Accuracy Of Numerical Simulation Results Research Articles

Analysis of the influence of different support types on the operation performance of bidirectional shaft tubular pump

Abstract Because of the particularity of the pump’s bidirectional operation, and the difference of the flow channels on both sides of the pump. The device has a mature impeller and guide vane combination when it is running forward. And when the device runs in reverse, the support on the shaft side acts as the rear guide vane of the impeller, which has great influence on the performance of the device. However, due to the few operating conditions in reverse operation, the importance of support is often ignored. In this paper, the influence of different support types on the bidirectional flow pattern and performance of the device is analyzed by numerical simulation. The results indicate that by optimizing the variation trend of the edge arc radius of the supporting baffle section, it is possible to effectively control the section with poor flow distribution, thereby reducing hydraulic losses. The support adopts three partitions arranged at an interval of 120°, which has little difference in performance during forward operation compared with other schemes. But during reverse operation, it reduces the impact and friction losses of water flow. And it fully utilizes the direct guide vane function of recovering vorticity, resulting in a significant increase in efficiency. At the same time, the accuracy of numerical simulation results is verified by model tests. The stability of positive and negative operating pressure pulsation supporting the inlet and outlet under the optimal scheme is analyzed.

Investigation of mixing and heat transfer characteristics of long-hole SK direct contact heat exchanger

In this study, in order to improve the efficiency of direct contact heat exchanger (DCHE), SK static mixers with different perforation index (PI) were applied. Numerical simulation (volume of fluid model) were used to investigate the performance of the static mixer, which shape was designed as long-holes, under fixed aspect and helical ratios. The feasibility and accuracy of numerical simulation results were verified by self-established direct contact heat transfer (DCHT) experimental platform. Under six different PI values (0 %, 10 %, 18 %, 26 %, 32 %, and 38 %), the heat transfer performance of DCHE was evaluated by applying two heat transfer mediums (THERMINOL62 and R141b). The results indicated that the gaseous working medium outlet temperature, turbulence intensity, turbulence kinetic energy, and volumetric heat transfer coefficient (VHTC) of the system showed an increasing trend as PI increased from 0 % to 32 %, then a decreasing trend can be observed from 32 % to 38 %. The maximum turbulence intensity and turbulence kinetic energy of 17.56 % and 0.015 m2/s2 can be found in PI = 32 %, as well as a maximum enhancement ratio of 49 % in VHTC compared to PI = 0 % can be achieved. In addition, only a small pressure drop increase is observed in PI = 32 % compared to PI = 0 %.

Investigation of Cavitation Flow and Entropy Production Characteristics in a Dual-Rotor Turbine Flowmeter

Flow meters are extensively utilized in fields such as chemical engineering, petroleum, and aerospace, and are an indispensable component of modern industry. This paper examines the metrological properties of a dual-rotor turbine flow meter within its measurable flow range through experimental approaches and investigates the cavitation flow dynamics within the flow meter using numerical methods. First, the flow characteristics curve of the dual-rotor turbine flow meter was established experimentally, and the accuracy of numerical simulation results was validated. Secondly, the transient characteristics of the cavitation cavity were revealed using the Z-G-B cavitation model and dynamic mesh technology. Finally, entropy production theory was applied to investigate the energy losses caused by cavitation, analyzing the contributions of different types of energy losses during the cavitation process. Flow calibration experiments and numerical simulations reveal an increase in the meter coefficient of the dual-rotor turbine flow meter in high-flow cavitation zones, indicating that the displayed flow rate is slightly higher during cavitation compared to non-cavitating flows. Transient cavitation flow undergoes three stages: attachment, development, and collapse. At 323 K, the volume fractions of upstream and downstream cavities increase by 38.9% and 48.3%, respectively, with the cavitation cycle duration being 1.21 times that at 298 K. At 343 K, these increases are 75.3% and 239.2%, with the cycle duration being 2.63 times that at 298 K. Among the various sources of loss, the contribution from losses due to pulsating velocity gradients is the most significant, with maximum proportions of 81.95%, 85.1%, and 87.11% at 298 K, 323 K, and 343 K, respectively.

Dynamic simulation of double-cased perforation in deepwater high temperature and high-pressure oil and gas wells

In order to ensure the penetrability of double-cased perforation in offshore oil and gas fields and to maximize the capacity of perforation completion, This study establishes a dynamic model of double-cased perforation using ANSYS/LS-DYNA simulation technology. The combination of critical perforation parameters for double casing is obtained by studying the influencing factors of the jet-forming process, perforation depth, diameter, and stress changes of the inner and outer casing. The single-target perforation experiments under high-temperature and high-pressure (HTHP) conditions and ground full-scale ring target perforation tests are designed to verify the accuracy of numerical simulation results. The reduced factor is adopted as the quantitative measure of perforation depth and diameter for different types of perforation charge under different conditions. The results show that the perforation depth reduction increases with temperature and pressure, and the reduced factor is between 0.67 and 0.87 under HTHP conditions of 130 °C/44 MPa and 137 °C/60 MPa. Comparing the results of the numerical simulation and the full-scale test correction, the maximum error is less than 8.91%, and this numerical simulation has strong reliability. This research provides a basis for a reasonable range of double-cased perforation parameters and their optimal selection.

Numerical Investigation on the Aerodynamic and Aeroacoustic Characteristics in New Energy Vehicle Cooling Fan with Shroud

The cooling fan is one of the important noise sources for new energy vehicles, and the research on its aerodynamic and aeroacoustic characteristics is of great help to improve the noise, vibration and harshness performance of new energy vehicles. However, most of these studies focus on the impeller, and little consideration has been given to the study of the shroud. Based on the coupling calculation method of large eddy simulation and the Ffowcs-Williams and Hawkings acoustics model, the aerodynamic and aeroacoustic characteristics in a cooling fan with the shroud are investigated at flow rates from 0.623 kg/s to 1.019 kg/s (where 0.865 kg/s is the flow rate corresponding to the best efficiency point). The accuracy of numerical simulation results is verified by the grid independence verification and the comparison of experimental data. Research shows that several large-scale vortex structures are observed in the clearance between the impeller and the shroud. The maximum peak-to-peak values of pressure fluctuation at different flow rates occur in the intermediate section or outlet section of the shroud. Although the shroud contributes relatively less to the far field noise, its different distribution may change the position of the maximum sound pressure level. The dominant frequency of pressure fluctuation equals the blade passage frequency (BPF) and the maximum SPL is around the BPF, both of which are independent of flow rates. The maximum SPL and the amplitude of the dominant frequency decrease as the flow rate increases.

Structure Optimization and Performance Evaluation of Downhole Oil–Water Separation Tools: A Novel Hydrocyclone

Abstract Based on the principle of cyclone separation and 3D printing technology, a novel variable pitch hydrocyclone structure was proposed for the axial flow hydrocyclone separators of oil wells. The structural parameters of this variable pitch hydrocyclone were optimized via a combined approach of the Plackett–Burman design, response surface design, and computational fluid dynamics. A quadratic polynomial mathematical relationship between significant structural parameters and separation efficiency was established. The effects of the inlet flowrate, split ratio, and oil phase volume fraction on oil–water separation performance were systematically analyzed. A laboratory test system for oil–water swirl separation was constructed to verify the accuracy of numerical simulation results and the efficiency of the optimized structure. The optimal overflow split ratio, inlet flowrate, and oil concentration for the hydrocyclone are 30%, 96 m3/day, and 2%, respectively. The combination of these optimal parameters results in an experimental separation efficiency of 99.38%, which is higher than that of the conventional structure (98.8%). The experimental results are in good agreement with the simulation results.

Influence of geomechanics parameters on stress sensitivity in fractured reservoir

The complex fractures aggravate stress sensitivity and heterogeneity of the reservoir and seriously restrict effective development. Therefore, it is of great significance to study and quantitatively evaluate the stress sensitivity of the fractured reservoir. Taking the typical block of the Longmaxi shale reservoir in southern Sichuan as the engineering background, one uses the finite element method to develop a numerical model of a two-dimensional fracture closure variation subjected to the non-hydrostatic stress field. It explores the influence of different fracture occurrences and rock mechanical parameters on stress sensitivity. The theoretical model verifies the numerical simulation results to reveal the stress sensitivity mechanism of the fractured reservoir. The results show that the influence of the dip angle of fracture on the stress sensitivity depends on the anisotropy of applied in-situ stresses. The stronger stress sensitivity occurs in low-dip angles where the lateral pressure coefficient is less than 1. One defines the lateral pressure coefficient. On the contrary, the stronger stress sensitivity occurs in high-dip angles where the lateral pressure coefficient is more significant than 1. It is because the normal stress differences under different stress fields apply to the fracture. Under a given stress condition, the stress sensitivity of fracture negatively correlates with aspect ratio, elastic modulus, and Poisson’s ratio. Pressure maintenance may be more critical in a reservoir with a low aspect ratio and rich in soft minerals. The theoretical predicting model of fracture permeability under different conditions is established based on the linear elastic theory. The relative error between theoretically predicted results and numerical simulation ones is less than 10%, which verifies the accuracy of numerical simulation results. The fundamental reason for stress sensitivity in the fractured reservoir is the fracture geometry and mineral deformation change. The research results are of great significance for establishing the productivity equation considering the stress sensitivity, accurately evaluating the variation of reservoir seepage capacity, and formulating reasonable drainage and production system.

Review on Oil Displacement Technologies of Enhanced Oil Recovery: State-of-the-Art and Outlook

Despite rapid advances in renewable energy extraction and utilization, global oil demand continues to rise. Oil displacement technologies are widely studied and applied because they can extract more oil in depleted reservoirs or recover unconventional ones. This study introduces research methods and mechanisms of four oil displacement technologies, i.e., water flooding, chemical flooding, gas flooding, and steam flooding. Although oil displacement technologies are helping to meet the growing demand for oil and energy, there are still some challenges for industrial applications. Some agents adopted in the oil displacement have shortcomings in the corrosion of mining equipment and damage to the reservoir structure. Therefore, solutions to the problem are crucial and are investigated widely in the literature using experiments and simulations. For experimental research, a diffusion framework for studying mass transfer in the oil displacement process and an experimental system for simulating oil displacement in offshore reservoirs should be built, which will facilitate the widespread industrial application of oil displacement technology. Therefore, it is necessary to improve the accuracy and expand the application range of the experimental system. As for numerical simulation, reaction kinetics research is essential for selecting displacement agent materials and preventing harmful gas leakage for industrial applications. However, the dynamics of foam flooding and CO2 flooding are not thoroughly studied. Moreover, it is an acceptable research topic that reducing the uncertainty of discrete regions is an effective method to improve the accuracy of numerical simulation results. For the broader application of oil displacement technology to industry, several mechanisms regarding the research field could be studied more thoroughly and comprehensively in the future, i.e., (1) the influence mechanisms of some impurities and complex reservoir physical properties, (2) the method of combining various oil displacement technologies, (3) the T-H-M-C multifield coupling oil displacement mechanism at micro/nanoscale, (4) the cement failure mechanism caused by CO2 and H2S, and (5) the tube brittle fracture mechanism caused by stress corrosion. For the sustainable development and efficient utilization of oil displacement, this review summarizes the extensive information about four oil displacement technologies, thus encouraging and providing research topics for further development and applications.

The Present Issues of Control Automation for Levitation Metal Melting

This article is a review of current scientific problems in the field of automation of the electromagnetic levitation melting process control of non-ferrous metals and potential solutions using modern digital technologies. The article describes the technological process of electromagnetic levitation melting as a method of obtaining ultrapure metals and the main problems of the automation of this process taking into account domestic and international experience. Promising approaches to control the position of the melt in the inductor in real time on the basis of vision systems are considered. The main problems and factors preventing the mass introduction of levitation melting in the electromagnetic field to the industry are highlighted. The problem of passing the Curie point by the heated billet and the effect of the billet’s loss of magnetism on the vibrational circuit of the installation and the temperature of the inductor are also considered. The article also reflects key areas of research development in the field of levitation melting, including: optimization of energy costs, stabilization of the position of the melt in the inductor, predictive process control, and scaling of levitation melting units. The concept of a digital twin based on a numerical model as a component of an automatic process control system for the implementation of inductor control and prediction of process parameters of the melt is presented. The possibility of using vision for visual control of the melt position in the inductor based on video images for its further stabilization in the inductor and increasing the accuracy of numerical simulation results by specifying the real geometry of the melt in parallel with the calculation of the model itself is considered.

The Parameters Identification of High-Temperature Constitutive Model Based on Inverse Optimization Method and 3D Processing Map of Cr8 Alloy Steel.

As a novel kind of cold roller steel, Cr8 alloy steel has the characteristics of high hardness, high wear resistance and good toughness, which can effectively prolong the service life of the roller that is an important part of the steel rolling mill. How to accurately define the constitutive model parameters of metal materials is the major problem, because it seriously affects the accuracy of numerical simulation results of the roller hot forming process. In the study of Cr8 alloy steel’s thermal deformation behavior of the present paper, the high temperature compression test was done on a Gleebel-1500D thermal/force simulation testing machine. A novel method of parameter identification was proposed based on inverse optimization. The Hansel–Spittel constitutive model was established by using the inverse optimization method. To carry out the verification on the accuracy of the established constitutive model, the predicted flow-stress of constitutive model was made a contrast to the experimental flow-stress, and the standard statistical parameters were also applied to further evaluation. The results showed a relatively high prediction accuracy of the Hansel–Spittel constitutive model based on the inverse optimization algorithm. Meanwhile, to obtain optimal parameters of Cr8 alloy steel in the thermal processing, 3D thermal processing maps concerning strain-rate, strain and temperature were built based on the dynamic material model. According to the 3D processing map, the most adequate thermal processing parameters of Cr8 alloy steel were obtianed as follows: strain 0.2–0.4, strain-rate 0.05–0.005 s−1, temperature 1100–1150 °C.

Numerical Study on Failure Mechanisms of Shaft Wall Consisting of Steel Plate and Concrete under the Effects of Explosion

To enhance the antidynamic and static load resistance of reinforced concrete structures, the measure of covering steel plates on the inner surface of concrete structures arises, which has been rapidly developed and applied in civil engineering and other fields and has achieved a good performance. A new shaft wall structure consisting of steel plate reinforced concrete has been widely used in shaft of deep mining. In order to investigate the stability and obtain the optimum structure parameters of the new shaft structure, the numerical software of LS-DYNA was used to analyze the influences of different factors, including the explosive payload, steel plate thickness, concrete strength grade, and the included joint angle between two plates, on the stability of steel plate reinforced concrete structures. After the verification of the accuracy of numerical simulation results, 23 simulation schemes were proposed and numerically calculated. For all the tests, the principal tensile stress and particle vibration velocity were, respectively, chosen as the failure criteria to evaluate the impacts of those four factors. The results indicate that a quadratic function can be well used to describe the relationships between each factor and both the principal tensile stress and particle vibration velocity. Based on the results, the optimum structure parameters were finally determined, which are suggested as 250 kg, 15 mm, C85, and 40° for the explosive payload, steel plate thickness, concrete strength grade, and joint angle, respectively. The research results can provide a certain theoretical basis and design guidance for solving the problem of water leakage of single-layer shaft wall structures.

Analysis on the Dynamic Responses of an Overlapped Circular Shield Tunnel under the Different Vibration Loads

At present, there are many studies on the dynamic response of overlapped tunnels, but most of them are through numerical simulation. Very few has been conducted by the experimental model research and frequency domain analysis. Combined with the model test and the numerical simulation, the dynamic response of the tunnel lining structure under the action of different train speeds and different tunnel clear distances are investigated, which can remedy the deficiencies in the relevant fields and verify the accuracy of numerical simulation results. The results show that as the train speed increases, the amplitude of the energy spectra of the vibration loads decrease significantly. The tunnel response at the sidewalls is smaller than that at the tunnel crown and at the invert in the lower tunnel. As the net distance increases, the amplitudes of the acceleration frequency spectrum and the energy spectra of the lower tunnel decrease, but with a diminishing rate. The dynamic coefficients of circumferential of the upper tunnel under a train load are larger than those in the longitudinal direction in the invert.

Utilization of Advanced Computational Methods to Predict Spring-back of Aluminium Alloys in Automotive Industry

The automotive industry is one of the most dynamically developing segments of the industrial production worldwide. The introduction of still increasingly stringent emission limits for newly developed cars forces car producers to still reduce the fuel consumption of cars. One option is to use hybrid drive units in combination with a redesign of the automobile body while maintaining the highest possible level of vehicle safety. For these reasons, the automotive industry has been increasingly demanding to apply and process low density (lightweight) alloys, including aluminium-based alloys. These materials are subject to high demands both in terms of mechanical properties and technological workability in the mass production process. The utilization of mathematical modelling (numerical simulations) of production processes is now one of the standards in all phases of design and production the car-body and allows the implementation of variable designs in a relatively short time scale and the detection of potential production problems as well. In this paper, the influence of the kinematic hardening model on the accuracy of spring-back prediction is shown in comparison with the commonly used isotropic hardening model. For deformation analysis, a simple workpiece having ?U-shape? of EN AW 6111 material was used. Such aluminium alloys is used for production car-body panels in the automotive industry. Achieved accuracy of numerical simulation results is evaluated by the comparison shape obtained by numerical simulations and shape of experimentally bended workpiece.

Research and Application of Radial Borehole Fracturing Based on Numerical Simulation

The radial borehole fracturing technology has been applied in a certain number of oilfields with good results being achieved. However, the morphology and variation of fracture still require further study. In this paper, the reservoir model based on formation fluid-solid coupling equation is established with the extended finite element method (XFEM) in ABAQUS, and the fracture morphologies in the single-radial borehole, vertical multiradial borehole, and horizontal multiradial borehole are simulated and analyzed with criteria of maximum principal stress and maximum energy release rate as the damage mechanism. Moreover, the accuracy of numerical simulation results is verified with the large-scale true 3D physical simulation experiment. The results show that the induced stress field along the radial borehole during fracturing is the root cause of fracture directional propagation along the radial borehole whose effective guidance distance reaches 40 m. The vertical multiradial borehole can effectively enhance fracture directional propagation and is capable of reducing fracture initiation pressure. In the horizontal multiradial borehole, the major fracture propagating along each radial borehole is formed in the remote-borehole area, and the secondary fracture connecting the neighboring radial boreholes is formed in the near-borehole zone. Coordination of major and secondary fractures can effectively increase the drainage area and reduce the flow resistance in the near-borehole zone. Based on the research on fracture morphology of multiradial borehole fracturing, the scheme of radial borehole arrangement is optimized and verified through numerical simulation of deliverability. The final optimum borehole arrangement scheme is the intersectional angle of 45° between four orthogonal radial boreholes and horizontal maximum principal stress.

Numerical Simulation Analysis for ABS Bracket Based on MPI Technology

Numerical simulation for ABS bracket based on Mold Plastic Insight (MPI) technology was carried out to analyze the injection process of ABS bracket, and its injection system was also established correspondingly. In accordance with the structure characteristics of plastic part, the perimeter cooling system was optimized. The molding parameters such as melt front temperature, shear rate, weld lines and plastic deformation were systematically analyzed in order to shorten the mold manufacturing cycle and increase the relative efficiency. The objective of this paper is to assess the accuracy of numerical simulation results, and forecast the internal defects of plastic parts.

Cluster analysis for occupant-behavior based electricity load patterns in buildings: A case study in Shanghai residences

In building performance simulation, occupant behavior contributes to large uncertainties, which often lead to considerable discrepancies between actual energy consumption and simulation results. This paper aims to extract occupant-behavior related electricity load patterns using classical K-means clustering approach at the initial investigation stage. Smart-metering data from a case study in Shanghai, China, was used for the load pattern analysis. The electricity load patterns of occupants were examined on a daily/weekly/seasonal basis. According to their load patterns, occupants were categorized as (a) white-collar workers, (b) poor or older families and (c) rich or young families. The daily patterns indicated that electricity use was much more random and fluctuated over a wide range. Most households of the monitored communities consumed relatively-low electricity; the characteristic double peak with higher level of consumption in the morning and evening were only apparent in a relatively small subset of residents (mostly white-collar workers). The weekly analysis found that significant load shifting towards weekend days occurred in the poor or old family group. The electricity saving potential was greatest in the white-collar workers and the rich or young family groups. This study concludes with recommendations to stakeholders utilizing our load profiling results. The research provides a rare insight into the electricity-use-related occupant behaviors of Shanghai residents through the case study of two communities. The findings of the study are also presented in a meaningful way so that they can directly aid the decision-making of governments and other stakeholders interested in energy efficiency. The research results are also relevant to the building energy simulation community as they are derived from observations, and thus can have the potential to improve the efficiency and accuracy of numerical simulation results.

REVIEW OF CFD SIMULATION OF OXY-COAL COMBUSTION FOR ELETRICAL POWER GENERATION: OPPORTUNITIES AND CHALLENGES

The oxy-combustion has generated significant interested for reduction of CO2 emission when the fossil fuel is coal, due to simplification on the separation process of CO2 from the flue gas, it can be more easily stored in reservoir. The CFD numerical simulation techniques in oxy-coal combustion has the potential to contribute to designers in cost savings and reduced computational time; Furthermore, such techniques also provide a robust tool for better understanding and description of the aerothermodynamics processes involved, as well as, aiding the design of most efficient furnaces. However, to obtain representative results of the physical phenomena, the numerical models employed by CFD needs to be suitable for oxy-coal combustion. So, the aim of the paper is to carry out a review of the recent models that are being used for turbulence, combustion and pollutant emissions. Moreover, it is shown a comparison of different results obtained in the numerical simulation of oxy-coal combustion among new models, existing models and experiments. The analysis of the models and experiments shows that the challenges that are still being faced to obtain better accuracy of numerical simulation results. Improvements in the models for oxy-coal combustion can be seen like potential opportunities to investigate and optimize the process that occur in the combustion.

Temporal and Spatial Distribution of Respirable Dust After Blasting of Coal Roadway Driving Faces: A Case Study

Coal roadway driving is an important part of the underground mining system, and very common in Chinese coal mines. However, the high concentration of respirable dust produced in the blasting operation poses a great hazard to miners’ health as well as the underground environment. In this paper, based on the direct simulation Monte Carlo method, the gas–solid two-phase flow model of particle movement is established to study the respirable dust distribution in blasting driving face. The results show that there is an obvious vortex region in which airflow velocity is lower than that close to the roadway wall and driving face. After blasting, respirable dust in the front of the dust group jet from the driving face cannot be discharged timely, with the result that its concentration is higher than the critical value until it is expelled from the roadway, whereas respirable dust concentration at the back of the dust group is gradually diluted and exhibits an alternate thin dense phase distribution. Meanwhile, respirable dust concentration in the breathing zone is relatively higher than that at the top and bottom of roadway. The accuracy of numerical simulation results is verified by field measurements. The research results are helpful for further understanding the evolution of respirable dust distribution after blasting, and are good for providing guidance for efficient controlling of respirable dust and improving the working environment for underground miners.

CMS-Assisted rock mass stability assessment for underground excavation

The accurate shape and position of cavities in an underground mine are important factors that could affect the reliability of numerical modeling analysis result. The traditional numerical stability analysis of underground mined out stopes either considers the cavity shape as a regular geometric object or uses a simple model created for analysis purposes; both of the methods could affect the accuracy of numerical simulation results. Cavity monitoring system (CMS) is used to survey the actual 3D shape and the true position of the cavities. The 3D digital terrain model (DTM) of the grouped cavities is then created in the mine design software. A novel and integrated approach to access the stability of the underground cavity based on the DTM and numerical models is presented. By following a planned excavation sequence, the in situ stress distribution condition of the mining area has been assessed. The result will be considered as the basis of the excavation re-arrangement and safety strategy of the mining area Keywords CMS, FLAC, mining cavity, numerical simulation, rock mass, safety & stability Language: en

Numerical simulation on pressure-relief deformation characteristics of underlying coal-rock mass after upper protective layer excavation

Based on the occurrence features of Group B coal-seams at a coal mine in the Huainan coal mining area, the elasto-plastic mechanical damage constitutive functions and numerical model for the protective layer excavation were established. With the UDEC2D computer program, after the upper protective layer was mined, the stress field change trends, crack development, and expansion deformation trends of underlying coal rock seams in the floor of the working face were simulated and analyzed. The simulation results show the stress changes in coal rock seams, the evolution process of pre-cracks during the process of upper protective layer mining, the caved zone and fractured zone of the underlying coal rock seams. At the same time, the results from the actual investigation and analysis of protected layer deformation match the simulation values, which verifies the validity and accuracy of numerical simulation results. The study results have an important guiding significance for gas management in low permeability and high gas coal seams with similar mining conditions.