. The presented simulations of
the micro-cutting process show the influence of different machining parameters on the
process. Finally, the influence of a real microstructure on the plastic deformation and
the cutting force during the process is shown.
This thesis is concerned with the modeling of the solid-solid phase transformation, such as the martensitic transformation. The allotropes austenite and martensite are important for industry applications. As a result of its ductility, austenite is desired in the bulk, as opposed to martensite, which desired in the near surface region. The phase field method is used to model the phase transformation by minimizing the free energy. It consists of a mechanical part, due to elastic strain and a chemical part, due to the martensitic transformation. The latter is temperature dependent. Therefore, a temperature dependent separation potential is presented here. To accommodate multiple orientation variants, a multivariant phase field model is employed. Using the Khachaturyan approach, the effective material parameters can be used to describe a constitutive model. This however, renders the nodal residual vector and elemental tangent matrix directly dependent on the phase, making a generalization complicated. An easier approach is the use of the Voigt/Taylor homogenization, in which the energy and their derivatives are interpolated creating an interface for material law of the individual phases.
The detection and characterisation of undesired lead structures on shaft surfaces is a concern in production and quality control of rotary shaft lip-type sealing systems. The potential lead structures are generally divided into macro and micro lead based on their characteristics and formation. Macro lead measurement methods exist and are widely applied. This work describes a method to characterise micro lead on ground shaft surfaces. Micro lead is known as the deviation of main orientation of the ground micro texture from circumferential direction. Assessing the orientation of microscopic structures with arc minute accuracy with regard to circumferential direction requires exact knowledge of both the shaft’s orientation and the direction of surface texture. The shaft’s circumferential direction is found by calibration. Measuring systems and calibration procedures capable of calibrating shaft axis orientation with high accuracy and low uncertainty are described. The measuring systems employ areal-topographic measuring instruments suited for evaluating texture orientation. A dedicated evaluation scheme for texture orientation is based on the Radon transform of these topographies and parametrised for the application. Combining the calibration of circumferential direction with the evaluation of texture orientation the method enables the measurement of micro lead on ground shaft surfaces.
The present situation of control engineering in the context of automated production can be described as a tension field between its desired outcome and its actual consideration. On the one hand, the share of control engineering compared to the other engineering domains has significantly increased within the last decades due to rising automation degrees of production processes and equipment. On the other hand, the control engineering domain is still underrepresented within the production engineering process. Another limiting factor constitutes a lack of methods and tools to decrease the amount of software engineering efforts and to permit the development of innovative automation applications that ideally support the business requirements.
This thesis addresses this challenging situation by means of the development of a new control engineering methodology. The foundation is built by concepts from computer science to promote structuring and abstraction mechanisms for the software development. In this context, the key sources for this thesis are the paradigm of Service-oriented Architecture and concepts from Model-driven Engineering. To mold these concepts into an integrated engineering procedure, ideas from Systems Engineering are applied. The overall objective is to develop an engineering methodology to improve the efficiency of control engineering by a higher adaptability of control software and decreased programming efforts by reuse.
Cloud Computing, or the Cloud, became one of the most used technologies in today's world, right after its possibilities had been figured out. It is a renowned technology that enables ubiquitous access to tasks that need collaboration or remote monitoring. It is widely used in daily lives as well as the industry. The paradigm uses Internet Technologies which rely on best-effort communication. Best-effort communication limits the applicability of the technology in the domains where the timing is critical. Edge Computing is a paradigm that is seen as a complementary technology to the Cloud. It is expected to solve the Quality of Service (QoS) and latency problems that are raised due to the increased count of connected devices, and the physical distance between the infrastructure and devices. The Edge Computing adds a new tier between Information Technology (IT) and Operational Technology (OT) and brings the computing power close to the source of the data. Computing power near devices reduces the dependency to the Internet; hence, in case of a network failure, the computation can still continue. Close proximity deployments also enable the application of Edge Computing in the areas where real-timeliness is necessary. Computation and communication in Edge Computing are performed via Edge Servers. This thesis suggests a standardized and hardware-independent software reference architecture for Edge Servers that can be realized as a framework on servers, to be used on domains where the timing is critical. The suggested architecture is scalable, extensible, modular, multi-user supported, and decentralized. In decentralized systems, several precautions must be taken into consideration, such as latencies, delays, and available resources of the neighbouring servers. The resulting architecture evaluates these factors and enables real-time execution. It also hides the complexity of low-level communication and automates the collaboration between Edge Servers to enable seamless offloading in case of a need due to lack of resources. The thesis also validates an exemplary instance of the architecture with at framework, called Real-Time Execution Framework (RTEF), with multiple scenarios. The tasks used are resource-demanding and requested to be executed on an Edge Server in an Edge Network comprising multiple Edge Servers. The servers can make decisions by evaluating their availabilities, and determine the optimal location to execute the task, without causing deadline misses. Even under a heavy load, the decisions made by the servers to execute the tasks on time were correct, and the concept is proven.
The simulation of cutting process challenges established methods due to large deformations and topological changes. In this work a particle finite element method (PFEM) is presented, which combines the benefits of discrete modeling techniques and methods based on continuum mechanics. A crucial part of the PFEM is the detection of the boundary of a set of particles. The impact of this boundary detection method on the structural integrity is examined and a relation of the key parameter of the method to the eigenvalues of strain tensors is elaborated. The influence of important process parameters on the cutting force is studied and a comparison to an empirical relation is presented.
This thesis is concerned with a phase field model for martensitic transformations in metastable austenitic steels. Within the phase field approach an order parameter is introduced to indicate whether the present phase is austenite or martensite. The evolving microstructure is described by the evolution of the order parameter, which is assumed to follow the time-dependent Ginzburg-Landau equation. The elastic phase field model is enhanced in two different ways to take further phenomena into account. First, dislocation movement is considered by a crystal plasticity setting. Second, the elastic model for martensitic transformations is combined with a phase field model for fracture. Finite element simulations are used to study the single effects separately which contribute to the microstructure formation.