Open-source Computational Fluid Dynamics Research Articles

The application of the state-of-the-art turbulence models in the OpenFOAM CFD codes and the validation for different flow control cases in the continuous casting process

Computational fluid dynamics (CFD) is an established approach to study flow behaviour. Despite advances in mathematical numerical modelling in recent decades, accurately predicting the turbulent flow behaviour of steel using CFD remains a challenge. In the continuous casting process, two main flow control systems are employed to transfer liquid steel from the tundish to the mould, namely stopper control and slide gate control. In additional to these two main flow control systems, the casting nozzle geometries, casting rate, and casting mould dimensions vary considerably, and this complexity makes it difficult to precisely simulate turbulent flow in the casting channel. In this paper, examples are presented showing how different turbulence models influence the simulation results, using the latest version of the open source CFD simulation software OpenFOAM. Prior to the CFD modelling, RHI Magnesita's water modelling facilities in Leoben (Austria) were used to validate the state-of-the-art turbulence models selected for a particular casting nozzle geometry and flow control system.

Propensity of 21700 cylindrical cells to thermal runaway under slight overcharging cycling – A numerical study

Slight overcharge of lithium-ion batteries (LIBs) could occur due to inadequate design of battery management system or unexpected malfunction of charger. In comparison with other abuse conditions, the evolution of thermal runaway (TR) under slight overcharging often requires a lengthy incubation period, necessitating relatively long periods for experiments. Numerical simulations with validated models offer a viable alternative to evaluate such risks in modules/packs and associated mitigation measures. Since a current-cutting device is usually installed inside the LIB module/packs, the current will be cut off once the overcharge reaches a certain level, therefore, slight overcharging is of more potential relevance. However, previous simulations mainly focused on TR process induced by continuous overcharging, the conditions associated with slight overcharging have been overlooked. As slight overcharging is difficult to detect, the generated heat could easily accumulate as the cycle process prevails, result in unwanted cell temperature increases with increasing propensity for TR. A three-dimensional (3-D) predictive tool for the transition of cylindrical 21700 cell from slight overcharging cycle to TR has been developed by implementing the published models for heat generation from various thermal decomposition reactions and ISC into in-house version of the opensource computational fluid dynamics (CFD) code OpenFOAM. The code is validated with newly conducted experiments involving both normal and slight overcharging cycles. The validated model has then been used to conduct further parametric studies to investigate the effects of the overcharge voltage, current-rates and convective cooling on the propensity and run up time to TR as well as the maximum cell temperature during TR for cells with different cathode materials under different ambient temperatures. This work forms a sound basis for evaluating TR propagation in modules/packs under slight overcharging/discharging cycles to aid the development of mitigative measures to improve LIB process safety in practical applications.

Analyses of Jet Buoyant Flow in a Multicompartment Containment Using an Open-Source Solver

Hydrogen mixing and distribution in a nuclear power plant containment during a postulated severe accident is a phenomenon with high safety relevance for current and advanced light water reactors. The Organisation for Economic Co-operation and Development (OECD)/Nuclear Energy Agency (NEA) SESAR Thermal-Hydraulics (SETH) project was carried out to generate experimental data on basic containment phenomena with the required instrumentation to assess computational fluid dynamics (CFD) and lumped parameter codes. In this paper, we analyze the PANDA SETH Test 16 of the OECD/NEA SETH project using containmentFOAM, which is a tailored open-source CFD code package for containment analysis developed at Forschungszentrum Jülich GmbH based on OpenFOAM.® SETH Test 16 addressed steam-air mixture transport driven by jets and plumes in the multicompartment PANDA facility (two vessels and an interconnecting pipe) at the Paul Scherrer Institut in Switzerland. Steam as a wall plume was injected at 0.040 kg/s and 140°C in vessel 1, which was initially filled with dry air at 108°C. The steam-air mixture was vented out from the top of vessel 2. The system pressure was constant at 1.3 bar for the whole test duration (4000 s). To simulate SETH Test 16, the k-ω shear stress transport turbulence model was adopted with the generalized gradient diffusive hypothesis buoyancy turbulence model. The simulation represented the experimental phenomenology reasonably well. The trends for the calculated temperature distribution were similar to those of the experiments and only yielded a slight discrepancy of about 2.7%. In addition, the distribution of the steam molar fraction was well predicted above the injection tube in vessel 1. However, below the injection tube in vessel 1, some discrepancies between the simulations and the experimental results were observed. These may have been caused by the higher turbulent mass diffusivity in the physical model and the challenge of the mesh resolution in the middle region of vessel 1.

Development of conjugate heat- and moisture-transfer model for pineapple drying using OpenFOAM

The kinetic model of drying is important for food preservation, particularly for pineapples, which have a high moisture content and are highly perishable. This paper presents a novel approach utilizing OpenFOAM, which is an open-source computational fluid dynamics (CFD) software, to model the hot-air drying kinetics of pineapple slices. The developed conjugate heat- and moisture-transfer model integrates forced-convection phenomena with moisture-diffusion dynamics. Owing to enhancements to the original OpenFOAM solver, C++ programming facilitates the appropriate representation of heat and moisture transfer based on the finite-volume method. Experimental data are utilized to derive a moisture diffusivity model, which achieved high statistical quality with an average R2 of 0.9443. Additionally, the SST k–ω turbulence model accurately describes the airflow around the pineapple-slice model. The developed model agrees well with the experimental results, with an average error of less than 1.29 %. Further analysis using the model provides insights into the effects of variations in the pineapple-slice geometry, where increased inner diameter and reduced thickness result in enhancement indices of 1.002 and 1.005, respectively. This novel CFD solver is promising for simulating the drying processes of various agricultural products, including pineapples, thus contributing to improvements in process optimization and efficiency.

Study of combustion flow field in a scramjet engine under inflow oscillation variations based on OpenFOAM

In this study, a compressible supersonic numerical model was established based on the open-source computational fluid dynamics software OpenFOAM. The supersonic air inflow was set in sinusoidal variation and gas hydrogen was employed as fuel for the DLR engine numerical simulation. The SST k-ω model and a 9-species 27-reaction hydrogen/oxygen chemical reaction model was employed as the turbulence and reaction mechanical kinetics models respectively. The effect of continuous variable inflow on the combustion performance for the scramjet engine was analyzed and the results showed that the combustion flame inside the scramjet engine exhibited significant partitioning phenomena around the combustion stabilization zones under periodic continuous variable inflow conditions. It was found that intense combustion zones were formed at both upstream and downstream flow as the induction of intersecting shock waves. When the flame was stabilized in the engine, the initiation position of the intense combustion zone at the upstream was transferred to the distance of twice the strut length, while the initiation position of the intense combustion zone at the downstream was anchored at a distance of about five times the strut length.

Performance enhancement of a vortex ring thruster by adopting the Coanda effect

A vortex ring thruster (VRT) is a propulsion device in which a piston pushes fluid and thrusts it in reaction. As the fluid inside a VRT is moving, the boundary layer near the wall at the edge of the exit surface of a VRT separates and rolls up into a vortex ring. In this paper, we performed performance analysis on a regular VRT and a VRT enhanced by the Coanda effect (hereafter referred to as a CoVoRT) on axisymmetric geometry. A CoVoRT consists of two jets: a primary jet and a Coanda jet. The primary jet has a relatively large volume flow rate compared to the Coanda jet, and the Coanda jet attracts the surrounding fluid by flowing along the curved surface at a relatively small flow rate. The present study evaluates the propulsion performance in two ways using SNUFOAM. This software was developed based on OpenFOAM, which is an open-source computational fluid dynamics (CFD) toolkit and specialized for naval hydrodynamics. The first one quantifies the propulsion performance by calculating the ratio of energy input and energy output generated by two jets during a stroke of the piston motion. The second one is to observe the evolution and pinch-off process of a vortex ring with formation time, which is a non-dimensional time scale. The comparison of propulsion performance was conducted with changes in the curvature of the Coanda jet, changes in the length of the Coanda jet exit, and changes in the Coanda jet velocity and piston stroke ratio. For quantitative evaluation of propulsion performance, the propulsion performance evaluation index (PPEI) was introduced. The results showed that the PPEI of a CoVoRT was improved by about 50% compared to that of a VRT, and it was confirmed that the dynamic characteristics of a CoVoRT’s vortex ring were superior to those of a VRT in terms of propulsion performance.

Numerical investigation of vortex induced vibrations on cylinders

The paper addresses Vortex Induced Vibrations (VIV) caused by tower vortex shedding through LES simulations of a wind tunnel experiment. A high-fidelity (HiFi), Fluid Structure Interaction (FSI) framework for aeroelastic analysis of 3D flexible cylinders is established, based on the open-source Computational Fluid Dynamics (CFD) code OpenFOAM and the coupling library preCICE. In the present study, the FSI framework is employed with the aim to replicate a low Reynolds (Re=26000) forced vibrations wind tunnel experiment of a circular cross-section rigid cylinder. The paper compares predictions of the aerodynamic damping of the oscillating cylinder for different oscillation frequencies within the lock-in range and amplitudes against experimental results. While the model consistently predicts the lock-in range of frequencies and the trends in the variation of the aerodynamic damping with the oscillation amplitude, it falls short of accurately capturing the maximum value of the aerodynamic damping at the onset of lock-in.

Investigating 3-D Flow Characteristics of Wind Turbine Airfoils using Delayed Detached Eddy Simulations at High Reynolds Numbers

This numerical study investigates the 3-D flow field and aerodynamic characteristics of DU 00-W-212 wind turbine airfoil at high Reynolds numbers. The Computational Fluid Dynamics (CFD) simulations are performed at Reynolds number of 3 million at three different angles of attack for the pre-stall, stall, and post-stall conditions, by using an open source CFD solver SU2. The Delayed Detached Eddy Simulations (DDES) with the Spalart-Allmaras (SA) turbulence model and Langtry-Menter (LM) transition model are performed to address the challenge of predicting unsteady flow characteristics with transition, particularly on the suction side of the airfoil. The 3-D DDES with SA results with and without LM transition model are compared with the 2-D RANS with SA simulations and available experimental data.

Towards exascale for wind energy simulations

We examine large-eddy-simulation modeling approaches and computational performance of two open-source computational fluid dynamics codes for the simulation of atmospheric boundary layer flows that are of direct relevance to wind energy production. The first code, NekRS, is a high-order, unstructured-grid, spectral element code. The second code, AMR-Wind, is a second-order, block-structured, finite-volume code with adaptive mesh refinement capabilities. The objective of this study is to co-develop these codes in order to improve model fidelity and performance for each. These features will be critical for running ABL-based applications such as wind farm analysis on advanced computing architectures. To this end, we investigate the performance of NekRS and AMR-Wind on the Oak Ridge Leadership Facility supercomputers Summit, using 4 to 800 nodes (24 to 4,800 NVIDIA V100 GPUs), and Crusher, the testbed for the Frontier exascale system, using 18 to 384 Graphics Compute Dies on AMD MI250X GPUs. We compare strong- and weak-scaling capabilities, linear solver performance, and time to solution. We also identify leading inhibitors to parallel scaling.

Computational fluid dynamics modeling of coronary artery blood flow using OpenFOAM: Validation with the food and drug administration benchmark nozzle model.

Cardiovascular disease (CVD), a global health concern, particularly coronary artery disease (CAD), poses a significant threat to well-being. Seeking safer and cost-effective diagnostic alternatives to invasive coronary angiography, noninvasive coronary computed tomography angiography (CCTA) gains prominence. This study employed OpenFOAM, an open-source Computational Fluid Dynamics (CFD) software, to analyze hemodynamic parameters in coronary arteries with serial stenoses. Patient-specific three-dimensional (3D) models from CCTA images offer insights into hemodynamic changes. OpenFOAM breaks away from traditional commercial software, validated against the FDA benchmark nozzle model for reliability. Applying this refined methodology to seventeen coronary arteries across nine patients, the study evaluates parameters like fractional flow reserve computed tomography simulation (FFRCTS), fluid velocity, and wall shear stress (WSS) over time. Findings include FFRCTS values exceeding 0.8 for grade 0 stenosis and falling below 0.5 for grade 5 stenosis. Central velocity remains nearly constant for grade 1 stenosis but increases 3.4-fold for grade 5 stenosis. This research innovates by utilizing OpenFOAM, departing from previous reliance on commercial software. Combining qualitative stenosis grading with quantitative FFRCTS and velocity measurements offers a more comprehensive assessment of coronary artery conditions. The study introduces 3D renderings of wall shear stress distribution across stenosis grades, providing an intuitive visualization of hemodynamic changes for valuable insights into coronary stenosis diagnosis.

Modelling urban canopy with object-based porosity model

We present a novel approach to modelling urban canopies based on the porosity model. The impact of objects in the canopy layer is implicitly accounted for by applying a high-value drag force in the parts of the canopy layer that objects would occupy. This effectively halts fluid flow in the defined space of the objects, mimicking the impact of solid objects in the canopy layer. The model addresses two common issues in urban canopy modelling: the definition of the drag coefficient and the loss of canopy morphology, which significantly affect flow and turbulence fields. The model is assessed for three cases: two idealised urban-like canopies with realistic urban flow conditions and one benchmark case based on the measurements of Hilderman and Chong (2007). The benchmark results, where the explicitly modelled objects are reduced from 109 to 9, show that the new model exhibits a level of accuracy similar to explicit modelling. We also computed the commonly used zone-based porosity and roughness models for the two idealised urban-like canopies. The new model produced results comparable to the results of explicit modelling and superior to those of the alternative approaches. All cases were computed in unsteady mode using a hybrid RANS/LES model based on elliptic-relaxation eddy-viscosity RANS and the dynamic Smagorinsky model. The simulations were performed using the open-source computational fluid dynamics code T-Flows, available on Github.

Effects of the asymmetric and oscillating turbulent melt flow on the heat transfer and solidification inside the thin slab continuous casting (TSC) mold under the applied electromagnetic brake (EMBr)

The thin slab casting (TSC) is a breakthrough near-net-shape technique for flat products accompanied by rapid casting and solidification rates. The TSC quality hinges on the turbulence, super-heat flow and growth of the solidified shell. The electromagnetic brake (EMBr) is commonly applied to control the fresh melt flow after feeding through a submerged entry nozzle (SEN). Numerical modelling is a perfect tool to investigate the multiphase phenomena in the continuous casting (CC). The presented study considers the heat transfer through the solid shell and water-cooled copper mold including the averaged thermal resistance of the slag skin and the air gap coupled with the turbulent flow and magnetohydrodynamics (MHD) model using an in-house code developed inside the open-source computational fluid dynamics (CFD) package OpenFOAM®. The model is applied to investigate different undesired asymmetric melt flow issues: (i) with the misaligned or (ii) partially blocked SEN; (iii) caused by the mean flow fluctuations with the natural frequencies; (iv) related to the oscillations of the fresh melt jets for the specific SEN designs and casting regimes. The variation of the flow pattern and superheat distribution is studied and presented for different scenarios both with and without applied EMBr.

On the feasibility of overnight industrial high-fidelity simulations of CSP technologies on modern HPC systems

In the last decades, computational fluid dynamics (CFD) has become a standard design tool in many fields, such as the automotive, aeronautical, and renewable energy industries. The driving force behind this is the development of numerical techniques in conjunction with the progress of high-performance computing (HPC) systems. However, simulation time remains the most limiting factor for large-eddy simulations (LES) to be adopted in the industry. A consensus exists that, to be feasible, LES simulations should be completed overnight In this context, this work assesses the feasibility of overnight LES simulations on GPU-accelerated supercomputers with TFA, our novel in-house code, which relies on a symmetry-preserving discretisation for unstructured collocated grids that, apart from being virtually free of artificial dissipation, is shown to be unconditionally stable. The study cases will be taken from central receivers used in concentrated solar power (CSP) plants, and a comparison with open-source CFD codes will be made.

Thermo-electric modeling and analysis of lithium-ion battery pack for E-mobility

AbstractElectric Vehicles (EVs) have emerged as a viable and environmentally sustainable alternative to traditional internal combustion vehicles by utilizing a clean energy source. The advancement and expansion of electric cars rely on the progress of electrochemical batteries. The utilization of Lithium-Ion Batteries is widespread primarily because of its notable energy density. Changes influence the performance of these batteries in temperature. The Thermal Management System of the battery is one of the very important systems in EVs to improve the performance and life of the battery. The geometrical spacing of the cell modules is considered identical for a more accurate comparison of temperature distribution. For better cooling and heat dissipation, the battery pack’s two sides are kept entirely open to facilitate the inflow of air. In this work, active BTMS solutions are selected and analyzed using the development of three-dimensional free, open-source OpenFOAM computational fluid dynamics simulations for accurate thermal modeling and hotspot zones in cylindrical battery packs. The outcome of the simulations is compared using parameters like temperature distribution in battery cells, battery modules, and heat generation. Among all the cell temperature zones, the temperature maximum is near the sixth cell of the module depth. OpenFOAM results validated with the existing literature’s experimental and Ansys results. Air cooling is utilized for cooling performance because of its relatively simple structure and lightweight.

Numerical investigations on the hydrodynamic performances of an isolated OWC and its integration with a semi-circular breakwater

The exploration of multifunctional systems to harvest wave energy has become increasingly prominent in recent research. This paper presents a comprehensive investigation into the effectiveness of utilizing a wave energy converter (WEC) not only for energy generation but also as a coastal protection measure. Among the various types of WECs, the Oscillating Water Column (OWC) stands out as particularly promising due to its inherent advantages and notable efficiency. The versatility of the OWC allows for standalone installation or integration into hybrid systems, such as combining it with breakwaters. While numerous studies have examined the integration of OWCs with Caisson-type breakwaters, research on their integration with Semi-circular breakwaters (SCBW) is scarce. This study fills this gap by utilizing the open-source computational fluid dynamics (CFD) tool, OpenFOAM, to analyze the hydrodynamic performance of an OWC embedded within an SCBW. The numerical findings are validated against existing experimental data, enabling a thorough comparative analysis between the performance of an isolated OWC and a hybrid OWC integrated with SCBW. The investigation delves into various parameters, including wave amplification factor, chamber air and water pressure, external water pressure, energy transfer efficiency from chamber water to air, and wave run-up over the SCBW face. The results conclusively demonstrate that an OWC integrated with SCBW exhibits superior hydrodynamic performance compared to standalone configurations.

Effect of Wavelength on Turbine Performances and Vortical Wake Flows for Various Submersion Depths

When tidal turbines are deployed in water areas with significant waves, assessing the surface wave effects becomes imperative. Understanding the dynamic impact of wave–current conditions on the fluid dynamic performance of tidal turbines is crucial. This paper aims to establish a fundamental understanding of the influence of surface waves on tidal turbines. OpenFOAM, an open-source computational fluid dynamics (CFD) library platform, is utilized to predict the performance of current turbine under waves and currents. This research investigates the effects of two critical wave parameters, wave height and wavelength, on the fluid dynamics and wake structures of current turbine. Additionally, this study explores the influence of various submersion depths on turbine performance. The findings indicate that, under various wave conditions, the turbine’s average power coefficient remains constant, but significant fluctuations are shown. Increasing submersion depth can mitigate the impact of waves. However, in regions characterized by longer wavelengths, altering the submersion depth has limited effects on turbine performance.

Electro-thermal performance evaluation of a prismatic battery pack for an electric vehicle

Abstract In recent years, electric vehicles (EVs) have grown in popularity as a viable way to reduce greenhouse gas emissions by replacing conventional vehicles. The need for EV batteries is steadily increasing. An essential and expensive part of electric transportation is the battery. The operating temperature of the lithium-ion (Li-ion) battery significantly impacts the performance of the EV battery pack. Battery packs undergo temperature fluctuations during the charging and discharging procedures due to internal heat generation, necessitating an examination of the temperature distribution of the battery pack. The geometrical spacing between cells is considered larger and identical and is kept open on two sides for free air circulation. A novel battery thermal management system (BTMS) design is required to effectively dissipate heat from the prismatic battery pack module. The electro-thermal behaviour of the prismatic Li-ion battery pack module was investigated based on the high charge/discharge rate. This study presents the development of a three-dimensional free open-source OpenFOAM computational fluid dynamics model for prismatic cell battery packs that simulates heat generation, air flow field, and temperature distribution across the width and depth of the battery pack module. The prismatic battery pack simulation results are compared with the experimental and simulation results of the cylindrical battery pack. It was also revealed that prismatic cells generate more heat on the backside, requiring battery packs to have increased cooling and space between individual cells to ensure sufficient air circulation for cooling and gas removal. The BTMS is improved by designing with increased space among the prismatic battery cells as compared with the conventional prismatic cell battery pack design.

Numerical Simulation of Pipeline Scour and Sedimentation around Submerged Pipelines with an Open-Source Multiphase-CFD Model

This paper presents a comprehensive study on pipeline scour and sedimentation phenomena using an open-source multiphase Computational Fluid Dynamics (CFD) model. The research focuses on understanding the complex interactions between fluid flow, sediment transport, and scour formation around submerged pipelines. The proposed analysis aims to enhance the understanding of scour development and sedimentation deposition, which is crucial for the design, operation, and maintenance of various engineering structures, including offshore pipelines and underwater infrastructure. The results show that the model exhibits the ability to compute sediment transport without depending on traditional assumptions related to bed-load and suspended-load layers. The simulation results affirm the model's proficiency in replicating the underlying mechanisms accountable for the onset of these processes, notably seepage flow and piping. Furthermore, this model can successfully depict the vortex phenomenon, which promotes the accumulation of sediment around the pipe. This phenomenon arises from the contrast in pressure between the centre of the vortex and the pressure exerted on the sediment beneath it.

Numerical investigation of combustion in a panela furnace using openfoam

To develop biomass combustion as a viable renewable energy source it is necessary to improve the furnace efficiency and investigate the potential of agricultural wastes as fuels. Computational Fluid Dynamics (CFD) modeling is a valuable tool to accomplish these objectives, OpenFOAM is a powerful open-source CFD software that has been little used in this type of application. This paper reports the study of combustion in a device of great importance for Colombia, the panela furnace, using a model developed in OpenFOAM. The combustion chamber of a Ward-Cimpa furnace, measuring 2.68 m in width and 3.32 m in height was modeled. This model was validated, by comparing the simulated values of CO and temperature at the furnace exit with data taken from literature, resulting in differences of 13.72 % and 12.23 % respectively. These discrepancies are slightly lower than those reported in other studies about the subject. The model was employed to analyze the effect of the air-flow rate on the combustion performance. The findings indicate that the increase in air-flow causes an increase in combustion activity manifested in higher temperature and CO2 emissions, which could indicate that in common operational conditions, the furnace operates under deficient air conditions and its performance could be improve by using higher air flow rates.

The Performance of Flexible Fluid-Structure Interaction Module for Saltmarsh Vegetation Under Flow and Wave Action

This paper evaluates the performance of a new flexible fluid-structure interaction (FSI) module in an open-source computational fluid dynamics (CFD) software - REEF3D - for use in modelling saltmarsh vegetation. Unlike previous studies, which focussed on hydrodynamic response to plants (for example, wave attenuation) to check the accuracy of their numerical modelling efforts, this work attempts to replicate the plants’ drag force and motion behavior, based on results from several physical modelling studies. The flexible FSI module was found to consistently overestimate both the drag and motion of the numerical plants when compared to their physical counterparts. It is hypothesized that this is due to the module’s use of linearly elastic material theory for the flexible structures. This is arguably inadequate for the relatively flexible materials of saltmarsh vegetation.