Gap Flow Research Articles

Numerical investigation on immiscible two-phase flow in the mechanical seal gap

Numerical investigation on immiscible two-phase flow in the mechanical seal gap

Microparticle sorting in microfluidic Taylor–Couette flows

In this experimental study, we demonstrate that settling polymethyl methacrylate (PMMA) microparticles with diameters ranging from 6 to 60 µm segregate into distinct bands according to their size when subjected to a rotating laminar annular gap flow with a diverging gap width in the axial direction. Different gap widths ranging from 130 to 1200 µm have been investigated in the fully laminar flow regime. Distinct, spatially separated particle bands of different particle sizes have been observed for nine different geometric configurations, including non-conical, conical, double conical, and variously inclined conical inner cylinder shapes. The study considers different rotation rates, geometric combinations, particle volume fractions, and particle size combinations. Particle size separation was achieved at volume fractions ranging from 2.2% to 11% for rotating inner cylinders. In contrast, no separation occurs during the experimental run when both the outer and inner cylinders are perfectly cylindrical, with no significant variation in the annular gap height. Our experiments also show that rotation of the inner cylinder results in more pronounced particle separation than rotation of the outer cylinder. Microscopic particle image velocimetry (µPIV) measurements show that the presence of particles induces an axial velocity component, which acts as a key transport mechanism. In addition, a significant variation in shear rate is observed across particle bands, which may explain size segregation by shear-induced migration. Furthermore, single particle simulations show that particle trajectories and velocities vary significantly with particle size.

Introduction of Axisymmetric Grooves as a Tip Seal Treatment for Small-Core Turbines

Abstract The aerodynamic penalties associated with the tip gap flow in axial turbines remains a challenging problem for turbine manufacturers. As modern gas turbines with small-core architectures are brought online, the influence of the tip gap continues to grow. While technologies to reduce tip losses have been implemented into the blades, little attention has been paid to the casing around the rotor. In this study, an introduction of axisymmetric groove enhancements for the casing are examined computationally. These studies use the National Experimental Turbine (NExT) geometry, an engine-representative high-pressure turbine blade. Steady, RANS simulations are used to assess the basic characteristics of grooves, such as depth, location, and arrangement. The objective of this introductory study was to determine the feasibility of impacting the tip leakage vortex formation and the associated losses in rotor efficiency. Furthermore, analyses were done with different tip gap heights along with both flat- and squealer-tipped blades. Tip seals with a single groove are demonstrated to improve rotor aerodynamic efficiency relative to ungrooved seals by 0.4 points when applied to flat-tipped rotor blades and 0.15 points with squealer tips. Arrays of grooves show improvements for flat-tipped blade performance by 0.76 points, while having little additional aerodynamic effect on squealer tip over single-groove designs. Finally, grooved tip seals appear to exert greater influence on turbine aerodynamic performance at larger tip gaps, indicating that grooved tip seals alter the sensitivity of rotor performance to the tip clearance gap.

Investigation of varying tip clearance gap and operating conditions on the fulfilment of low-speed axial flow fan

Abstract The present study aims to identify the suitable tip clearance and volumetric flow rates for low-speed axial flow fans. The performance of an axial fan depends on various parameters like fan speed, available tip clearance gap, volumetric flow rate, power consumption, and working fluid. Leakage flow occurring at a rotating component such as a blade and solid casing of a ducted axial fan is typically linked to losses and the potential emergence of a rotating stall. The numerical analysis for this study uses the Reynolds Averaged Navier–Stokes equations with the k-omega SST turbulence model to perform the steady-state simulations by varying tip gap and volumetric flow rate. The results proved that the optimum performance was obtained with a tip clearance gap of 1 mm, and maximum fan efficiency was achieved at a volumetric flow rate of 3.9–4.5 m3/s. The novelty of this proposed work is to enhance the efficiency of axial flow fans with circular arc-cambered aerofoils using optimum tip clearance and volumetric flow rate through steady-state simulations. This method can be used in turbomachinery to improve fan performance.

Understanding the effect of physical aging on slip dynamics in soft-glassy materials using pure elongation flow

Slip over a solid surface is a very common occurrence in industrial scale transport and the processing of complex fluids. The knowledge of slip also plays a huge role in the correct estimation of rheological properties. In this work, we have studied the slip dynamics in a model soft-glassy material that exhibits physical aging, wherein the structure evolves gradually toward a more solid-like character via rearrangement of constituents. More precisely, we have investigated the impact of physical aging on slip associated with pure elongation flow of the material. We have allowed the sample to age over different waiting times, followed by the sample being deformed slowly in elongation mode by pulling the top plate to achieve a pure elongation flow. Normal force as a function of gap has been recorded during such pure elongation. These normal force–gap curves demonstrated a remarkable gap-waiting time superposition, manifesting the strong signature of self-similarity in the pure elongation flow of the soft-glassy system. We have adopted a slip layer model, which predicted these normal force–gap flow curves remarkably well. Such prediction also rendered slip layer thickness as a function of waiting time, using which we have explained the intriguing self-similar nature of normal force–gap dependence. Finally, we have established a relationship between the slip layer thickness and the age-dependent bulk rheological properties. We have provided a possible physical reasoning to explain this link between the physical aging-driven state of material and the slip dynamics.

Flow over two inline rough cylinders in the postcritical regime

This study investigates the flow behavior over roughened inline cylinders for postcritical flow, a parameter space with relatively little prior scrutiny. Two cylinders of the same relative surface roughness, ks/D=1.9×10−3, separated by a pitch (i.e., L, distance between the centers of two cylinders) between 1.175≤L/D≤10 are studied at Reynolds numbers from 3×105 to 6×105 using unsteady surface pressure measurements. As pitch ratio is increased from L/D=1.175, CD of the downstream cylinder increases sharply at (L/D)c=3.25. This critical pitch ratio (L/D)c is toward the lower end of the reported range for subcritical smooth cylinders. Asymmetric mean gap flow along with alternating reattachment is found for 1.5≤L/D<2.25 (i.e., two asymmetric modes in the gap, mode 1 and mode 2, that are the reflections of each other), and symmetric gap flow with a continuous reattachment is found for 2.25<L/D≤3. The gap flow is also symmetric for the closest pitch ratio tested of L/D=1.175. While the change in upstream cylinder drag coefficient with Reynolds number broadly follows that of an isolated cylinder, for the downstream cylinder, it is approximately independent. The critical separation is also insensitive to Reynolds number within 3×105≤Re≤6×105. Transitions between the reattachment and the co-shedding flow are predominantly continuous over the spanwise planes tested. On the other hand, alternating reattachment occurs in spanwise cells, where one sectional measurement exhibits the asymmetric mode 1 while a spanwise-adjacent section exhibits the asymmetric mode 2 or even symmetric flow. Previously reported maxima in the fluctuating lift and drag coefficients of the downstream cylinder at L/D≈2.4 at subcritical Reynolds numbers are absent in the current investigation.

Feature-based manifold modeling for the quasiperiodic wake dynamics of a pair of side-by-side cylinders

We propose a feature-based manifold modeling (FeMM) framework for the quasiperiodic wake dynamics of a pair of side-by-side cylinders. The key enabler is to embed the most parsimonious mean-field manifold based on the extracted features, such as force coefficients and probing data from experiments and numerical simulations. The manifold model is then identified under the mean-field constraints of the model structure, ensuring human-interpretability. The FeMM method is demonstrated with a two-dimensional incompressible flow crossing a pair of side-by-side cylinders, exhibiting a flip-flopping wake in quasiperiodic behavior. The transient and post-transient dynamics are characterized by two coupled oscillators associated with vortex shedding and gap flow oscillations. Dynamic mode decomposition analysis reveals significant modal interactions between these two flow mechanisms, posing a serious challenge to projection-based modeling approaches, such as the Galerkin projection method. Nevertheless, the FeMM approach, based on force measurements, yields an interpretable model that accounts for the mechanisms underlying the quasiperiodic dynamics, demonstrating its applicability to higher-order dynamics with multiple scales and invariant sets. This approach is expected to have broad applicability in dynamic modeling and state estimation in various real-world scenarios.

Feasibility study on the heat transfer enhancement of gap flow induced by wasted vibration of linear compressor body

Refrigerators account for 20–30 % of household electricity consumption, with the compressor contributing to 80 % of the total consumption. Therefore, it is essential to increase the compressor efficiency. One approach to enhance compressor performance involves increasing heat dissipation to lower the temperature of the suction system and boost the refrigerant density entering the suction chamber. To achieve that innovatively, we harnessed the waste vibration of the linear compressor body to create a gap flow between the body and the housing, enhancing compressor performance by augmenting heat dissipation. Measurements of gap flow temperature, cylinder surface temperature, and heat flux on the cylinder surface were conducted, varying the RPM, gap size, and the shape of the gap flow path. We also observed variations in the gap flow rate with RPM and stroke. The results revealed that gap temperature and heat flux increased with higher RPM and smaller gap size, and the application of ribs to the gap flow path proved to be more effective in enhancing temperature and heat flux. Additionally, it is anticipated that heat flux will further increase with a longer stroke as the flow rate increases. Therefore, to optimize heat dissipation through gap flow using the waste vibration of the compressor body, it is advantageous to employ a smaller gap size, higher RPM, longer stroke, and apply ribs to the gap flow path. Future research should focus on verifying the effectiveness of increased heat dissipation and improved Energy Efficiency Ratio (EER) through actual compressor experiments.

Effects of particle size and reciprocating frequency of the plunger on performance and flow characteristics of a diaphragm pump

ABSTRACT The present study aims to reveal characteristics of the diaphragm pump applied in transporting the mixture of liquid and solid particles. The computational fluid dynamics (CFD) technique was used in combination with the six degree of freedom (SDOF) method to simulate the solid-liquid two-phase flow in the diaphragm pump. The zero-gap overlapping grid technique was employed to treat unsteady gap flows near the two valves. Effects of particle size and the reciprocating frequency of the plunger were investigated. The results indicate that solid particles pass smoothly through the diaphragm pump. When particle size increases from 2.0 mm to 3.0 mm, the solid volume fraction (SVF) in the pump chamber increases. When the reciprocating frequency of the plunger increases from 150 to 250 cycles per minute, the SVF increases and then decreases. When the reciprocating frequency of the plunger increases, the performance of the diaphragm pump declines, whereas the distribution of particles in the pump chamber is gradually uniformized due to the disturbance of the reversed flow from the pump outlet.

Effect of annulus ratio on the residence time distribution and Péclet number in micro/milli‐scale reactors

AbstractMicro/milli‐scale annular reactor with straight and helical forms has excellent heat and mass transfer performance due to the short molecular diffusion distance and dual‐wall surface transport. The annular gap spacing is scalable by adjusting the inner and outer tube diameter. The influence of diffusion and convection effects on axial dispersion as expanding the flow scale requires further elucidation with the help of residence time distribution (RTD) curves and Péclet (Pe) numbers. The correlation of RTD characteristics with annulus ratio γ = Dh/D (ratio of annulus characteristic size to outer diameter) is investigated using computational fluid dynamics. Results show that with enlarging the straight annular gap from micro‐scale to milli‐scale, RTD characteristics exhibit opposing patterns. This can be attributed to the transition from diffusion‐dominated to convection‐dominated on momentum transfer, and the transition interval is 0.167 < γ < 0.250. Correlation equations of Pe number with Reynolds (Re) number and γ are established under diffusion‐dominated and convection‐dominated states. The symmetrically distributed secondary flow in the helical annular gap effectively elevates the Pe (Pemax > 100). Correlation equations of Pe with Re and γ are established in helical annular gaps with 0.083 < γ < 0.208 and 0.167 < γ < 0.500. The above results contribute to understanding the annular flow RTD characteristics for better applications of tube‐in‐tube reactors.

Visualization of the two-phase flow in the air gap of an optically accessible generic electric motor and its effect on torque

Electric motors with high-power densities are required for the implementation of electromobility. To achieve this, direct liquid cooling methods are increasingly being considered, in which oil is injected into the motor compartment. This results in a two-phase flow that can be used for efficient cooling. However, the oil, which can also penetrate the air gap between the rotor and stator, can also lead to additional losses due to increased friction. Since little is known about the two-phase flow in such systems, especially in the air gap, it is investigated by means of simple optical visualizations and high-speed laser-induced fluorescence imaging as well as torque measurements. The measurements are carried out in the air gap of an optically accessible generic model of a directly cooled electric motor. Speed variations were performed from 100 to 2000 rpm, and three different two-phase flow regimes were observed. At low speeds (Flow Regime 1), the air gap is filled locally with oil in radial direction, in the medium speed range (Flow Regime 2) with foam, while at high speeds (Flow Regime 3) separated films were observed on the rotor and stator. The torque difference between the two-phase and single-phase operation, which quantifies the mechanical losses due to the injected oil, increased continuously due to the oil in the air gap until it reached a maximum in Flow Regime 2 due to foam formation. In Flow Regime 3, the torque difference was negative. This was attributed to the fact that the grooves in the stator were filled with oil, thus reducing the turbulence generation of the air flow.

Experiments and three-dimensional flow simulations on twin-screw pumps operated as control valves for energy recovery

This study explores the characteristics of twin-screw pumps when operated in turbine, i.e., reverse mode as an alternative to traditional control valves in piping systems for recovering energy. Experimental and flow simulation methods are employed. By an overset grid technique, unsteady three-dimensional (3D) flow simulations are conducted, ensuring high cell quality and high spatial resolution, particularly in wall proximity and within the gaps. To assess viscosity effects, pump and turbine mode characteristics are analyzed for water and oil. Compared to water, a pronounced reduction of the flow rate dependence on pressure difference is revealed for highly viscous oil. The gap flow in oil is significantly affected by the spindles’ rotational speed and direction, whereas water displays minimal influence. Analyzing the variation in gap sizes, a 50% reduction in the minimum flank gap width leads to a slight rise in volumetric efficiency with negligible overall efficiency effects. Our findings underscore that utilizing twin-screw pumps as turbines for high-viscosity fluids can potentially recover up to 50% of the energy instead of dissipating it by using conventional control valves.

Investigation of flow and heat transfer characteristics around two tandem and side-by-side cylinders using double-distribution lattice Boltzmann method

This article describes a numerical investigation of the flow over two circular cylinders in tandem and side-by-side arrangements with different spacings at a Reynolds number of 100 using double-distribution lattice Boltzmann method. By comparing and analyzing the vorticity field, temperature field, phase diagram structure and St, the relationship between the typical flow pattern and heat transfer characteristics of the two cylinders in series and side-by-side arrangement is established. The numerical results reveal two distinct flow patterns in the tandem arrangement. In the co-shedding pattern, where the incoming flow condition of the downstream cylinder is the oscillating hot wake of the upstream cylinder. The Nusselt number of the upstream cylinder can rapidly increase to the value of a single cylinder, but the Nusselt number of the downstream cylinder can only increase to 80% of that of the upstream cylinder. Four flow patterns can be identified in the side-by-side arrangement. In the flip-flopping pattern, the interference of the gap flow with variable deflection angle on the near-wake region leads to a rapid increase of Nusselt number, but the flow and heat transfer characteristics appear to be chaotic. The appearance of the two coupled vortex streets in the two synchronized patterns further increases the Nusselt number. In addition, the variation of Nusselt number with spacing in the side-by-side arrangement is positively correlated with the vortex shedding frequency.

Investigating mechanisms of debris removal in ultrasonic vibration-assisted EDM drilling

In traditional electrical discharge machining (EDM) of micro-holes, the debris removal becomes increasingly challenging as hole depth increases, significantly affecting the machining of difficult-to-machine materials. To address this issue,we first developed a micro-hole gap flow field model for a novel longitudinal–torsional ultrasonic vibration (LTV) electrode EDM drilling method. We analyzed the effects of three types of electrodes — rotation electrodes, longitudinal ultrasonic vibration (LUV) electrodes, and LTV electrodes — on the flow velocity in the micro-hole interstitial flow field. Next, we simulated the motion of fluid and debris in the interstitial flow field of micro-holes, theoretically verifying the advantage of electrode ultrasonic vibration in enhancing debris removal efficiency. Additionally, we observed the electrode tip morphology, the elemental composition on the electrode surface, and the morphology of the micro-hole inlet/outlet and inner wall to further elucidate the debris removal mechanism and confirm the superior drilling performance of the ultrasonic vibration electrodes. At an optimal ultrasonic amplitude (AL=4μm), the LUV electrode demonstrated improved consistency in the micro-hole inlet/outlet and achieved a micro-hole taper of 0.014°. The material removal rate (MRR) using the LTV electrode reached 5.14 × 105μm3/s, nearly 1.5 times higher rotation electrode. This method successfully produced a positively tapered hole suitable for injector nozzles.

Reynolds number sensitivity of the vortex dynamics around a long-span rail-cum-road bridge girder with three separated boxes

The novel separated three-box girder is gradually adopted for very long-span cable-stayed bridges due to its excellent flutter stability. Due to its special design of cross section, it exhibits notable Reynolds number effects in the flow patterns and vortex dynamics when subject to incoming flow. To explore its Reynolds number sensitivity, this paper performs a three-dimensional large eddy simulation (LES) on the flow around a static long-span rail-cum-road bridge girder with three separated boxes at different Reynolds numbers. The overall centre height H of the bridge model is chosen as the characteristic length, and the investigated Reynolds number regime falls into the regime of 1e2≤Re≤2.8e4. Through the analysis of the flow characteristics of three distinct regions in the flow field(the windward leading edge region, the gap region and the wake region), a successive transition of the wake flow, gap flow, and leading edge shear flow is observed with increasing Reynolds number. The surrounding flow patterns are divided by different Reynolds number regimes as: laminar separation at the trailing edge (Re<5e2); simultaneous instability of the gap shear layer and the wake (5e2≤Re<1e3); restabilisation of the upstream gap shear layer (1e3≤Re<3e3); secondary instability of the upstream gap shear layer and transition of the wake (3e3≤Re<8e3); transition of the separated shear layer at the leading edge (8e3≤Re≤2.8e4). This paper reveals in detail the complex vortex dynamics in the surrounding flow field of the special cross section with three separated boxes.

Effect of crown gap thickness on axial force of high-head pump turbine

Abstract The size of the runner crown gap is one of the factors affecting the volume loss of the pump turbine, and the unreasonable gap thickness is unfavourable to the unit operation. By establishing a three-dimensional full-channel fluid domain model of a high-head pump turbine, and using the computational fluid dynamics (CFD) method to perform numerical calculations on models with different crown gap thicknesses, the effects of axial water thrust on runners with different upper crown gap thicknesses are clarified. The results of simulation indicates that the resultant force of axial water thrust on the runner is vertically upward under different gap thicknesses, which is far less than the weight of the whole rotating part. The axial water thrust is very sensitive to the change of the seal gap value, the greater the seal gap value, the greater the axial water thrust on the unit, and the axial water thrust begins to decrease after increasing to a certain value. The research results are referable for the study of the gap flow characteristics and the crown gap design.

Experimental study on radial suction flow and its effect in water vortex unit

A water vortex unit is a non-contact adsorption unit that utilizes water as a flowing medium. Negative pressure is generated on the adsorbed surface through the high-velocity rotation of the fluid, resulting in suction force. In comparison to the air vortex unit, the water vortex unit exhibits a substantial increase in suction force and has the capability to deliver greater power. However, the presence of the central bubble in the water vortex unit weakens the suction force. To address the impact of the central bubble, a suction hole was introduced on the vortex unit to remove them. Experimental results indicate that solely removing the central bubble has almost no effect on the radial pressure gradients in the gap flow path and chamber center of the water vortex unit. However, in the cylindrical neighborhood, the radial pressure gradient increases, leading to a certain degree of improvement in suction force. Further increasing the suction flow rate induces inward radial flow within the vortex chamber. This flow field further enhances the suction force. To analyze the reasons for this pressure distribution, we indirectly obtained the radial velocity distribution by examining the relationship between the pressure gradient and tangential velocity. The results of the tangential velocity distribution indicate that the radially inward suction flow significantly increases the rotational velocity of the fluid in the chamber center, enhancing the centrifugal inertial effect. This further reduces the negative pressure, resulting in a significant improvement in the suction of the vortex unit.

Analysis of OWC impulse turbine flow characteristics considering the blade tip clearance

Abstract Oscillating water column (OWC) ocean wave energy recovery device is a popular technology in current wave energy research, which possesses the advantages of a sturdy structure and low-maintenance requirements. The device recovers energy by unidirectional rotation in the reciprocating airflow generated by an impulse turbine. Its operational performance depends on the flow efficiency of the core component, the air turbine. In this paper, a prototype impulse turbine with blades tip clearance of 1 mm was considered, and the SST k-ω turbulence model is used to calculate the operating performance of the air turbine at different operating points. The calculation result shows that the efficiency of the turbine under the optimal operating conditions is about 51.41%. When the flow coefficient is less than 0.8, the primary focus of energy loss in the rotor occurs at the blade tip. The low flow rate leads to a high inlet angle causing fluid friction. In these small flow conditions, the pressure drop at the leaf top gap is cantered on the inlet, and the speed in the gap flow field is significantly reduced. When the flow coefficient is greater than 1.4, the concentration of energy loss in the rotor primarily occurs within the flow channel, where the high-velocity air causing a local high-speed zone.

Study on the solder flow in a narrow gap with metal surface texture

Obvious voids in the solder in a narrow gap is a common problem that greatly affects the reliability of mechanical connections. Due to its high heating rate, laser soldering causes more severe voids and even evolves into dispersion of the solder. A method of metal surface texturing is put forward, in which the texture gradient is used to directionally transport solder for lower dispersity, and the pattern design of texture is used to reduce the void rate. The directional transport of solder is realized through the differences in oxidation degree and microstructure of stainless steel surface under different ultrafast laser scanning speeds. The discharge of voids in the solder is achieved through the reservation of the central area in the solder and the oscillation during the laser heating process. Based on the present method, the aggregation of solder is achieved, with the void rate of 18 % and the joining strength of 10.4 MPa.

The evaluation of error estimation for the Casson hybrid nanofluid flow in the uniform gap between two tubes for drug delivery applications

ABSTRACT Hybrid nanofluids are capable of being used as a carrier for delivering drugs to targeted areas in the body. For this purpose, the Casson hybrid nanofluids (HNFs) flow is suggested between the gap of two tubes. The study involves analyzing blood-based hybrid nanofluids (HNFs) that consist of silver (Ag) and titanium dioxide (TiO2) nanoparticles for applications of drug delivery. Titanium oxide nanoparticles, or TiO2 NPs, have strong photoactivity, low toxicity, and excellent biocompatibility, making them promising candidates for cancer treatment. The attractiveness of silver nanoparticles (AgNPs) for cancer therapy is due to their unique properties. Graphic representations are provided based on the simulations of non-dimensional velocity, temperature, and skin friction under physical parameter variations, for the applications of drug delivery are investigated and discussed. The control volume finite element method (CVFEM), is used to solve the problem. The new strategy of artificial neural networks (ANN) is also used to solve the transform equations. Nanoparticles increase drug stability and extend shelf life by protecting them from degradation or inactivation.