Kaiserslautern - Fachbereich Maschinenbau und Verfahrenstechnik
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In this contribution a phase field model for ductile fracture with linear isotropic hardening is presented. An energy functional consisting of an elastic energy, a plastic dissipation potential and a Griffith type fracture energy constitutes the model. The application of an unaltered radial return algorithm on element level is possible due to the choice of an appropriate coupling between the nodal degrees of freedom, namely the displacement and the crack/fracture fields. The degradation function models the mentioned coupling by reducing the stiffness of the material and the plastic contribution of the energy density in broken material. Furthermore, to solve the global system of differential equations comprising the balance of linear momentum and the quasi-static Ginzburg-Landau type evolution equation, the application of a monolithic iterative solution scheme becomes feasible. The compact model is used to perform 3D simulations of fracture in tension. The computed plastic zones are compared to the dog-bone model that is used to derive validity criteria for KIC measurements.
In grinding, the crystal grain size of the workpiece material is relatively same range compared to the removal depth. This raises a question if an anisotropic material model, which considers the effect of the crystal grain size and orientations, would better predict the process forces when compared to an isotropic material model. Initially, a simple micro-indentation process is chosen to compare the two models. In this work, a crystal plasticity model and an isotropic Johnson-Cooke plasticity model are employed to simulate micro-identation of a twinning induced plasticity (TWIP) steel. The results of the two models are compared using the force-displacement curves from the micro-indentation experiments. In the future, the study will be extended to describe the material removal process during a single grit scratch test.
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.
In cake filtration processes, where particles in a suspension are separated by forming a filter
cake on the filter medium, the resistances of filter cake and filter medium cause a specific pressure
drop which consequently defines the process energy effort. The micromechanics of the filter cake
formation (interactions between particles, fluid, other particles and filter medium) must be considered
to describe pore clogging, filter cake growth and consolidation correctly. A precise 3D modeling
approach to describe these effects is the resolved coupling of the Computational Fluid Dynamics with
the Discrete Element Method (CFD-DEM). This work focuses on the development and validation of a
CFD-DEM model, which is capable to predict the filter cake formation during solid-liquid separation
accurately. The model uses the Lattice-Boltzmann Method (LBM) to directly solve the flow equations
in the CFD part of the coupling and the DEM for the calculation of particle interactions. The developed
model enables the 4-way coupling to consider particle-fluid and particle-particle interactions. The
results of this work are presented in two steps. First, the developed model is validated with an
empirical model of the single particle settling velocity in the transition regime of the fluid-particle
flow. The model is also enhanced with additional particles to determine the particle-particle influence.
Second, the separation of silica glass particles from water in a pressurized housing at constant pressure
is experimentally investigated. The measured filter cake, filter medium and interference resistances
are in a good agreement with the results of the 3D simulations, demonstrating the applicability of the
resolved CFD-DEM coupling for analyzing and optimizing cake filtration processes.
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.
The subject of this thesis is the design of axial flow machines. The type of turbomachine under examination is used to supply energy for high viscous fluid flow, as used in mixing and stirring tasks. The high viscous media treated in these tasks usually have non-Newtonian fluid properties. This kind of fluid flow is frequently associated with the field of energy and process engineering.
In order to narrow down the problem described, the field of turbomachinery is restricted to the consideration of propellers. Propellers are used in a wide range of fluid mechanics tasks. In the form of wind turbines, propellers extract kinetic energy from a control room and thereby slow down the flow. Propeller stirrers, on the other hand, increase the energy level of a flow and accelerate it. Both machines are based on the same principle - only the direction of the energy flow is to be considered as the opposite direction.
The design of new agitators is usually based on experience. Often, agitators are, therefore, not flow-optimised, and cannot be optimally operated. In this thesis, it is investigated whether the design processes of modern wind turbines, which are considered to be mature, can be adapted in order to generate a flow-optimised geometry for this type of turbomachine as well.
This thesis will first examine the basics of wind turbine design processes. Special attention will be paid to the differences caused by the viscous fluid properties under consideration. The highly viscous behaviour of the fluids under consideration means that the theoretical fundamentals have to be extended as a result. Such extensions are identified and supplement the theoretical basis. The thesis will then present and examine an analytically based design process for flow-optimised propeller mixers. The procedure is based on blade element momentum theory.
Application of blade element momentum theory requires detailed knowledge of the aerodynamic behaviour of the profiles used. This behaviour is usually only known for low viscosity and high-Re applications, as is usually the case for wind turbines or propeller engines. Comprehensive profile characteristics are not available for highly viscous and low-Re applications. In this thesis, these basics are generated using numerical methods.
In the next step, the newly introduced design method is combined with the results of the investigations of profile aerodynamics for high viscous low-Re fluid flow. This combination is done using a calculation process which produces the flow-optimised geometry of a propeller mixer. The theoretical principles of the methods are implemented in an algorithm in such a way that the resultant turbomachine can be designed for a previously selected operating point, the design point. In contrast to classical turbomachinery, the design point additionally requires the specification of viscous fluid properties.
However, in practical use, the final selected operating point of a turbomachine is often not the design point. The algorithm is examined for its suitability for inverse power calculation as well in order to compute the complete characteristic curve for a previously generated propeller mixer already in the design process.
The fatigue life of metals manufactured via laser-based powder bed fusion (L-PBF) highly
depends on process-induced defects. In this context, not only the size and geometry of the defect, but
also the properties and the microstructure of the surrounding material volume must be considered.
In the presented work, the microstructural changes in the vicinity of a crack-initiating defect in a
fatigue specimen produced via L-PBF and made of AISI 316L were analyzed in detail. Xenon plasma
focused ion beam (Xe-FIB) technique, scanning electron microscopy (SEM), and electron backscatter
diffraction (EBSD) were used to investigate the phase distribution, local misorientations, and grain
structure, including the crystallographic orientations. These analyses revealed a fine grain structure
in the vicinity of the defect, which is arranged in accordance with the melt pool geometry. Besides
pronounced cyclic plastic deformation, a deformation-induced transformation of the initial austenitic
phase into α’-martensite was observed. The plastic deformation as well as the phase transformation
were more pronounced near the border between the defect and the surrounding material volume.
However, the extent of the plastic deformation and the deformation-induced phase transformation
varies locally in this border region. Although a beneficial effect of certain grain orientations on the
phase transformation and plastic deformability was observed, the microstructural changes found
cannot solely be explained by the respective crystallographic orientation. These changes are assumed
to further depend on the inhomogeneous distribution of the multiaxial stresses beneath the defect as
well as the grain morphology
A detailed study of a cylinder activation concept by efficiency loss analysis and 1D simulation
(2020)
Cylinder deactivation is a well-known measure for reducing fuel consumption, especially when applied to gasoline engines. Mostly, such systems are designed to deactivate half of the number of cylinders of the engine. In this study, a new concept is investigated for deactivating only one out of four cylinders of a commercial vehicle diesel engine (“3/4-cylinder concept”). For this purpose, cylinders 2–4 of the engine are operated in “real” 3-cylinder mode, thus with the firing order and ignition distance of a regular 3-cylinder engine, while the first cylinder is only activated near full load, running in parallel to the fourth cylinder. This concept was integrated into a test engine and evaluated on an engine test bench. As the investigations revealed significant improvements for the low-to-medium load region as well as disadvantages for high load, an extensive numerical analysis was carried out based on the experimental results. This included both 1D simulation runs and a detailed cylinder-specific efficiency loss analysis. Based on the results of this analysis, further steps for optimizing the concept were derived and studied by numerical calculations. As a result, it can be concluded that the 3/4-cylinder concept may provide significant improvements of real-world fuel economy when integrated as a drive unit into a tractor.
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.