Studies of turbulent flows in continuous casting of steel with and without magnetic field

This thesis develops and tests various transient and steady-state computational models such as direct numerical simulation (DNS), large eddy simulation (LES), filtered unsteady Reynolds-averaged Navier-Stokes (URANS) and steady Reynolds-averaged Navier-Stokes (RANS) with and without magnetic field to investigate turbulent flows in canonical as well as in the nozzle and mold geometries of the continuous casting process. The direct numerical simulations are first performed in channel, square and 2:1 aspect rectangular ducts to investigate the effect of magnetic field on turbulent flows. The rectangular duct is a more practical geometry for continuous casting nozzle and mold and has the option of applying magnetic field either perpendicular to broader side or shorter side. This work forms the part of a graphic processing unit (GPU) based CFD code (CU-FLOW) development for magnetohydrodynamic (MHD) turbulent flows. The DNS results revealed interesting effects of the magnetic field and its orientation on primary, secondary flows (instantaneous and mean), Reynolds stresses, turbulent kinetic energy (TKE) budgets, momentum budgets and frictional losses, besides providing DNS database for two-wall bounded square and rectangular duct MHD turbulent flows. Further, the low- and high-Reynolds number RANS models (k-ε and Reynolds stress models) are developed and tested with DNS databases for channel and square duct flows with and without magnetic field. The MHD sink terms in k- and ε-equations are implemented as proposed by Kenjereš and Hanjalić using a user defined function (UDF) in FLUENT. This work revealed varying accuracies of different RANS models at different levels. This work is useful for industry to understand the accuracies of these models, including continuous casting. After realizing the accuracy and computational cost of RANS models, the steady-state k-ε model is then combined with the particle image velocimetry (PIV) and impeller probe velocity measurements in a 1/3rd scale water model to study the flow quality coming out of the well- and mountain-bottom nozzles and the effect of stopper-rod misalignment on fluid flow. The mountain-bottom nozzle was found more prone to the longtime asymmetries and higher surface velocities. The left misalignment of stopper gave higher surface velocity on the right leading to significantly large number of vortices forming behind the nozzle on the left. Later, the transient and steady-state models such as LES, filtered URANS and steady RANS models are combined with ultrasonic Doppler velocimetry (UDV) measurements in a GaInSn model of typical continuous casting process. LES-CU-LOW is the fastest and the most accurate model owing to much finer mesh and a smaller timestep. This work provided a good understanding on the performance of these models. The behavior of instantaneous flows, Reynolds stresses and proper orthogonal decomposition (POD) analysis quantified the nozzle bottom swirl and its importance on the turbulent flow in the mold. Afterwards, the aforementioned work in GaInSn model is extended with electromagnetic braking (EMBr) to help optimize a ruler-type brake and its location for the continuous casting process. The magnetic field suppressed turbulence and promoted vortical structures with their axis aligned with the magnetic field suggesting tendency towards 2-d turbulence. The stronger magnetic field at the nozzle well and around the jet region created large scale and lower frequency flow behavior by suppressing nozzle bottom swirl and its front-back alternation. Based on this work, it is advised to avoid stronger magnetic field around jet and nozzle bottom to get more stable and less defect prone flow.

Turbulent Time and Length Scale Measurements in High-Velocity Open Channel Flows

In high-velocity open channel flows, the measurements of air-water flow properties are complicated by the strong interactions between the flow turbulence and the entrained air. In the present study, an advanced signal processing of traditional single- and dual-tip conductivity probe signals is developed to provide further details on the air-water turbulent level, time and length scales. The technique is applied to turbulent open channel flows on a stepped chute conducted in a large-size facility with flow Reynolds numbers ranging from 3.8 E+5 to 7.1 E+5. The air water flow properties presented some basic characteristics that were qualitatively and quantitatively similar to previous skimming flow studies. Some self-similar relationships were observed systematically at both macroscopic and microscopic levels. These included the distributions of void fraction, bubble count rate, interfacial velocity and turbulence level at a macroscopic scale, and the auto- and cross-correlation functions at the microscopic level. New correlation analyses yielded a characterisation of the large eddies advecting the bubbles. Basic results included the integral turbulent length and time scales. The turbulent length scales characterised some measure of the size of large vortical structures advecting air bubbles in the skimming flows, and the data were closely related to the characteristic air-water depth Y90. In the spray region, present results highlighted the existence of an upper spray region for C > 0.95 to 0.97 in which the distributions of droplet chord sizes and integral advection scales presented some marked differences with the rest of the flow.

The modeling of turbulent reactive flows based on multiple mapping conditioning

A new modeling approach-multiple mapping conditioning (MMC)-is introduced to treat mixing and reaction in turbulent flows. The model combines the advantages of the probability density function and the conditional moment closure methods and is based on a certain generalization of the mapping closure concept. An equivalent stochastic formulation of the MMC model is given. The validity of the closuring hypothesis of the model is demonstrated by a comparison with direct numerical simulation results for the three-stream mixing problem. (C) 2003 American Institute of Physics.

Air Entrainment Processes in a Full-Scale Rectangular Dropshaft at Large Flows

Rectangular dropshafts, commonly used in sewers and storm water systems, are characterised by significant flow aeration. New detailed air-water flow measurements were conducted in a near-full-scale dropshaft at large discharges. In the shaft pool and outflow channel, the results demonstrated the complexity of different competitive air entrainment mechanisms. Bubble size measurements showed a broad range of entrained bubble sizes. Analysis of streamwise distributions of bubbles suggested further some clustering process in the bubbly flow although, in the outflow channel, bubble chords were in average smaller than in the shaft pool. A robust hydrophone was tested to measure bubble acoustic spectra and to assess its field application potential. The acoustic results characterised accurately the order of magnitude of entrained bubble sizes, but the transformation from acoustic frequencies to bubble radii did not predict correctly the probability distribution functions of bubble sizes.

Self-Similarity of Air-Water Flows in Skimming Flows on Stepped Spillways

Skimming flows on stepped spillways are characterised by a significant rate of turbulent dissipation on the chute. Herein an advanced signal processing of traditional conductivity probe signals is developed to provide further details on the turbulent time and length scales. The technique is applied to a 22° stepped chute operating with flow Reynolds numbers between 3.8 and 7.1 E+5. The new correlation analyses yielded a characterisation of large eddies advecting the bubbles. The turbulent length scales were related to the characteristic depth Y90. Some self-similar relationships were observed systematically at both macroscopic and microscopic levels. These included the distributions of void fraction, bubble count rate, interfacial velocity and turbulence level, and turbulence time and length scales. The self-similarity results were significant because they provided a picture general enough to be used to characterise the air-water flow field in prototype spillways.

Turbulence Characterisation of High-Velocity Free-Surface Flows

In high-velocity free-surface flows, air is continuously being trapped and released through the free-surface. Such high-velocity highly-aerated flows cannot be studied numerically because of the large number of relevant equations and parameters. Herein an advanced signal processing of traditional single- and dual-tip conductivity probes provides some new information on the air-water turbulent time and length scales. The technique is applied to turbulent open channel flows in a large-size facility. The auto- and cross-correlation analyses yield some characterisation of the large eddies advecting the bubbles. The transverse integral turbulent length and time scales are related to the step height: i.e., Lxy/h ~ 0.02 to 0.2, and T.sqrt(g/h) ~ 0.004 to 0.04. The results are irrespective of the Reynolds numbers. The present findings emphasise that turbulent dissipation by large-scale vortices is a significant process in the intermediate zone between the spray and bubbly flow regions (0.3 < C < 0.7). Some self-similar relationships were observed systematically at both macroscopic and microscopic levels. The results are significant because they provide a picture general enough to be used to characterise the air-water flow field in prototype spillways.

Undergraduate teaching of ideal and real fluid flows: The value of real-world experimental projects

This study describes the pedagogical impact of real-world experimental projects undertaken as part of an advanced undergraduate Fluid Mechanics subject at an Australian university. The projects have been organised to complement traditional lectures and introduce students to the challenges of professional design, physical modelling, data collection and analysis. The physical model studies combine experimental, analytical and numerical work in order to develop students’ abilities to tackle real-world problems. A first study illustrates the differences between ideal and real fluid flow force predictions based upon model tests of buildings in a large size wind tunnel used for research and professional testing. A second study introduces the complexity arising from unsteady non-uniform wave loading on a sheltered pile. The teaching initiative is supported by feedback from undergraduate students. The pedagogy of the course and projects is discussed with reference to experiential, project-based and collaborative learning. The practical work complements traditional lectures and tutorials, and provides opportunities which cannot be learnt in the classroom, real or virtual. Student feedback demonstrates a strong interest for the project phases of the course. This was associated with greater motivation for the course, leading in turn to lower failure rates. In terms of learning outcomes, the primary aim is to enable students to deliver a professional report as the final product, where physical model data are compared to ideal-fluid flow calculations and real-fluid flow analyses. Thus the students are exposed to a professional design approach involving a high level of expertise in fluid mechanics, with sufficient academic guidance to achieve carefully defined learning goals, while retaining sufficient flexibility for students to construct there own learning goals. The overall pedagogy is a blend of problem-based and project-based learning, which reflects academic research and professional practice. The assessment is a mix of peer-assessed oral presentations and written reports that aims to maximise student reflection and development. Student feedback indicated a strong motivation for courses that include a well-designed project component.

Turbulent flow around a rotating stepped cylinder

Direct numerical simulation (DNS) of turbulent flow around a rotating cylinder with two backward-facing steps axisymmetrically mounted in the circumferential direction was performed and compared with DNS of plane backward-facing step flow (PBSF) of Le [J. Fluid Mech. 330, 349 (1997)]. The original motivation of this work stemmed from the efforts to design a simple device which can generate flows of high turbulence intensity at low cost for corrosion researchers. It turned out that the current flow shows flow structures quite similar to those of PBSF downstream of the step, even though configurations of the two flows are totally different from one another. The stepped cylinder appears to be a cost-effective tool in the generation of flow structures similar to those of PBSF. (C) 2002 American Institute of Physics.

Numerical investigation of turbulent flow around a rotating stepped cylinder for corrosion study

Direct numerical simulation has been carried out for turbulent flow set up by a rotating cylinder with two backward-facing steps axisymmetrically mounted in the circumferential direction. This flow geometry creates a qualitatively similar flow pattern as observed near, a sudden, pipe expansion or a plane backward-facing step, characterized by flow separation and reattachment. A region of intense turbulence intensity and high wall-shear-stress fluctuations is formed in,the recirculating I region downstream of the step, where high mass-transfer capacity was also experimentally observed. Since, corrosion is frequently mass-transfer., controlled, our findings, put forward this apparatus as useful tool for future corrosion research.

A law of the wall formulation for recirculating flows

This work presents a new law of the wall formulation for recirculating turbulent flows. An alternative expression for the internal length which can be applied in the separated region is also presented. The formulation is implemented in a numerical code which solves the k-epsilon model through a finite volume method. The theoretical results are compared with the experimental data of Vogel and Eaton (J. of Heat Transfer, Transactions of ASME, vol.107, pp. 922-929, 1985). The paper shows that the present formulation furnishes better results than the standard k-epsilon formulation.

Turbulent shallow-water model for orographic subgrid-scale perturbations

A parallel pseudo-spectral method for the simulation in distributed memory computers of the shallow-water equations in primitive form was developed and used on the study of turbulent shallow-waters LES models for orographic subgrid-scale perturbations. The main characteristics of the code are: momentum equations integrated in time using an accurate pseudo-spectral technique; Eulerian treatment of advective terms; and parallelization of the code based on a domain decomposition technique. The parallel pseudo-spectral code is efficient on various architectures. It gives high performance onvector computers and good speedup on distributed memory systems. The code is being used for the study of the interaction mechanisms in shallow-water ows with regular as well as random orography with a prescribed spectrum of elevations. Simulations show the evolution of small scale vortical motions from the interaction of the large scale flow and the small-scale orographic perturbations. These interactions transfer energy from the large-scale motions to the small (usually unresolved) scales. The possibility of including the parametrization of this effects in turbulent LES subgrid-stress models for the shallow-water equations is addressed.

On the initiation of surface waves by turbulent shear flow

An analytical model is developed for the initial stage of surface wave generation at an air-water interface by a turbulent shear flow in either the air or in the water. The model treats the problem of wave growth departing from a flat interface and is relevant for small waves whose forcing is dominated by turbulent pressure fluctuations. The wave growth is predicted using the linearised and inviscid equations of motion, essentially following Phillips [Phillips, O.M., 1957. On the generation of waves by turbulent wind. J. Fluid Mech. 2, 417-445], but the pressure fluctuations that generate the waves are treated as unsteady and related to the turbulent velocity field using the rapid-distortion treatment of Durbin [Durbin, P.A., 1978. Rapid distortion theory of turbulent flows. PhD thesis, University of Cambridge]. This model, which assumes a constant mean shear rate F, can be viewed as the simplest representation of an oceanic or atmospheric boundary layer. For turbulent flows in the air and in the water producing pressure fluctuations of similar magnitude, the waves generated by turbulence in the water are found to be considerably steeper than those generated by turbulence in the air. For resonant waves, this is shown to be due to the shorter decorrelation time of turbulent pressure in the air (estimated as proportional to 1/Gamma), because of the higher shear rate existing in the air flow, and due to the smaller length scale of the turbulence in the water. Non-resonant waves generated by turbulence in the water, although being somewhat gentler, are still steeper than resonant waves generated by turbulence in the air. Hence, it is suggested that turbulence in the water may have a more important role than previously thought in the initiation of the surface waves that are subsequently amplified by feedback instability mechanisms.

DIFFUSION OF MAGNETIC FIELD AND REMOVAL OF MAGNETIC FLUX FROM CLOUDS VIA TURBULENT RECONNECTION

The diffusion of astrophysical magnetic fields in conducting fluids in the presence of turbulence depends on whether magnetic fields can change their topology via reconnection in highly conducting media. Recent progress in understanding fast magnetic reconnection in the presence of turbulence reassures that the magnetic field behavior in computer simulations and turbulent astrophysical environments is similar, as far as magnetic reconnection is concerned. This makes it meaningful to perform MHD simulations of turbulent flows in order to understand the diffusion of magnetic field in astrophysical environments. Our studies of magnetic field diffusion in turbulent medium reveal interesting new phenomena. First of all, our three-dimensional MHD simulations initiated with anti-correlating magnetic field and gaseous density exhibit at later times a de-correlation of the magnetic field and density, which corresponds well to the observations of the interstellar media. While earlier studies stressed the role of either ambipolar diffusion or time-dependent turbulent fluctuations for de-correlating magnetic field and density, we get the effect of permanent de-correlation with one fluid code, i.e., without invoking ambipolar diffusion. In addition, in the presence of gravity and turbulence, our three-dimensional simulations show the decrease of the magnetic flux-to-mass ratio as the gaseous density at the center of the gravitational potential increases. We observe this effect both in the situations when we start with equilibrium distributions of gas and magnetic field and when we follow the evolution of collapsing dynamically unstable configurations. Thus, the process of turbulent magnetic field removal should be applicable both to quasi-static subcritical molecular clouds and cores and violently collapsing supercritical entities. The increase of the gravitational potential as well as the magnetization of the gas increases the segregation of the mass and magnetic flux in the saturated final state of the simulations, supporting the notion that the reconnection-enabled diffusivity relaxes the magnetic field + gas system in the gravitational field to its minimal energy state. This effect is expected to play an important role in star formation, from its initial stages of concentrating interstellar gas to the final stages of the accretion to the forming protostar. In addition, we benchmark our codes by studying the heat transfer in magnetized compressible fluids and confirm the high rates of turbulent advection of heat obtained in an earlier study.

A Law of the Wall Formulation for Recirculating Flows

ABSTRACT: This work presents a new law of the wall formulation for recirculating turbulent flows. An alternative expression for the internal length which can be applied in the separated region is also presented. The formulation is implemented in a numerical code which solves the k-e model through a finite volume method. The theoretical results are compared with the experimental data of Vogel and Eaton (J. of Heat Transfer, Transactions of ASME, vol.107, pp. 922-929, 1985). The paper shows that the present formulation furnishes better results than the standard k-e formulation.

High reynolds numbers turbulent boundary layers

Esta tesis estudia las similitudes y diferencias entre los flujos turbulentos de pared de tipo externo e interno, en régimen incompresible, y a números de Reynolds moderada¬mente altos. Para ello consideramos tanto simulaciones numéricas como experimentos de capas límites con gradiente de presiones nulo y de flujos de canal, ambos a números de Reynolds en el rango δ+ ~ 500 - 2000. Estos flujos de cortadura son objeto de numerosas investigaciones debido a la gran importancia que tienen tanto a nivel tecnológico como a nivel de física fundamental. No obstante, todavía existen muchos interrogantes sobre aspectos básicos tales como la universalidad de los perfiles medios y de fluctuación de las velocidades o de la presión, tanto en la zona cercana a la pared como en la zona logarítmica, el escalado y el efecto del número de Reynolds, o las diferencias entre los flujos internos y externos en la zona exterior. En éste estudio hemos utilizado simulaciones numéricas ya existentes de canales y capas límites a números de Reynolds δ+ ~ 2000 y δ+ ~ 700, respectivamente. Para poder comparar ambos flujos a igual número de Reynolds hemos realizado una nueva simulación directa de capa límite en el rango δ+ ~ 1000-2000. Los resultados de la misma son presentados y analizados en detalle. Los datos sin postprocesar y las estadísticas ya postprocesadas están públicamente disponibles en nuestro sitio web.162 El análisis de las estadísticas usando un único punto confirma la existencia de perfiles logarítmicos para las fluctuaciones de la velocidad transversal w'2+ y de la presión p'2+ en ambos tipos de flujos, pero no para la velocidad normal v'2+ o la velocidad longitudinal u'2+. Para aceptar o rechazar la existencia de un rango logarítmico en u'2+ se requieren números de Reynolds más altos que los considerados en éste trabajo. Una de las conse¬cuencias más importantes de poseer tales perfiles es que el valor máximo de la intensidad, que se alcanza cerca de la pared, depende explícitamente del número de Reynolds. Esto ha sido confirmado tras analizar un gran número de datos experimentales y numéricos, cor¬roborando que el máximo de u'2+, p/2+, y w'2+ aumenta proporcionalmente con el log(δ+). Por otro lado, éste máximo es más intenso en los flujos externos que en los internos. La máxima diferencia ocurre en torno a y/δ ~ 0.3-0.5, siendo esta altura prácticamente independiente del número de Reynolds considerado. Estas diferencias se originan como consecuencia del carácter intermitente de las capas límites, que es inexistente en los flujos internos. La estructura de las fluctuaciones de velocidad y de presión, junto con la de los esfuer¬zos de Reynolds, se han investigado por medio de correlaciones espaciales tridimensionales considerando dos puntos de medida. Hemos obtenido que el tamaño de las mismas es gen¬eralmente mayor en canales que en capas límites, especialmente en el caso de la correlación longitudinal Cuu en la dirección del flujo. Para esta correlación se demuestra que las es¬tructuras débilmente correladas presentan longitudes de hasta 0(75), en el caso de capas límites, y de hasta 0(185) en el caso de canales. Estas longitudes se obtienen respecti-vamente en la zona logarítmica y en la zona exterior. Las longitudes correspondientes en la dirección transversal son significativamente menores en ambos flujos, 0(5 — 25). La organización espacial de las correlaciones es compatible con la de una pareja de rollos casi paralelos con dimensiones que escalan en unidades exteriores. Esta organización se mantiene al menos hasta y ~ 0.65, altura a la cual las capas límites comienzan a organi¬zarse en rollos transversales. Este comportamiento es sin embargo más débil en canales, pudiéndose observar parcialmente a partir de y ~ 0.85. Para estudiar si estas estructuras están onduladas a lo largo de la dirección transver¬sal, hemos calculado las correlaciones condicionadas a eventos intensos de la velocidad transversal w'. Estas correlaciones revelan que la ondulación de la velocidad longitudinal aumenta conforme nos alejamos de la pared, sugiriendo que las estructuras están más alineadas en la zona cercana a la pared que en la zona lejana a ella. El por qué de esta ondulación se encuentra posiblemente en la configuración a lo largo de diagonales que presenta w'. Estas estructuras no sólo están onduladas, sino que también están inclinadas respecto a la pared con ángulos que dependen de la variable considerada, de la altura, y de el contorno de correlación seleccionado. Por encima de la zona tampón e independien¬temente del número de Reynolds y tipo de flujo, Cuu presenta una inclinación máxima de unos 10°, las correlaciones Cvv y Cm son esencialmente verticales, y Cww está inclinada a unos 35°. Summary This thesis studies the similitudes and differences between external and internal in¬compressible wall-bounded turbulent flows at moderately-high Reynolds numbers. We consider numerical and experimental zero-pressure-gradient boundary layers and chan¬nels in the range of δ+ ~ 500 — 2000. These shear flows are subjects of intensive research because of their technological importance and fundamental physical interest. However, there are still open questions regarding basic aspects such as the universality of the mean and fluctuating velocity and pressure profiles at the near-wall and logarithmic regions, their scaling and the effect of the Reynolds numbers, or the differences between internal and external flows at the outer layer, to name but a few. For this study, we made use of available direct numerical simulations of channel and boundary layers reaching δ+ ~ 2000 and δ+ ~ 700, respectively. To fill the gap in the Reynolds number, a new boundary layer simulation in the range δ+ ~ 1000-2000 is presented and discussed. The original raw data and the post-processed statistics are publicly available on our website.162 The analysis of the one-point statistic confirms the existence of logarithmic profiles for the spanwise w'2+ and pressure p'2+ fluctuations for both type of flows, but not for the wall-normal v'2+ or the streamwise u'2+ velocities. To accept or reject the existence of a logarithmic range in u'2+ requires higher Reynolds numbers than the ones considered in this work. An important consequence of having such profiles is that the maximum value of the intensities, reached near the wall, depends on the Reynolds number. This was confirmed after surveying a wide number of experimental and numerical datasets, corrob¬orating that the maximum of ul2+, p'2+, and w'2+ increases proportionally to log(δ+). On the other hand, that maximum is more intense in external flows than in internal ones, differing the most around y/δ ~ 0.3-0.5, and essentially independent of the Reynolds number. We discuss that those differences are originated as a consequence of the inter¬mittent character of boundary layers that is absent in internal flows. The structure of the velocity and pressure fluctuations, together with those of the Reynolds shear stress, were investigated using three-dimensional two-point spatial correlations. We find that the correlations extend over longer distances in channels than in boundary layers, especially in the case of the streamwise correlation Cuu in the flow direc-tion. For weakly correlated structures, the maximum streamwise length of Cuu is O(78) for boundary layers and O(188) for channels, attained at the logarithmic and outer regions respectively. The corresponding lengths for the transverse velocities and for the pressure are shorter, 0(8 — 28), and of the same order for both flows. The spatial organization of the velocity correlations is shown to be consistent with a pair of quasi-streamwise rollers that scales in outer units. That organization is observed until y ~ 0.68, from which boundary layers start to organize into spanwise rollers. This effect is weaker in channels, and it appears at y ~ 0.88. We present correlations conditioned to intense events of the transversal velocity, w', to study if these structures meander along the spanwise direction. The results indicate that the streamwise velocity streaks increase their meandering proportionally to the distance to the wall, suggesting that the structures are more aligned close to the wall than far from it. The reason behind this meandering is probably due to the characteristic organization along diagonals of w'. These structures not only meander along the spanwise direction, but they are also inclined to the wall at angles that depend on the distance from the wall, on the variable being considered, and on the correlation level used to define them. Above the buffer layer and independent of the Reynolds numbers and type of flow, the maximum inclination of Cuu is about 10°, Cvv and Cpp are roughly vertical, and Cww is inclined by 35°.