Hot wire manufacturing and resolution effects in high Reynolds number flows

Lo studio della turbolenza è di fondamentale importanza non solo per la fluidodinamica teorica ma anche perchè viene riscontrata in una moltitudine di problemi di interesse ingegneristico. All'aumentare del numero di Reynolds, le scale caratteristiche tendono a ridurre le loro dimensioni assolute. Nella fluidodinamica sperimentale già da lungo tempo si è affermata l'anemometria a filo caldo, grazie ad ottime caratteristiche di risoluzione spaziale e temporale. Questa tecnica, caratterizzata da un basso costo e da una relativa semplicità, rende possibile la realizzazione di sensori di tipo artigianale, che hanno il vantaggio di poter essere relizzati in dimensioni inferiori. Nonostante l'ottima risoluzione spaziale degli hot-wire, infatti, si può verificare, ad alto numero di Reynolds, che le dimensioni dell'elemento sensibile siano superiori a quelle delle piccole scale. Questo impedisce al sensore di risolvere correttamente le strutture più piccole. Per questa tesi di laurea è stato allestito un laboratorio per la costruzione di sensori a filo caldo con filo di platino. Sono in questo modo stati realizzati diversi sensori dalle dimensioni caratteristiche inferiori a quelle dei sensori disponibili commercialmente. I sensori ottenuti sono quindi stati testati in un getto turbolento, dapprima confrontandone la risposta con un sensore di tipo commerciale, per verificarne il corretto funzionamento. In seguito si sono eseguite misure più specifiche e limitate ad alcune particolari zone all'interno del campo di moto, dove è probabile riscontrare effetti di risoluzione spaziale. Sono stati analizzati gli effetti della dimensione fisica del sensore sui momenti statistici centrali, sugli spettri di velocità e sulle funzioni di densità di probabilità.

A numerical study of temperature effects on hot wire measurements inside turbulent channel flows

A way to investigate turbulence is through experiments where hot wire measurements are performed. Analysis of the in turbulence of a temperature gradient on hot wire measurements is the aim of this thesis work. Actually - to author's knowledge - this investigation is the first attempt to document, understand and ultimately correct the effect of temperature gradients on turbulence statistics. However a numerical approach is used since instantaneous temperature and streamwise velocity fields are required to evaluate this effect. A channel flow simulation at Re_tau = 180 is analyzed to make a first evaluation of the amount of error introduced by temperature gradient inside the domain. Hot wire data field is obtained processing the numerical flow field through the application of a proper version of the King's law, which connect voltage, velocity and temperature. A drift in mean streamwise velocity profile and rms is observed when temperature correction is performed by means of centerline temperature. A correct mean velocity pro�le is achieved correcting temperature through its mean value at each wall normal position, but a not negligible error is still present into rms. The key point to correct properly the sensed velocity from the hot wire is the knowledge of the instantaneous temperature field. For this purpose three correction methods are proposed. At the end a numerical simulation at Re_tau =590 is also evaluated in order to confirm the results discussed earlier.

Effetti della risoluzione spaziale nella stima della dissipazione con sensore hot-wire

L'obiettivo primario di questo elaborato di tesi è quello di stimare l'effetto della risoluzione spaziale e quindi della lunghezza finita del sensore di un anemometro a filo caldo, sul calcolo delle derivate che contribuiscono a valutare la dissipazione.

Experimental characterization of a planar jet by hot-wire anemometry

The study of turbulence is also nowadays a problem that does not have solution from the mathematical point of view due to the lack of solution to link the mean part of the flow with the fluctuating one. To solve this problem, in the CICLoPE laboratory of Predappio, experiments on different type of jets are performed in order to derive a closure model able to close our mathematical model. One of the most interesting type of jet that could be studied is the planar turbulent free jet which is a two dimensional canonical jet characterized by the self-similarity condition of the velocity profiles. To study this particular jet, a new facility was built. The aim of this project is to characterize the jet at different distances from the nozzle exit, for different values of Reynolds number, to demonstrate that the self-similarity condition is respected. To do that, the evaluation of quantities such as spreading rate, centerline velocity decay and relation between fluctuations and mean part of the flow has to be obtain. All these parameters could be detected thanks to the use of single and X hot-wire anemometry with which it is possible to analyzed the fluctuating behaviour of the flow by associating to an electric signal a physical variable expressed in terms of velocity. To justify the data obtain by the measures, a comparison with results coming from the literature has to be shown.

Computational design of a new type of sandwich cross-section for a defined solution of a tree-like column produced by wire-and-arc additive manufacturing

When it comes to designing a structure, architects and engineers want to join forces in order to create and build the most beautiful and efficient building. From finding new shapes and forms to optimizing the stability and the resistance, there is a constant link to be made between both professions. In architecture, there has always been a particular interest in creating new shapes and types of a structure inspired by many different fields, one of them being nature itself. In engineering, the selection of optimum has always dictated the way of thinking and designing structures. This mindset led through studies to the current best practices in construction. However, both disciplines were limited by the traditional manufacturing constraints at a certain point. Over the last decades, much progress was made from a technological point of view, allowing to go beyond today's manufacturing constraints. With the emergence of Wire-and-Arc Additive Manufacturing (WAAM) combined with Algorithmic-Aided Design (AAD), architects and engineers are offered new opportunities to merge architectural beauty and structural efficiency. Both technologies allow for exploring and building unusual and complex structural shapes in addition to a reduction of costs and environmental impacts. Through this study, the author wants to make use of previously mentioned technologies and assess their potential, first to design an aesthetically appreciated tree-like column with the idea of secondly proposing a new type of standardized and optimized sandwich cross-section to the construction industry. Parametric algorithms to model the dendriform column and the new sandwich cross-section are developed and presented in detail. A catalog draft of the latter and methods to establish it are then proposed and discussed. Finally, the buckling behavior of this latter is assessed considering standard steel and WAAM material properties.

Development and Automatization of a Planar Jet Wind Tunnel for the X-wire Calibration

The scope of this study is to design an automatic control system and create an automatic x-wire calibrator for a facility named Plane Air Tunnel; whose exit creates planar jet flow. The controlling power state as well as automatic speed adjustment of the inverter has been achieved. Thus, the wind tunnel can be run with respect to any desired speed and the x-wire can automatically be calibrated at that speed. To achieve that, VI programming using the LabView environment was learned, to acquire the pressure and temperature, and to calculate the velocity based on the acquisition data thanks to a pitot-static tube. Furthermore, communication with the inverter to give the commands for power on/off and speed control was also done using the LabView VI coding environment. The connection of the computer to the inverter was achieved by the proper cabling using DAQmx Analog/Digital (A/D) input/output (I/O). Moreover, the pressure profile along the streamwise direction of the plane air tunnel was studied. Pressure tappings and a multichannel pressure scanner were used to acquire the pressure values at different locations. Thanks to that, the aerodynamic efficiency of the contraction ratio was observed, and the pressure behavior was related to the velocity at the exit section. Furthermore, the control of the speed was accomplished by implementing a closed-loop PI controller on the LabView environment with and without using a pitot-static tube thanks to the pressure behavior information. The responses of the two controllers were analyzed and commented on by giving suggestions. In addition, hot wire experiments were performed to calibrate automatically and investigate the velocity profile of a turbulent planar jet. To be able to analyze the results, the physics of turbulent planar jet flow was studied. The fundamental terms, the methods used in the derivation of the equations, velocity profile, shear stress behavior, and the effect of vorticity were reviewed.

Temperature measurements in turbulent pipe flow with cold wire anemometry

Passive scalars measurements in turbulent pipe flows are difficult to perform and only few experimental data are available in literature. The present thesis deals with the experimental acquisition and study of the first turbulent temperature profile inside the CICLoPE wind tunnel through cold wire anemometry technique at Reτ = 6000 and Reτ = 9500. This type of measurements provides not only useful data on temperature (and passive scalars) behaviour and statistics in turbulent pipe flows, but could be used also for temperature correction of turbulent velocity profiles. In the present work, subsequent acquisitions of temperature and velocity profiles has been performed at the same Reynolds number and in the same points, through cold wire and hot wire techniques respectively. Taking as reference data from both DNS and experimental campaigns, the activity has been carried out obtaining satisfactory results. We have verified the presence of turbulent temperature profile inside the CICLoPE wind tunnel and then studied its statistical and spectral behaviours obtaining results in agreement with existing data from Hishida, Nagano, and Ferro. Cold wire temperature data were then used to correct hot wire velocity data, obtaining a slightly improvement in the near wall region.

Design, fabrication and mechanical characterization of a structural node made using Wire and Arc Additive Manufacturing (WAAM) technology

Additive Manufacturing (AM), also known as “3D printing”, is a recent production technique that allows the creation of three-dimensional elements by depositing multiple layers of material. This technology is widely used in various industrial sectors, such as automotive, aerospace and aviation. With AM, it is possible to produce particularly complex elements for which traditional techniques cannot be used. These technologies are not yet widespread in the civil engineering sector, which is slowly changing thanks to the advantages of AM, such as the possibility of realizing elements without geometric restrictions, with less material usage and a higher efficiency, in particular employing Wire-and-Arc Additive Manufacturing (WAAM) technology. Buildings that benefit most from AM are all those structures designed using form-finding and free-form techniques. These include gridshells, where joints are the most critical and difficult elements to design, as the overall behaviour of the structure depends on them. It must also be considered that, during the design, the engineer must try to minimize the structure's own weight. Self-weight reductions can be achieved by Topological Optimization (TO) of the joint itself, which generates complex geometries that could not be made using traditional techniques. To sum up, weight reductions through TO combined with AM allow for several potential benefits, including economic ones. In this thesis, the roof of the British Museum is considered as a case study, analysing the gridshell structure of which a joint will be chosen to be designed and manufactured, using TO and WAAM techniques. Then, the designed joint will be studied in order to understand its structural behaviour in terms of stiffness and strength. Finally, a printing test will be performed to assess the production feasibility using WAAM technology. The computational design and fabrication stages were carried out at Technische Universität Braunschweig in Germany.

Calibration of design strength values of Wire and Arc Additive Manufacturing inclined bars and intersections

Although being studied only for few years, Wire and Arc Additive Manufacturing (WAAM) will become the predominant way of producing stainless-steel elements in a near-like future. The analysis and study of such elements has yet to be defined in a proper way, but the projects regarding this subject are innovating more and more thanks to the findings discovered by the latter. This thesis is focused on an initial stage on the analysis of mechanical and geometrical properties of such stainless-steel elements produced by MX3D laboratories in Amsterdam, and to perform a calibration of the design strength values by means of Annex D of Eurocode 0, which talks about the analysis of the semi-probabilistic safety factors, hence the definition of characteristic values. Moreover, after testing the stainless-steel specimens by means of strain gauges and after obtaining mechanical and geometrical properties, a statistical analysis of such properties and an evaluation of characteristic values is performed. After this, there is to execute the calibration of design strength values of WAAM inclined bars and intersections.

Numerical and experimental investigation of turbulent dissipation

Turbulent energy dissipation is presented in the theoretical context of the famous Kolmogorov theory, formulated in 1941. Some remarks and comments about this theory help the reader understand the approach to turbulence study, as well as give some basic insights to the problem. A clear distinction is made amongst dissipation, pseudo-dissipation and dissipation surrogates. Dissipation regulates how turbulent kinetic energy in a flow gets transformed into internal energy, which makes this quantity a fundamental characteristic to investigate in order to enhance our understanding of turbulence. The dissertation focuses on experimental investigation of the pseudo-dissipation. Indeed this quantity is difficult to measure as it requires the knowledge of all the possible derivatives of the three dimensional velocity field. Once considering an hot-wire technique to measure dissipation we need to deal with surrogates of dissipation, since not all the terms can be measured. The analysis of surrogates is the main topic of this work. In particular two flows, the turbulent channel and the turbulent jet, are considered. These canonic flows, introduced in a brief fashion, are often used as a benchmark for CFD solvers and experimental equipment due to their simple structure. Observations made in the canonic flows are often transferable to more complicated and interesting cases, with many industrial applications. The main tools of investigation are DNS simulations and experimental measures. DNS data are used as a benchmark for the experimental results since all the components of dissipation are known within the numerical simulation. The results of some DNS were already available at the start of this thesis, so the main work consisted in reading and processing the data. Experiments were carried out by means of hot-wire anemometry, described in detail on a theoretical and practical level. The study of DNS data of a turbulent channel at Re=298 reveals that the traditional surrogate can be improved Consequently two new surrogates are proposed and analysed, based on terms of the velocity gradient that are easy to measure experimentally. We manage to find a formulation that improves the accuracy of surrogates by an order of magnitude. For the jet flow results from a DNS at Re=1600 of a temporal jet, and results from our experimental facility CAT at Re=70000, are compared to validate the experiment. It is found that the ratio between components of the dissipation differs between DNS and experimental data. Possible errors in both sets of data are discussed, and some ways to improve the data are proposed.

Anemometria a filo caldo: studio di un sistema di calibrazione per sonde a due fili con applicazione al "long pipe" in CICLoPE

L’anemometro a filo caldo (in inglese hot wire) é lo strumento maggiormente usato per studiare sperimentalmente la turbolenza. A seconda di quante componenti della velocitá interessa studiare, esistono anemometri a uno, due o tre fili. Questo elaborato di tesi si concentra su sonde a due fili. Per prima cosa, ogni volta che si utilizza questo strumento bisogna effettuare una calibrazione, fase molto importante perché permette di relazionare le tensioni che ogni filo acquisisce con la velocitá reale del flusso. Sono presentati tre differenti metodi utilizzati per sonde a due fili e, dopo averli analizzati, sono stati applicati a dati acquisiti prima al CAT (Coaxial Aerodinamic Tunnel), struttura presente a Forlí, nell’hangar dell’Universitá di Bologna e poi al CICLoPE (Center for International Cooperation in Long Pipe Experiments), Long-Pipe costruito a Predappio, utilizzato per lo studio della turbolenza. La calibrazione per sonde a due fili si puó dividere in due parti, quella di velocitá e quella per gli angoli. Mentre al CAT é possibile effettuarle entrambi, al CICLoPE non é attualmente possibile eseguire la calibrazione angolare perché non esiste alcuno strumento utilizzabile per regolare la sonda all’angolo desiderato. Lo scopo di questo elaborato di tesi è trovare un metodo di calibrazione per sonde a due fili applicabile al CICLoPE eseguendo sul posto solamente una calibrazione di velocitá e adattando quella angolare effettuata precedentemente al CAT. Questo puó provocare dei problemi perché la calibrazione risulta fortemente dipendente da condizioni interne dei fili, come la resistenza, ma anche da condizioni al contorno, come la temperatura e la pressione dell’ambiente esterno. Dopo aver eseguito due campagne sperimentali di test, una al CAT e una al CICLoPE, i dati acquisiti sono stati elaborati per valutare l’efficacia dei vari metodi.