Physical Simulation Method Research Articles

A Fast Simulation Method for Wind Turbine Blade Icing Integrating Physical Simulation and Statistical Analysis

Simulating wind turbine blade icing quickly is important for wind farms to issue early warnings and effectively deal with the adverse effects of cold weather. However, current numerical simulation methods suffer from high computational costs and lack straightforward acceleration techniques for practical ice prediction. Here, we developed a fast and simple blade icing simulation method via an integrated physical simulation and statistical analysis method. This method consists of two steps: firstly, numerical simulation with CFD, and secondly, table look-up calculations. Over 10,000 sets of wind turbine blade icing simulations based on FENSAP-ICE and an NACA64-A17 wing were conducted to develop this method and analyze the influences of environmental factors on blade icing. The results show that ice thickness generally increases with an increase in wind speed, a decrease in temperature, and an increase in liquid water content (LWC), but there is a nonlinear relationship between them. For example, ice thickness has a linear relationship with the LWC within a certain range but hardly changes with a LWC beyond that range. The validation results show that the fast simulation method established in this paper has good consistency with the original numerical simulation method. It can greatly improve the computational efficiency of icing simulations while retaining the accuracy of numerical simulations. It takes less than 1 s to complete over 1000 sets of icing simulations, which offers potential for the fast prediction of wind turbine blade icing in the future.

Advancing the understanding of metal additive manufacturing via physical simulation and in situ transmission electron microscopy: a viewpoint

The complex microstructure evolution and heterogeneities in metal additive manufacturing (AM) continue to delay the adoption of AM parts by additional industries. Achieving uniform and superior properties in AM parts requires better fundamental understanding of the microstructural evolution. A suitable pathway to gain such understanding is via in situ techniques such as high-speed X-ray imaging, high-resolution infrared cameras, or via synchrotron and neutron diffraction. However, these methods are complex and resource intensive. Modeling may be a more economical avenue, yet, to make these models more robust and reliable, data from in situ techniques are often required. We believe that in some cases, physical simulation methods originally developed for research on conventional processing such as forging, rolling, and welding may provide similar insights. This viewpoint article discusses existing experimental methods for tracking the microstructure evolution during AM in lab-scale settings, focusing on Ni-based superalloys as a case study. The proposed physical simulation methods include the Gleeble thermo-mechanical simulator, dilatometry, and the arc-melting heat treatment technique. These methods can also be integrated into various X-ray, synchrotron, and neutron diffraction set-ups. We discuss how insights derived from thermo-kinetic modeling can underpin the experimental observations from physical simulations. Last, in situ transmission electron microscopy is evaluated as a powerful method with unparalleled resolution for observing the microstructure evolution directly during simulated AM processes. We believe that these methods can be extended to other alloy systems, enhancing scientific understanding, and streamlining the efficient development of AM parts with superior and more uniform properties, promoting the more widespread adoption of AM.

An innovative thermal simulation study of microstructure improvement by delay forging during solidification

The solid fraction at the beginning of the forging process is an important factor affecting the performance of the casting-forging integrated forming, which is an innovative and efficient process. The solid fraction depends on the delayed forging time during the casting-forging integrated forming. This paper investigates the effect of delayed forging time on the microstructure of aluminum alloy forged during solidification using an innovative physical simulation method. In this work, a solidification-forging device compatible with the Gleeble system has been developed. Then, experiments were conducted at various delayed forging time. Temperature and force data were collected using the Gleeble system for analysis. Microstructural evolution was investigated using methods including Optical Microscopy (OM), Scanning Electron Microscopy (SEM), Electron Backscattered Diffraction (EBSD), and Three Dimensional Computed Tomography (3D-CT). The results demonstrate that with the extension of the delayed forging time, the grain size of the alloy decreases gradually, and the coarse dendrite structure changes to the rose-shaped grains, and the local misorientation in the grain increases. Moreover, the effect of forging under different forging time on the casting defects of the alloy is studied. When the forging delay is extended to 8 s, the forging promotes the porosity caused by the liquid phase convection. However, with further extension of forging delay, the reduction of the liquid phase and the fracture of dendrites lead to the complexity of liquid phase channels, resulting in the increase of porosity. Additionally, forging near solidification can close shrinkage porosity.

Physical mechanism-based simulation methods for soil and ground heat flux from observations at multi-sites

It is important to obtain the soil heat flux at a specific depth (Gz) and at the ground’s surface (G0) to understand the surface energy balance and climate change. However, previous evaluations of Gz and G0 simulations based on multiple sites have been relatively insufficient. We evaluated the accuracy of using physical mechanism-based gradient and calorimetry methods to simulate Gz and changes in heat storage (ΔS) based on observations collected at 28 sites. Three methods for simulating G0 were also evaluated using triple collocation (TC) and extended triple collocation (ETC) metrics. The ability of the gradient method to simulate Gz was strong, particularly for the lower soil layer, with a median Nash-Sutcliffe efficiency (NSE), correlation coefficient (CC), and index of agreement for the evaluated sites of 0.76, 0.86, and 0.91, respectively. The accuracy of the calorimetry method for simulating ΔS was generally lower than that of the gradient method for determining Gz. Overall, the combination of gradient analysis and calorimetry showed the best performance in simulating G0. The TC evaluation showed that the combination of gradient and calorimetry had a strong ability to simulate G0 in most land cover types (root mean square error (RMSE) <4 W/m2) but this ability was lost in the snow cover type (RMSE > 10 W/m2). When evaluated by ETC, the three methods had strong effects only on alpine meadow, floodland, and shrub types (CC > 0.70). Appropriate evaluation indices were recommended based on the application of the model.

A hybrid load prediction method of office buildings based on physical simulation database and LightGBM algorithm

Building load prediction plays an important role in building energy savings and mechanical and electrical system optimization control. The dynamic energy consumption can be accurately calculated using the traditional physical energy simulation method that entails a complex setup and verification process due to the numerous input parameters required. It is also difficult to change the physical model once it has been determined. The data-mining method is fast in calculation and simple to use, but its prediction accuracy is limited by historical data quality. It is difficult to predict the load of new buildings without historical data. To solve these problems, this study proposes a hybrid building load prediction method for office buildings. The proposed method uses EnergyPlus to generate a building load database that includes than 25.14 million data cases, covering 35 types of building geometry and 2870 building examples. Based on the above database, the LightGBM algorithm was selected to extract feature variables that affect the load and build a load prediction model. The training results show that there are 24 key feature variables for office building load prediction. The hourly MAPE of the cooling load prediction model is 6.95 % and RMSE is 4.31 W/m2, and the hourly MAPE of the heating load prediction model is 7.09 % and RMSE is 11.64 W/m2 compared with EnergyPlus model. Two actual office buildings are selected as case studies to validate the model prediction accuracy. Results show that comparing predicted results with measured data, the hourly cooling load of the MAPE is 12.42 %. Coparing predicted results with actual heating load, daily MAPE is 7.97 %.

A Review of Data-Driven Methods in Building Retrofit and Performance Optimization: From the Perspective of Carbon Emission Reductions

In order to reduce the contribution of the building sector to global greenhouse gas emissions and climate change, it is important to improve the building performance through retrofits from the perspective of carbon emission reductions. Data-driven methods are now widely used in building retrofit research. To better apply data-driven techniques in low-carbon building retrofits, a better understanding is needed of the connections and interactions in optimization objectives and parameters, as well as optimization methods and tools. This paper provides a bibliometric analysis of selected 45 studies, summarizes current research hotspots in the field, discusses gaps to be filled, and proposes potential directions for future work. The results show that (1) the building-performance optimization (BPO) process established through physical simulation methods combines the site, retrofit variables, and carbon-related objectives, and the generated datasets are either directly processed using multi-objective optimization (MOO) algorithms or trained as a surrogate model and iteratively optimized using MOO methods. When a sufficient amount of data is available, data-driven methods can be used to develop mathematical models and use MOO methods for performance optimization from the perspective of building carbon emission reductions. (2) The benefits of retrofits are maximized by holistically taking environmental, economic, and social factors into account; from the perspectives of carbon emissions, costs, thermal comfort, and more, widely adopted strategies include improving the thermal performance of building envelopes, regulating HVAC systems, and utilizing renewable energy. (3) The optimization process based on data-driven methods, such as optimization algorithms and machine learning, apply mathematical models and methods for automatic iterative calculations and screen out the optimal solutions with computer assistance with high efficiency while ensuring accuracy. (4) Only 2.2% and 6.7% of the literature focus on the impacts of human behavior and climate change on building retrofits, respectively. In the future, it is necessary to give further consideration to user behaviors and long-term climate change in the retrofit process, in addition to improving the accuracy of optimization models and exploring the generalization and migration capabilities of surrogate models.

Study on the microscopic percolation mechanism of different aqueous media huff‐n‐puff with cores in Fengxi tight oil reservoirs of Qinghai Oilfield

AbstractHuff‐n‐puff (HnF) is a crucial technology for effectively enhancing the oil recovery (EOR) of tight oil reservoirs. Soaking period is the primary platform for injection medium interacting with formation fluid and reservoir rock in HnF. Elucidating the micro‐percolation mechanism of the soaking period is immensely significant for guiding oilfield production practices. The present study established a physical simulation method combining HnF experiments with nuclear magnetic resonance to reveal the microscopic percolation mechanisms, including water, fracturing fluid, and surfactant. Furthermore, the impacts of soaking time, HnF cycles, wettability, and pore structure on oil recovery degree were quantified. The results demonstrate the crucial significance of wettability and pore structure in the soaking period. The dominant mechanism during water HnF in reservoirs characterized by well‐connected pore networks and minimal clay pores is micropore imbibition, while conversely, macropore displacement plays a predominant role. The oil recovery degree of fracturing fluid HnF primarily relies on mitigating solid‐fluid forces within macropores. The surfactant HnF in preferential water‐ and oil‐wet reservoirs is primarily governed by oil films stripped from macropore walls and micropore imbibition, respectively. Specifically, water and fracturing fluid HnF are suitable for shorter soaking time and fewer HnF cycles, whereas the surfactant HnF exhibits an inverse relationship.

Research on Roof Weighting Mechanism of Coal Pillar Mining in Shallow Buried Closely Spaced Multi-seams

Abstract In the process of mining, the lower working face through the coal pillar (CP) in shallow-buried closely coal seams (SBCCS), noticeable roof step sinking, and dynamic load effects on the support were observed. In order to reveal the mechanism of strong ground pressure, the theoretical model of roof structure during the period of CP is established, and the calculation formula of the position of strong mine pressure is given. Taking the 22,408 working faces through the overlying concentrated CP of the Bulianta Coal Mine was selected as the research object. Using the methods of field measurement, physical simulation, and theoretical analysis to master the law of movement of the CP and overlying strata while passing the CP, the structural coupling impact of the key strata structure of the interburden and CP was revealed, which was the main reason for the cutting dynamic load effect during the passing of the CP of the working face. The advanced breaking mechanical model of the coupled roof structure of the “key strata structure of the interburden and the coal pillar” is established; the main factors affecting the breakthrough distance of the advanced breaking distance are analyzed; and the mechanism of the strong weighting caused by the cutting roof of the working surface is explained at the stage of CP. At the same time, it is obtained that when the width of the CP is 25 m, the working face is 20 m below the CP, which is the maximum bending moment point of the rock beam, indicating that the position that is prone to break under this width is about 5 m of the CP, which aligns with experimental data. The present study provides a theoretical guideline for the location and control of strong ground pressure during CP mining in SBCCS.

Minimum environmental flow assessment: a fuzzy TOPSIS decision-making system for selecting the best approach

The literature has explored various methods for assessing minimum environmental flow. Implementing holistic approaches proves to be prohibitively expensive and impractical for many small and medium projects. Hence, desktop and cost-effective methods are commonly employed without an integrated decision-making system to justify the assessed values. This study introduces a systematic decision-making framework aimed at selecting the most suitable method for assessing the actual needs of river habitats. Employing a fuzzy technique known as the Order Preference Similarity to the Ideal Solution (FTOPSIS), the study considers factors such as physical, thermal, and dissolved oxygen habitat suitability, maximum habitat area, and water demand loss function to determine the most appropriate method among established ones, including the Tennant method, flow duration curve analysis method, wetted perimeter method, and physical habitat simulation method. The results prioritize physical habitat simulation, wetted perimeter by slope method, and flow indices of 70%, 75%, and 80% by flow duration curve analysis method as the optimal approaches for assessing minimum environmental flow. This proposed decision-making system offers a viable platform to explore the applicability of existing cost-effective methods for assessing minimum environmental flow. It also serves as an effective mechanism for reducing negotiations among stakeholders by comprehensively considering all relevant aspects in the environmental management of river ecosystem requirements.

Propagation of interfered hydraulic fractures by alternated radial-circumferential extensions and its impact on proppant distribution

The fracture extension mechanisms and proppant transport characteristics play key roles for optimizing hydraulic fracturing in unconventional reservoirs. In this work, the visual physical simulation method was used to analyze the 3D dynamic extension processes of multi-stage hydraulic fractures and the subsequent impact on proppant distribution. The interfered fracture in multi-stage hydraulic fracturing exhibit alternated radial-circumferential extension behavior. More specifically, these behavior changes from unilaterally radial initiation, circumferential extension to radial extension. Unilaterally radial initiation results in the formation of both mirror and conchoidal features, while circumferential extension leads to stepped feature, and radial extension gives rise to feather feature. The four features of hydraulic fractures result in four types of non-uniform proppant distribution: uniform, scattered, cluster, and regional distribution. The proppant transport shifted from linear to radial mode, promoting further fracture extension. The effects of segment spacing and proppant injection sequence were studied. The results showed that the influence on the interfered fracture decreases as the segment spacing increases. In addition, the propped fracture area is larger when the small-size proppant is injected first, followed by large-size one. The research can improve understanding and optimization of multi-stage hydraulic fracturing in unconventional oil and gas reservoirs.

Model-data hybrid driven approach for remaining useful life prediction of cutting tool based on improved inverse Gaussian process

In the cutting process, reasonable evaluation of tool remaining useful life (RUL) is essential to ensure machining stability and safety. However, traditional data-driven methods rely on datasets with complete degradation data and prior knowledge, which are usually difficult to obtain in real scenarios. For these problems, this paper proposed a model-data hybrid driven approach for RUL prediction of cutting tool based on improved inverse Gaussian process. The tool wear degradation is considered as a random process, the cutting physical model and the data-driven stochastic process model are fused, so that the prior knowledge from the physical model and the statistical law of measured data are fully utilized to improve the accuracy of tool RUL prediction. The cutting physical model is established, and the prior knowledge of tool wear degradation is obtained based on physical simulation method. A data-driven random effects inverse Gaussian process model is constructed for tool RUL modeling and prediction. According to Bayesian method, the unknown parameters are estimated and updated integrating physical simulated and measured wear data, so as to obtain the probability density function for specific tool RUL, and quantify the prediction uncertainty. Finally, comparative experiments are conducted to validate the performance of the proposed method. The results suggest that the hybrid approach has the best performance in different tool RUL prediction.

Optimal operation of natural ventilation using a combined method of machine learning and physical simulation

Optimal operation of natural ventilation using a combined method of machine learning and physical simulation

Research of influence of additional melt pouring in an ingot head on solidification and structure forming via the method of physical (cold) simulation

Research of influence of additional melt pouring in an ingot head on solidification and structure forming via the method of physical (cold) simulation

Main factors that control roadway damage when a steeply dipping coal seam crosses a fault

When the working face of a steeply dipping coal seam crosses a fault, the dynamic disturbance caused by the mining load induces fault activation, causing large deformation and failure of the roadway. In this study, a physical similarity simulation and numerical calculation method were used to determine the main factors that the deformation and failure of fault zone roadway and reveal the underlying mechanisms. The results show that when crosses a fault, the high static load formed by the coupling of mining stress and fault pillar stress induces mining stress-type fault activation, which leads to large deformation and damage to the roadway in the fault zone. The main controlling factors are the fault location and mining load intensity. In terms of fault location, the vertical stress concentration away from the roadway side of the fault surface was high, the principal stress deflection angle was large, and the surface deformation of the fault on the roadway left side was the greatest. In terms of mining load intensity, the deflection angle of the principal stress of the surrounding rock initially increased and then decreased, and tensile failure easily occurred near the fault surface. These results provide a reference for roadway support.

Experiment of dynamic seepage of tight/shale oil under matrix fracture coupling

A physical simulation method with a combination of dynamic displacement and imbibition was established by integrating nuclear magnetic resonance (NMR) and CT scanning. The microscopic production mechanism of tight/shale oil in pore throat by dynamic imbibition and the influencing factors on the development effect of dynamic imbibition were analyzed. The dynamic seepage process of fracking–soaking–backflow–production integration was simulated, which reveals the dynamic production characteristics at different development stages and their contribution to enhancing oil recovery (EOR). The seepage of tight/shale reservoirs can be divided into three stages: strong displacement and weak imbibition as oil produced rapidly by displacement from macropores and fractures, weak displacement and strong imbibition as oil produced slowly by reverse imbibition from small pores, and weak displacement and weak imbibition at dynamic equilibrium. The greater displacement pressure results in the higher displacement recovery and the lower imbibition recovery. However, if the displacement pressure is too high, the injected water is easy to break through the front and reduce the recovery degree. The higher the permeability, the greater the imbibition and displacement recovery, the shorter the time of imbibition balance, and the higher the final recovery. The fractures can effectively increase the imbibition contact area between matrix and water, reduce the oil-water seepage resistance, promote the oil-water displacement between matrix and fracture, and improve the oil displacement rate and recovery of the matrix. The soaking after fracturing is beneficial to the imbibition replacement and energy storage of the fluid; also, the effective use of the carrying of the backflow fluid and the displacement in the mining stage is the key to enhancing oil recovery.

Evolution Laws of Water-Flowing Fracture Zone and Mine Pressure in Mining Shallow-Buried, Hard, and Extra-Thick Coal Seams

Shallow-buried, hard, and extra-thick coal seams are very common in Xinjiang, China, but there are relatively few studies on the mine pressure law and the development characteristics of water-flowing fracture zones (WFFZs) during the mining of such coal seams. In this paper, the mine pressure of the top coal caving face in a shallow, hard coal seam with a hard roof and full bedrock (SHCSHRFB) is analysed, the laws of the surrounding rock deformation and stress of the open-off cut and roadway in the large-mining-height top coal caving face are studied, the characteristics of roof-breaking and overburden fracture development are analysed using the physical similarity simulation method, supporting suggestions for roadways are put forward, and three development stages of the WFFZ are analysed. Field monitoring shows that the hydraulic support stress in SHCSHRFB is weak, but the coal wall and roadway stability are good, which is significantly different from the results in the typical shallow-buried thin bedrock working faces. The measured height of the WFFZ is close to the physical similarity simulation results, but quite different from those arising from use of the empirical formula.

Release potential, neglected leakage and reduction countermeasures of COD and Ammonia in MSWLs

In order to eliminate the impact of the industrial revolution on the environment and improve the water ecological environment, pollutant discharge reduction is imperative. With the acceleration of global discharge reduction process, the huge pollutant release potential and potential environmental effects of municipal solid waste landfills gradually appear, but its release amount and intensity have not been quantitatively revealed. We propose a coupling method of parameter stochastic simulation and physical process model simulation to estimate the hidden leakage of large-scale regional municipal solid waste landfills, and provide a methodology for estimating the hidden leakage of landfills in other countries and even in the whole world by taking China, which has the largest amount of waste generation among developing countries, as an example. Prior to the implementation of stringent construction quality control and assurance management requirements, the average annual leachate generation potential over the entire life cycle of 2600 landfills in China was estimated to be 4.66 × 108 m3, in which the concentrations of COD and NH3-N are 5.38 × 102–6.48 × 104 mg/L and 6.10–3.50 × 103 mg/L, respectively, and the total amounts are 5.21 × 103–7.81 × 108 t and 8.09 × 102–6.65 × 107 t, respectively. About 14 % of these pollutants may leak into the environmental media through the landfill liner with the average number of holes of 21.5/ha. For different regions, the overall release, discharge and leakage of COD and NH3-N in East China account for 35.70 %, 36.68 % and 29.60 % respectively, making it the region with the highest potential for discharge and risk of leakage. Meanwhile, the implementation of mandatory regulations related to leachate generation and control has led to a significant reduction in the leakage of pollutants. For instance, comprehensively detecting and repair of holes in the impermeable liner has reduced the number of holes to 2/ha, resulting in a reduction of >90 % in the leakage of pollutants.

Research on mining-induced surface soil cracking mechanism and development depth of downward fracture

In order to reveal the cracking mechanism of surface soil layer caused by coal seam mining, and explore theoretical methods for predicting the development depth of downward fractures during mining. Based on the background of the No. 1–2 upper coal seam mining in Daliuta Coal Mine, combining with fracture mechanics, soil mechanics, physical similarity simulation and numerical calculation methods. The mining-induced cracking mechanism and criterion of surface soil layer were analyzed, the crack development pattern and expansion mechanism were revealed, and the prediction formula of downward crack development depth of surface soil layer was put forward. The research results show that surface cracks mainly occur in the tensile zone, the concentrated tensile stress produced by the subsidence of overburden in the tensile zone can lead to soil cracking. When the surface maximum horizontal tensile deformation exceeds the limit horizontal deformation of soil, the soil layer cracks, and the cracking criterion of the surface soil layer was given accordingly. The soil crack of coal seam mining belongs to the mixed mode crack, and the soil cracks tip starts cracking and expanding along the direction of the maximum principal stress, therefore, the initiation crack angle of soil crack tip was obtained, and the fracture criterion of soil crack was proposed. With the crack propagation and development, the microcosmic crack becomes the macroscopic downward fracture. When the horizontal stress of the soil decreases to the cohesive force of the soil, the downward fracture stops develop, and the calculation formula for the development depth of mining-induced downward fracture was proposed. The development and evolution law of downward fracture was revealed, after the surface cracks, with the advance of the longwall face, the downward crack continues to extend and develop to the deep. Downward fracture develops on the ground surface at the open cut side, the mined-out area and in front of the longwall face, the maximum development depth of downward fracture tends to be stable when the longwall face advances to a certain distance. According to the physical simulation, numerical calculation and theoretical calculation, the development depth of downward fracture in No 1–2 upper coal seam mining is 8.11 m, 8.21 m and 8.14 m respectively. The theoretical prediction formula is reliable, and the results can provide a new method for the research of the development depth of mining-induced surface downward fracture.

Investigation of the Process of Destruction of a Roain Massif by Borehole Charges with an Axial Air Cavity by the Method of Physical Simulation

the design of downhole explosive charges with an axial air cavity was developed, which ensures uniform crushing of the rock mass and reduces the specific consumption of explosives. A technique has been developed for modeling the process of destruction of a rock mass by borehole charges with an axial air cavity. It has been established that with an increase in the diameter of the axial cavity, the mass of the charge and the specific consumption of explosives for breaking decrease. However, this decrease occurs only up to a certain limit, after which the volume of the chipped mass decreases and the specific consumption of explosives increases. The most efficient way is to reduce the specific consumption of explosives for breaking when the ratio of cavity diameters and charge diameters is 1.3:5–2.2:5. For other values of the ratio, the specific consumption of explosives increases dramatically.

The Effect of Slickwater on Shale Properties and Main Influencing Factors in Hydraulic Fracturing

As shale gas reservoirs have low porosity and low permeability, hydraulic fracturing is a necessary means for industrial exploitation of shale gas. In this study, aiming at the problem of reservoir damage in the process of hydraulic fracturing of shale gas reservoir, a physical simulation method of slickwater fracturing fluid flow in shale core has been established. The change laws of physical parameters of the shale were quantified after slickwater fracturing fluid filtrating into it. The main factors affecting physical parameters of shale matrix around fractures were found out in the process of fracturing, shut-in, and flowback of slickwater fracturing fluid. The results show that after treated by slickwater fracturing fluid, the wettability of shale becomes more uniform in distribution (the water contact angles from 43° to 48°). In the fracturing filtration zone, the damage rate of fracturing fluid to shale porosity is 6.4%-42.0%. Low differential pressure flowback can reduce the damage of the shale, and prolonging the time of shut-in has no obvious effect on the damage to porosity. After 0.3 d (imbibition stability time), the damage of fracturing fluid to shale permeability is basically stable (55.9%). Permeability damage is mainly caused by residue of the fracturing fluid in large pores and bound water in small pores. Analysis of weights of all fracturing parameters shows that flowback differential pressure has the largest influence weight on shale porosity (51.4%), and well shut-in time has the largest influence weight on shale permeability (62.7%). Therefore, in the production process, it is suggested to properly reduce the backflow differential pressure and moderately shorten the well shut-in time.