Computational studies for the design of process equipment with complex geometries

This study combines several projects related to the flows in vessels with complex shapes representing different chemical apparata. Three major cases were studied. The first one is a two-phase plate reactor with a complex structure of intersecting micro channels engraved on one plate which is covered by another plain plate. The second case is a tubular microreactor, consisting of two subcases. The first subcase is a multi-channel two-component commercial micromixer (slit interdigital) used to mix two liquid reagents before they enter the reactor. The second subcase is a micro-tube, where the distribution of the heat generated by the reaction was studied. The third case is a conventionally packed column. However, flow, reactions or mass transfer were not modeled. Instead, the research focused on how to describe mathematically the realistic geometry of the column packing, which is rather random and can not be created using conventional computeraided design or engineering (CAD/CAE) methods. Several modeling approaches were used to describe the performance of the processes in the considered vessels. Computational fluid dynamics (CFD) was used to describe the details of the flow in the plate microreactor and micromixer. A space-averaged mass transfer model based on Fick’s law was used to describe the exchange of the species through the gas-liquid interface in the microreactor. This model utilized data, namely the values of the interfacial area, obtained by the corresponding CFD model. A common heat transfer model was used to find the heat distribution in the micro-tube. To generate the column packing, an additional multibody dynamic model was implemented. Auxiliary simulation was carried out to determine the position and orientation of every packing element in the column. This data was then exported into a CAD system to generate desirable geometry, which could further be used for CFD simulations. The results demonstrated that the CFD model of the microreactor could predict the flow pattern well enough and agreed with experiments. The mass transfer model allowed to estimate the mass transfer coefficient. Modeling for the second case showed that the flow in the micromixer and the heat transfer in the tube could be excluded from the larger model which describes the chemical kinetics in the reactor. Results of the third case demonstrated that the auxiliary simulation could successfully generate complex random packing not only for the column but also for other similar cases.

Coupling time-stepping numerical methods and standard aerodynamics codes for instability analysis of flows in complex geometries

The development of a global instability analysis code coupling a time-stepping approach, as applied to the solution of BiGlobal and TriGlobal instability analysis 1, 2 and finite-volume-based spatial discretization, as used in standard aerodynamics codes is presented. The key advantage of the time-stepping method over matrix-formulation approaches is that the former provides a solution to the computer-storage issues associated with the latter methodology. To-date both approaches are successfully in use to analyze instability in complex geometries, although their relative advantages have never been quantified. The ultimate goal of the present work is to address this issue in the context of spatial discretization schemes typically used in industry. The time-stepping approach of Chiba 3 has been implemented in conjunction with two direct numerical simulation algorithms, one based on the typically-used in this context high-order method and another based on low-order methods representative of those in common use in industry. The two codes have been validated with solutions of the BiGlobal EVP and it has been showed that small errors in the base flow do not have affect significantly the results. As a result, a three-dimensional compressible unsteady second-order code for global linear stability has been successfully developed based on finite-volume spatial discretization and time-stepping method with the ability to study complex geometries by means of unstructured and hybrid meshes

Fatigue apparatus for geometrically complex non-standardized specimens

Standard Test Methods (e.g. ASTM, DIN) for materials characterization in general, and for fatigue in particular, do not contemplate specimens with complex geometries, as well as the combination of axial and in-plane bending loads in their methodologies. The present study refers to some patents and the new configuration or configurations of specimens (non-standardized by the status quo of test methods) and a device developed to induce axial and bending combined forces resultants from axial loads applied by any one test equipment (dynamic or monotonic) which possesses such limitation, towards obtaining more realistic results on the fatigue behavior, or even basic mechanical properties, from geometrically complex structures. Motivated by a specific and geometrically complex aeronautic structure (motor-cradle), non-standardized welded tubular specimens made from AISI 4130 steel were fatigue-tested at room temperature, by using a constant amplitude sinusoidal load of 20 Hz frequency, load ratio R = 0.1 with and without the above referred auxiliary fatigue apparatus. The results showed the fatigue apparatus was efficient for introducing higher stress concentration factor at the welded specimen joints, consequently reducing the fatigue strength when compared to other conditions. From the obtained results it is possible to infer that with small modifications the proposed apparatus will be capable to test a great variety of specimen configurations such as: squared tubes and plates with welded or melted junctions, as well as other materials such as aluminum, titanium, composites, polymeric, plastics, etc. © 2009 Bentham Science Publishers Ltd.

Inspection of parts with complex geometry and welds with structural health monitoring techniques

Structural Health Monitoring (SHM) systems were developed to evaluate the integrity of a system during operation, and to quickly identify the maintenance problems. They will be used in future aerospace vehicles to improve safety, reduce cost and minimize the maintenance time of a system. Many SHM systems were already developed to evaluate the integrity of plates and used in marine structures. Their implementation in manufacturing processes is still expected. The application of SHM methods for complex geometries and welds are two important challenges in this area of research. This research work started by studying the characteristics of piezoelectric actuators, and a small energy harvester was designed. The output voltages at different frequencies of vibration were acquired to determine the nonlinear characteristics of the piezoelectric stripe actuators. The frequency response was evaluated experimentally. AA battery size energy harvesting devices were developed by using these actuators. When the round and square cross section devices were excited at 50 Hz frequency, they generated 16 V and 25 V respectively. The Surface Response to Excitation (SuRE) and Lamb wave methods were used to estimate the condition of parts with complex geometries. Cutting tools and welded plates were considered. Both approaches used piezoelectric elements that were attached to the surfaces of considered parts. The variation of the magnitude of the frequency response was evaluated when the SuRE method was used. The sum of the square of the differences was calculated. The envelope of the received signal was used for the analysis of wave propagation. Bi-orthogonal wavelet (Binlet) analysis was also used for the evaluation of the data obtained during Lamb wave technique. Both the Lamb wave and SuRE approaches along with the three methods for data analysis worked effectively to detect increasing tool wear. Similarly, they detected defects on the plate, on the weld, and on a separate plate without any sensor as long as it was welded to the test plate.

An EFG method for the nonlinear analysis of plates undergoing arbitrarily large deformations

The applicability of a meshfree approximation method, namely the EFG method, on fully geometrically exact analysis of plates is investigated. Based on a unified nonlinear theory of plates, which allows for arbitrarily large rotations and displacements, a Galerkin approximation via MLS functions is settled. A hybrid method of analysis is proposed, where the solution is obtained by the independent approximation of the generalized internal displacement fields and the generalized boundary tractions. A consistent linearization procedure is performed, resulting in a semi-definite generalized tangent stiffness matrix which, for hyperelastic materials and conservative loadings, is always symmetric (even for configurations far from the generalized equilibrium trajectory). Besides the total Lagrangian formulation, an updated version is also presented, which enables the treatment of rotations beyond the parameterization limit. An extension of the arc-length method that includes the generalized domain displacement fields, the generalized boundary tractions and the load parameter in the constraint equation of the hyper-ellipsis is proposed to solve the resulting nonlinear problem. Extending the hybrid-displacement formulation, a multi-region decomposition is proposed to handle complex geometries. A criterium for the classification of the equilibrium`s stability, based on the Bordered-Hessian matrix analysis, is suggested. Several numerical examples are presented, illustrating the effectiveness of the method. Differently from the standard finite element methods (FEM), the resulting solutions are (arbitrary) smooth generalized displacement and stress fields. (c) 2007 Elsevier Ltd. All rights reserved.

Theory manual to OctVCE – a cartesian cell CFD code with special application to blast wave problems, Department of Mechanical Engineering Report 2007/12

OctVCE is a cartesian cell CFD code produced especially for numerical simulations of shock and blast wave interactions with complex geometries, in particular, from explosions. Virtual Cell Embedding (VCE) was chosen as its cartesian cell kernel for its simplicity and sufficiency for practical engineering design problems. The code uses a finite-volume formulation of the unsteady Euler equations with a second order explicit Runge-Kutta Godonov (MUSCL) scheme. Gradients are calculated using a least-squares method with a minmod limiter. Flux solvers used are AUSM, AUSMDV and EFM. No fluid-structure coupling or chemical reactions are allowed, but gas models can be perfect gas and JWL or JWLB for the explosive products. This report also describes the code’s ‘octree’ mesh adaptive capability and point-inclusion query procedures for the VCE geometry engine. Finally, some space will also be devoted to describing code parallelization using the shared-memory OpenMP paradigm. The user manual to the code is to be found in the companion report 2007/13.

User guide for shock and blast simulation with the OctVCE code (version 3.5+), Department of Mechanical Engineering Report 2007/13

OctVCE is a cartesian cell CFD code produced especially for numerical simulations of shock and blast wave interactions with complex geometries. Virtual Cell Embedding (VCE) was chosen as its cartesian cell kernel as it is simple to code and sufficient for practical engineering design problems. This also makes the code much more ‘user-friendly’ than structured grid approaches as the gridding process is done automatically. The CFD methodology relies on a finite-volume formulation of the unsteady Euler equations and is solved using a standard explicit Godonov (MUSCL) scheme. Both octree-based adaptive mesh refinement and shared-memory parallel processing capability have also been incorporated. For further details on the theory behind the code, see the companion report 2007/12.

Desenvolvimento de uma ferramenta para cálculo de estruturas em material compósito

Os desafios à engenharia moderna são cada vez maiores, pretendendo-se quase sempre obter estruturas mais leves, com propriedades mecânicas atrativas e muitas vezes com geometrias complexas. Com tais requisitos, um dos materiais que tem vindo a ter uma crescente aplicação é o material compósito. Contudo, no que toca ao cálculo estrutural destes materiais, tudo se torna mais complexo, já que são materiais que geralmente são formados por empilhamento de várias camadas de material heterogéneo, podendo estas encontrarem-se dispostas segundo diferentes orientações. Assim, a utilização de um software que permita a previsão das propriedades mecânicas de uma estrutura em material compósito através da micromecânica, a aplicação da Teoria Clássica dos Laminados e de um critério de rotura, como por exemplo o de Tsai-Hill, é fundamental para agilizar o processo de estudo da estrutura a fabricar. Para dar uma resposta a tal necessidade foi desenvolvida uma aplicação, em MATLAB® GUI, denominada CAFE – Composite Analysis For Engineers, com ambiente gráfico apelativo, que permite determinar todas as variáveis importantes no estudo de estruturas em material compósito. Esta aplicação visa suportar e agilizar a aprendizagem desta área do conhecimento, permitindo também o acesso ao código de cálculo por parte do utilizador, de modo a conhecerem-se as equações utilizadas e, eventualmente, ser alvo de futuros desenvolvimentos. O programa desenvolvido foi alvo de validação, recorrendo-se para tal, a uma comparação dos resultados obtidos entre o respetivo programa e por um outro programa de grande fiabilidade. Assim sendo, concluiu-se que o software CAFE apresenta resultados válidos, encontrando-se apto a ser utilizado.

Adherend thickness effect on the tensile fracture toughness of a structural adhesive using an optical data acquisition method

Adhesive bonding is nowadays a serious candidate to replace methods such as fastening or riveting, because of attractive mechanical properties. As a result, adhesives are being increasingly used in industries such as the automotive, aerospace and construction. Thus, it is highly important to predict the strength of bonded joints to assess the feasibility of joining during the fabrication process of components (e.g. due to complex geometries) or for repairing purposes. This work studies the tensile behaviour of adhesive joints between aluminium adherends considering different values of adherend thickness (h) and the double-cantilever beam (DCB) test. The experimental work consists of the definition of the tensile fracture toughness (GIC) for the different joint configurations. A conventional fracture characterization method was used, together with a J-integral approach, that take into account the plasticity effects occurring in the adhesive layer. An optical measurement method is used for the evaluation of crack tip opening and adherends rotation at the crack tip during the test, supported by a Matlab® sub-routine for the automated extraction of these quantities. As output of this work, a comparative evaluation between bonded systems with different values of adherend thickness is carried out and complete fracture data is provided in tension for the subsequent strength prediction of joints with identical conditions.

Aglomeração de cortiça por compressão a quente

A diversificação do uso dos produtos de cortiça exige uma adaptação constante dos processos produtivos utilizados para a transformação deste produto. Este trabalho tem como principal intuito a idealização e investigação de um novo processo de fabrico adaptado a um tipo muito particular de produto, os aglomerados puros de cortiça. Estes, não recorrem a qualquer tipo de aglutinante para assegurar a sua ligação, apenas as resinas contidas na própria cortiça são utilizadas para esse efeito. Analisando os processos de fabrico atuais, verifica-se que, a conceção de geometrias complexas com aglomerados puros de cortiça, só é possível com recurso à maquinação. Este processo gera desperdício e tem uma série de processos que o antecedem, destacando-se a aglomeração prévia numa forma mais simples (bloco paralelepípedo ou cilindro) e o corte numa pré forma. A ideia de se executar uma peça complexa sem recurso à maquinação é o objetivo primordial deste trabalho. Para isso foi construído um molde, com todos os mecanismos auxiliares necessários, à semelhança do que já se faz noutro tipo de indústrias, nomeadamente, do vidro e do plástico. Esse mesmo molde foi submetido a uma série de ensaios para determinação dos parâmetros de enchimento e moldação, tendo-se chegado a uma formulação que garante características atrativas na peça final. A aglutinação do granulado de cortiça revelou-se bastante dependente de três parâmetros: a temperatura aplicada, a humidade do granulado e o grau de compactação aplicado. A industrialização do processo revelou-se também plausível de execução, sendo apenas necessários alguns melhoramentos. A utilização deste tipo de processo revela-se, portanto, atrativa para grandes séries de peças, conseguindo-se elevada reprodutibilidade das mesmas com apenas um processo, sem necessidade de procedimentos adicionais de acabamento.

Development of a new 3D OpenFOAM® solver to model the cooling stage in profile extrusion

[Excerpt] The advantages resulting from the use of numerical modelling tools to support the design of processing equipment are almost consensual. The design of calibration systems in profile extrusion is not an exception . H owever , the complex geome tries and heat exchange phenomena involved in this process require the use of numerical solvers able to model the heat exchange in more than one domain ( calibrator and polymer), the compatibilization of the heat transfer at the profile - calibrator interface and with the ability to deal with complex geometries. The combination of all these features is usually hard to find in commercial software. Moreover , the dimension of the meshes required to ob tain accurate results, result in computational times prohibitive for industrial application. (...)

Simulation of interface dynamics across pore discontinuities

We study the dynamics of a water-oil meniscus moving from a smaller to a larger pore. The process is characterised by an abrupt change in the configuration, yielding a sudden energy release. A theoretic study for static conditions provides analytical solutions of the surface energy content of the system. Although the configuration after the sudden energy release is energetically more convenient, an energy barrier must be overcome before the process can happen spontaneously. The energy barrier depends on the system geometry and on the flow parameters. The analytical results are compared to numerical simulations that solve the full Navier-Stokes equation in the pore space and employ the Volume Of Fluid (VOF) method to track the evolution of the interface. First, the numerical simulations of a quasi-static process are validated by comparison with the analytical solutions for a static meniscus, then numerical simulations with varying injection velocity are used to investigate dynamic effects on the configuration change. During the sudden energy jump the system exhibits an oscillatory behaviour. Extension to more complex geometries might elucidate the mechanisms leading to a dynamic capillary pressure and to bifurcations in final distributions of fluid phases in porous

Monte Carlo simulation of a clearance box monitor used for nuclear power plant decommissioning.

When decommissioning a nuclear facility it is important to be able to estimate activity levels of potentially radioactive samples and compare with clearance values defined by regulatory authorities. This paper presents a method of calibrating a clearance box monitor based on practical experimental measurements and Monte Carlo simulations. Adjusting the simulation for experimental data obtained using a simple point source permits the computation of absolute calibration factors for more complex geometries with an accuracy of a bit more than 20%. The uncertainty of the calibration factor can be improved to about 10% when the simulation is used relatively, in direct comparison with a measurement performed in the same geometry but with another nuclide. The simulation can also be used to validate the experimental calibration procedure when the sample is supposed to be homogeneous but the calibration factor is derived from a plate phantom. For more realistic geometries, like a small gravel dumpster, Monte Carlo simulation shows that the calibration factor obtained with a larger homogeneous phantom is correct within about 20%, if sample density is taken as the influencing parameter. Finally, simulation can be used to estimate the effect of a contamination hotspot. The research supporting this paper shows that activity could be largely underestimated in the event of a centrally-located hotspot and overestimated for a peripherally-located hotspot if the sample is assumed to be homogeneously contaminated. This demonstrates the usefulness of being able to complement experimental methods with Monte Carlo simulations in order to estimate calibration factors that cannot be directly measured because of a lack of available material or specific geometries.

Calculations of Boiling Two-Phase Flow Using a Porous Media Model

Boiling two-phase flow and the equations governing the motion of fluid in two-phase flows are discussed in this thesis. Disposition of the governing equations in three-dimensional complex geometries is considered from the perspective of the porous medium concept. The equations governing motion in two-phase flows were formulated, discretized and implemented in a subroutine for pressure-velocity solution utilizing the SIMPLE algorithm modified for two-phase flow. The subroutine was included in PORFLO, which is a three-dimensional 5-equation porous media model developed at VTT by Jaakko Miettinen. The development of two-phase flow and the resulting void fraction distribution was predicted in a geometry resembling a section of BWR fuel bundle in a couple of test cases using PORFLO.

Suivi des vaisseaux sanguins en temps réel à partir d’images ultrasonores mode-B et reconstruction 3D : application à la caractérisation des sténoses artérielles

La maladie des artères périphériques (MAP) se manifeste par une réduction (sténose) de la lumière de l’artère des membres inférieurs. Elle est causée par l’athérosclérose, une accumulation de cellules spumeuses, de graisse, de calcium et de débris cellulaires dans la paroi artérielle, généralement dans les bifurcations et les ramifications. Par ailleurs, la MAP peut être causée par d`autres facteurs associés comme l’inflammation, une malformation anatomique et dans de rares cas, au niveau des artères iliaques et fémorales, par la dysplasie fibromusculaire. L’imagerie ultrasonore est le premier moyen de diagnostic de la MAP. La littérature clinique rapporte qu’au niveau de l’artère fémorale, l’écho-Doppler montre une sensibilité de 80 à 98 % et une spécificité de 89 à 99 % à détecter une sténose supérieure à 50 %. Cependant, l’écho-Doppler ne permet pas une cartographie de l’ensemble des artères des membres inférieurs. D’autre part, la reconstruction 3D à partir des images échographiques 2D des artères atteintes de la MAP est fortement opérateur dépendant à cause de la grande variabilité des mesures pendant l’examen par les cliniciens. Pour planifier une intervention chirurgicale, les cliniciens utilisent la tomodensitométrie (CTA), l’angiographie par résonance magnétique (MRA) et l’angiographie par soustraction numérique (DSA). Il est vrai que ces modalités sont très performantes. La CTA montre une grande précision dans la détection et l’évaluation des sténoses supérieures à 50 % avec une sensibilité de 92 à 97 % et une spécificité entre 93 et 97 %. Par contre, elle est ionisante (rayon x) et invasive à cause du produit de contraste, qui peut causer des néphropathies. La MRA avec injection de contraste (CE MRA) est maintenant la plus utilisée. Elle offre une sensibilité de 92 à 99.5 % et une spécificité entre 64 et 99 %. Cependant, elle sous-estime les sténoses et peut aussi causer une néphropathie dans de rares cas. De plus les patients avec stents, implants métalliques ou bien claustrophobes sont exclus de ce type d`examen. La DSA est très performante mais s`avère invasive et ionisante. Aujourd’hui, l’imagerie ultrasonore (3D US) s’est généralisée surtout en obstétrique et échocardiographie. En angiographie il est possible de calculer le volume de la plaque grâce à l’imagerie ultrasonore 3D, ce qui permet un suivi de l’évolution de la plaque athéromateuse au niveau des vaisseaux. L’imagerie intravasculaire ultrasonore (IVUS) est une technique qui mesure ce volume. Cependant, elle est invasive, dispendieuse et risquée. Des études in vivo ont montré qu’avec l’imagerie 3D-US on est capable de quantifier la plaque au niveau de la carotide et de caractériser la géométrie 3D de l'anastomose dans les artères périphériques. Par contre, ces systèmes ne fonctionnent que sur de courtes distances. Par conséquent, ils ne sont pas adaptés pour l’examen de l’artère fémorale, à cause de sa longueur et de sa forme tortueuse. L’intérêt pour la robotique médicale date des années 70. Depuis, plusieurs robots médicaux ont été proposés pour la chirurgie, la thérapie et le diagnostic. Dans le cas du diagnostic artériel, seuls deux prototypes sont proposés, mais non commercialisés. Hippocrate est le premier robot de type maitre/esclave conçu pour des examens des petits segments d’artères (carotide). Il est composé d’un bras à 6 degrés de liberté (ddl) suspendu au-dessus du patient sur un socle rigide. À partir de ce prototype, un contrôleur automatisant les déplacements du robot par rétroaction des images échographiques a été conçu et testé sur des fantômes. Le deuxième est le robot de la Colombie Britannique conçu pour les examens à distance de la carotide. Le mouvement de la sonde est asservi par rétroaction des images US. Les travaux publiés avec les deux robots se limitent à la carotide. Afin d’examiner un long segment d’artère, un système robotique US a été conçu dans notre laboratoire. Le système possède deux modes de fonctionnement, le mode teach/replay (voir annexe 3) et le mode commande libre par l’utilisateur. Dans ce dernier mode, l’utilisateur peut implémenter des programmes personnalisés comme ceux utilisés dans ce projet afin de contrôler les mouvements du robot. Le but de ce projet est de démontrer les performances de ce système robotique dans des conditions proches au contexte clinique avec le mode commande libre par l’utilisateur. Deux objectifs étaient visés: (1) évaluer in vitro le suivi automatique et la reconstruction 3D en temps réel d’une artère en utilisant trois fantômes ayant des géométries réalistes. (2) évaluer in vivo la capacité de ce système d'imagerie robotique pour la cartographie 3D en temps réel d'une artère fémorale normale. Pour le premier objectif, la reconstruction 3D US a été comparée avec les fichiers CAD (computer-aided-design) des fantômes. De plus, pour le troisième fantôme, la reconstruction 3D US a été comparée avec sa reconstruction CTA, considéré comme examen de référence pour évaluer la MAP. Cinq chapitres composent ce mémoire. Dans le premier chapitre, la MAP sera expliquée, puis dans les deuxième et troisième chapitres, l’imagerie 3D ultrasonore et la robotique médicale seront développées. Le quatrième chapitre sera consacré à la présentation d’un article intitulé " A robotic ultrasound scanner for automatic vessel tracking and three-dimensional reconstruction of B-mode images" qui résume les résultats obtenus dans ce projet de maîtrise. Une discussion générale conclura ce mémoire. L’article intitulé " A 3D ultrasound imaging robotic system to detect and quantify lower limb arterial stenoses: in vivo feasibility " de Marie-Ange Janvier et al dans l’annexe 3, permettra également au lecteur de mieux comprendre notre système robotisé. Ma contribution dans cet article était l’acquisition des images mode B, la reconstruction 3D et l’analyse des résultats pour le patient sain.