Flow Front Velocity Research Articles

Ultrasonic micro-injection moulding: characterisation of interfacial friction by varying feedstock shape and high-speed thermal imaging for microneedle feature replication

This study explores the interfacial friction in ultrasonic micro-injection moulding by using different polymer feedstock shapes, characterisation of micromoulding melts through thermal imaging and assessing microneedle feature replication. Industry standard polypropylene pellets and discs with different thicknesses were used for varying the amount of interfacial friction during sonication. High-speed thermal imaging and tooling containing sapphire windows were used to visualise the melt characteristics. Moulded products were characterised using laser-scanning confocal microscopy to quantify microneedle replication. The study demonstrates that (i) the interfacial area for the different feedstock shapes affects the heating in ultrasonic micro-injection moulding significantly, (ii) disc-shaped feedstocks result in initially higher flow front velocities and exhibit dominance of viscoelastic heating over interfacial friction and (iii) industrial pellet feedstocks provide a good combination interfacial friction and viscoelastic heating and more viscosity reduction in overall leading to better microreplication efficiency. The results presented could have a significant impact on the process development of ultrasonic micro-injection moulding where process repeatability can be improved by controlling the interfacial friction. The research provides an essential contribution to the development of this process, where interfacial frictional heating can be tailored specifically for miniature functional components, offering improved precision and reduced energy use when compared with conventional methods.

Investigating the effect of polydispersity on the dynamics of multiphase flows using computational fluid dynamics tools

Granular flows consist of discrete macroscopic particles. If they are non-cohesive, their status is determined by the interaction of particle-particle frictional forces, external boundaries and gravity. In particular, the understanding of the transport mechanisms of granular materials is of paramount importance for the characterization of volcanic granular flows and for hazard assessments associated with these flows. In order to investigate dynamics of these kinds of flows, we replicated large-scale experiments with multiphase computational fluid dynamic (CFD) simulations using the Two-Fluid Model approach, with an emphasis on the polydispersity effect on the flow behaviour. The CFD simulations were run using the software MFIX. The present work consists of: 1) investigations on the drag force relationships implemented in MFIX; 2) applications of MFIX to replicate large-scale experiments on volcanic dry granular flows sliding on an inclined channel; 3) comparisons between experimental and simulated data with particular emphasis on the velocity of the granular flow front. Simulations on polydisperse granular flows demonstrated the simulated flows capability to replicate segregation dynamics active in real granular flows, and the polydispersity effects on velocities and shapes of granular flows. The non-uniformity of solid phases highly affects the dynamic of the whole flow and results in a better agreement between simulated and experimental flow velocities than the simplest monodisperse particles systems. In particular, the greater the number of the solid phases, the lower the velocity of granular flows and the mean square error, which decreases by ca. 50%.

Low-Gradient Magnetophoresis of Nanospheres and Nanorods through a Single Layer of Paper.

The possible magnetophoretic migration of iron oxide nanoparticles through the cellulosic matrix within a single layer of paper is challenging with its underlying mechanism remained unclear. Even with the recent advancements of theoretical understanding on magnetophoresis, mainly driven by cooperative and hydrodynamics phenomena, the contributions of these two mechanisms on possible penetration of magnetic nanoparticles through cellulosic matrix of paper have yet been proven. Here, by using iron oxide nanoparticles (IONPs), both nanospheres and nanorods, we have investigated the migration kinetics of these nanoparticles through grade 4 Whatman filter paper with a particle retention of 20-25 μm. By performing droplet tracking experiments, the real-time stained area growth of the particle droplet on the filter paper, under the influences of a grade N40 NdFeB magnet, were recorded. Our results show that the spatial and temporal expansion of the IONP stain is biased toward the magnet and such an effect is dependent on (i) particle concentration and (ii) particle shape. The kinetics data were first analyzed by treating it as a radial wicking fluid, and later the IONP distribution within the cellulosic matrix was investigated by optical microscopy. The macroscopic flow front velocities of the stained area ranged from 259 μm/s to 16 040 μm/s. Moreover, the microscopic magnetophoretic velocity of nanorod cluster was also successfully measured as ∼214 μm/s. Findings in this work have indirectly revealed the strong influence of cooperative magnetophoresis and the engineering feasibility of paper-based magnetophoretic technology by taking advantage of magnetoshape anisotropy effect of the particles.

Application of capacitive sensors and controlled injection pressure to minimize void formation in resin transfer molding

AbstractVoid formation as a result of irregular resin flow at the flow front is discussed and a practical method for reducing void formation during resin transfer molding (RTM) is introduced. In this study, a sensor system is developed for in situ measurement of resin velocity inside a closed cavity. Assisted by the acquired data, a resin injection system is augmented to automatically adjust the injection pressure and achieve a uniform flow front velocity. It is proven, that the developed system is suited to monitor the resin flow front and is able to sufficiently control flow velocity of a linear flow front. Test specimen produced by this method show significantly reduced void contents in comparison to a common resin transfer molding process.

Computational fluid dynamic simulations of granular flows: Insights on the flow-wall interaction dynamics

Dry volcanic granular flows are gravity-driven currents composed of solid particles where particle-particle interactions dominate the motion. The interaction with topography is a relevant factor controlling the propagation of such flows. In this paper we investigate the dynamics of channelised volcanic granular flows by comparing large-scale experiments with multiphase computational fluid dynamic simulations using the Two-Fluid Model approach, with an emphasis on the dynamics regulating the flow-wall interactions. We use the software MFIX to carry out sensitivity analysis of the boundary conditions for the solid phase implemented in the numerical code. The sensitivity analysis shows how the choice of the boundary condition and of the relevant parameters controlling the boundary conditions highly affect the dynamics of the whole flow. Finally, a preliminary benchmark of the MFIX boundary conditions with one large-scale experiment is presented, showing good agreement between the simulated and experimental flow front velocities.

Applied computer vision for composite material manufacturing by optimizing the impregnation velocity: An experimental approach

The application of the cutting edge industrial solutions in composite manufacturing are optimizing the processes, quality control and resources usage. Computer vision is currently used in many quality control stages, although its potential advantages have not been applied in the process control. In this paper, computer vision is used to control the impregnation velocity in VARI (Vacuum Assisted Resin Infusion) process. As it is known, there is a relationship between the impregnation velocity and the final mechanical properties in LCM (Liquid Composite Manufacturing) processes. Constant and optimum flow front velocity mean optimum mechanical properties, although the nature of the process makes it difficult to keep these conditions. Then, a methodology has been proposed to identify and use the optimum velocity during the manufacturing process. Firstly, the flow front recognition algorithm was calibrated to be used in different reinforcement and fluid systems. Then, tensile and impact specimens have been manufactured and tested at different controlled and uncontrolled velocities. As a result, the tensile modulus has been increased up to 12.6%, as the tensile strength has increased up to 8.7%. Similarly, the maximum reaction force during the impact test has been increased up to 6.5%, as the damaged area has been reduced by 8.8%. For stitched laminates, force results increase up to 3.2%, as the damaged area has been reduced up to 31% when the optimum velocity is used. The experimental results have demonstrated the advantage of using mechanisms to control the impregnation process to achieve improved mechanical properties of composite materials.

Rheology of three-phase suspensions determined via dam-break experiments.

Three-phase suspensions, of liquid that suspends dispersed solid particles and gas bubbles, are common in both natural and industrial settings. Their rheology is poorly constrained, particularly for high total suspended fractions (≳0.5). We use a dam-break consistometer to characterize the rheology of suspensions of (Newtonian) corn syrup, plastic particles and CO2 bubbles. The study is motivated by a desire to understand the rheology of magma and lava. Our experiments are scaled to the volcanic system: they are conducted in the non-Brownian, non-inertial regime; bubble capillary number is varied across unity; and bubble and particle fractions are 0 ≤ ϕ gas ≤ 0.82 and 0 ≤ ϕ solid ≤ 0.37, respectively. We measure flow-front velocity and invert for a Herschel-Bulkley rheology model as a function of , , and the capillary number. We find a stronger increase in relative viscosity with increasing in the low to intermediate capillary number regime than predicted by existing theory, and find both shear-thinning and shear-thickening effects, depending on the capillary number. We apply our model to the existing community code for lava flow emplacement, PyFLOWGO, and predict increased viscosity and decreased velocity compared with current rheological models, suggesting existing models may not adequately account for the role of bubbles in stiffening lavas.

Quasi-static dispersion of dusts for the determination of lower explosion limits of hybrid mixtures

Knowledge of the explosion limiting concentration of explosible materials is necessary for the design of explosion protection measures. Currently employed methods of testing the minimum explosible concentration (MEC) of a dust cloud or the lower explosion limit (LEL) of a hybrid mixture are based on arbitrary assumptions and possess technical limitations that often lead to values of MEC/LEL, which are unrealistically low or poorly reproducible.This contribution presents an improved method for the experimental determination of the MEC of a combustible dust cloud or the LEL of a flammable gas or a hybrid mixture. The new set-up operates under laminar conditions and allows a uniform suspension of dust particles in an open top acrylic glass tube. Dust concentration is measured with the help of infrared sensors installed a few centimeters above and below the ignition source.In order to evaluate the dependence of MEC on flow front velocity, MEC of lycopodium was determined at four flow velocities. The results show that the flow field intensity does not significantly influence the MEC of lycopodium for the flow ranges tested in this work. Moreover, LEL of hybrid mixtures of lycopodium and methane was also tested at flow velocities of 4.7 cm/s, 5.8 cm/s, 7 cm/s and 11 cm/s and compared with the values obtained from other sources. The results suggest that the requirement of high energy pyrotechnical igniter may be relinquished, provided that a truly homogeneous suspension of dust particles could be achieved.Moreover, the effect of relative amount of dust and gas, on the course of ignition and flame propagation in hybrid mixtures at their LEL, was studied by the help of high speed videos. For hybrid mixtures of carbonaceous dusts (like lycopodium) at their LEL, ignition occurs in the gas phase, however, flame propagation is only possible through a two-way interaction of dust and gas during the course of combustion.

Void content reduction of composites with sensor-aided injection strategy in liquid composite molding process

Void is one of the critical issues affecting the mechanical performance of fiber-reinforced polymer composites. Aiming at the composite parts formed by Liquid Composite Molding, this develops a sensor-aided injection strategy, including a real-time online monitoring module and a sensor-aided injection system, which realizes continuous detection of resin flow and the automatic injection flow rate adjustment to minimize void content. Flow front profile continuously recorded by the monitoring module in resin flow direction is reconstructed in real-time. It provides a digital representation of the saturation state of the fibrous preform, which is referred to Digital Process Twin (DPT) in present work. The local flow front velocity is then extracted from the DPT, thus the sensor-aided injection system can maintain the flow front velocity at a optimal level, regardless of the cross-sectional geometry. Experimental investigation confirms the representative of DPT to actual flow. Characterization of void content by micro-computed tomography shows that the proposed sensor-aided injection strategy not only effectively decreases the void content from 0.32%, 0.34%, and 0.79% to 0.18%, 0.18%, and 0.19%, but also significantly improves the part quality consistency. Furthermore, to the best knowledge of the authors, This work is the first to use micro CT to investigate the effect of velocity on void content from the mesoscopic and microscopic scales, although the topic has been widely investigated theoretically.

Experimental and SPH studies of reciprocal wet-bed dam-break flow over obstacles

Different permutations of the single and the two-fold dam-break flow have been investigated using the mesh-free smoothed-particle hydrodynamics and the experimental setup. The free-surface deformation in the case with the wet bed for five different downstream water heights has been investigated and respective numerical and experimental results were presented. The results demonstrate that the increase of the water height over the wet bed leads to the reduction of the flow front velocity. Effect of considering or omitting the dam gate during the numerical simulation has also been examined, which proves that the simulations including the dam gate show improved agreement with the experimental results. Influence of the three-dimensional cubic, triangular, circular and square cylindrical obstacles and their position on flow characteristics has been investigated. As the distance between the triangular obstacle and the gate increases, a bore is created at the position closer to the top of the triangle. In addition, it is found that larger force is exerted on the circular cylinder in comparison to the square cylinder.

Using High Sample Rate Lidar to Measure Debris-Flow Velocity and Surface Geometry

ABSTRACT Debris flows evolve in both time and space in complex ways, commonly starting as coherent failures but then quickly developing structures such as roll waves and surges. These processes are readily observed but difficult to study or quantify because of the speed at which they evolve. Many methods for studying debris flows consist of point measurements (e.g., flow height or basal stresses), which are inherently limited in spatial coverage and cannot fully characterize the spatiotemporal evolution of a flow. In this study, we use terrestrial lidar to measure debris-flow profiles at high sampling rates to examine debris-flow movement with high temporal and spatial precision and accuracy. We acquired measurements during gate-release experiments at the U.S. Geological Survey debris-flow flume, a unique experimental facility where debris flows can be artificially generated at a large scale. A lidar scanner was used to record repeat topographic profiles of the moving debris flows along the length of the flume with a narrow swath width (∼1 mm) at a rate of 60 Hz. The high-resolution lidar profiles enabled us to quantify flow front velocity of the debris flows and provided an unprecedented record of the development and evolution of the flow structure with a sub-second time resolution. The findings of this study demonstrate how to obtain quantitative measurements of debris-flow movement. In addition, the data help us to quantitatively define the development of a saltating debris-flow front and roll waves behind the debris-flow front. Such measurements may help constrain future modeling efforts.

The Effects of Particle Segregation on Debris Flow Fluidity Over a Rigid Bed

ABSTRACTIt is essential to consider the fluidity of a debris flow front when calculating its impact. Here we flume-tested mono-granular and bi-granular debris flows and compared the results to those of numerical simulations. We used sand particles with diameters of 0.29 and 0.14 cm at two mixing ratios of 1:1 and 3:7. Particle segregation was recorded with a high-speed video camera. We evaluated the fronts of debris flows at 0.5-second intervals. Then we numerically simulated one-dimensional debris flows under the same conditions and used the mean particle diameter when simulating mixed-diameter flows. For the mono-granular debris flows, the experimental and simulated results showed good agreement in terms of flow depth, front velocity, and flux. However, for the bi-granular debris flows, the simulated flow depth was less, and both the front velocity and flux were greater than those found experimentally. These differences may be attributable to the fact that the dominant shear stress was caused by the concentration of smaller sediment particles in the lower flow layers; such inverse gradations were detected in the debris flow bodies. Under these conditions, most shear stress is supported by smaller particles in the lower layers; the debris flow characteristics become similar to those of mono-granular flows, in contrast to the numerical simulation, which incorporated particle segregation with gradually decreasing mean diameter from the front to the flow body. Consequently, the calculated front velocities were underestimated; particle segregation at the front of the bi-granular debris flows did not affect fluidity either initially or over time.

Application of an Inertia Dependent Flow Friction Model to Snow Avalanches: Exploration of the Model Using a Ping-Pong Ball Experiment

Snow avalanches are catastrophic phenomena because of their destructive power. Therefore, it is very important to forecast the affected area of snow avalanches using numerical simulations. In our study, we focus on applying a numerical model to snow avalanches. The inertia-dependent flow friction model, which we call the “I-dependent” model, is a promising numerical model based on granular flow experiments and includes the local inertial effect. This model was introduced in previous studies as it predicts the shape and velocity of the granular flow accurately. We numerically investigated the particle diameter effect of the I-dependent model, and found that the smaller the particle diameter is, the faster the flow front velocity becomes. The final flow shape is similar to a crescent shape when the particle diameter is small. We applied this model to the ping-pong ball flow experiment, which imitated a snow avalanche on a ski jump slope. Comparing between the experimental and simulated results, the flow shape is better reproduced when the particle diameter is small, while the numerical simulation using a real ping-pong ball diameter did not show the clear crescent shape. Moreover, the relative error analysis shows that the best fit between experimental and simulated flow front velocity occurs when the particle diameter is larger than the actual size of a ping-pong ball. We conjecture that this discrepancy is mainly caused by aerodynamic effects, which, in this case, are large due to the low density of ping-pong balls. Therefore, it is necessary to explore the granular features of ping-pong balls or snow avalanches by conducting experiments, as done in previous experimental studies. Through such efforts, it may be possible to apply this I-dependent model to snow avalanches in the future.

Evolution of stony debris flows in laboratory experiments

The run out and destructive potential of gravitational multi-phase flows is largely determined by the mixture composition, the material properties of the solid particles and the fluid. One instrument to expand the understanding of the governing processes of flow is laboratory experiments. In this study, we concentrate experimentally on landslide-induced stony debris flows as a particular type of flow-like mass movement. We aim to observe different natural flow types for varying initial and boundary conditions. In a laboratory flume, 12.0 m long, 1.3 m wide and 0.3 m deep, we initiate stony debris flows and measured flow variables such as flow depth, mass, bulk density, front velocity and front shape for varying particle size, solid volume fraction and basal roughness. Our experimental results reveal that flow type and evolution changes significantly for different solid volume fractions, as well as for different basal roughness. The particle size had a noticeable effect on flow velocity and front shape. The smooth surface facilitated rapid, shallow, and turbulent flows. In contrast, experiments with rough beds showed relatively lower velocities and dense flow behaviour. Although the flow parameters covered only a small spectrum of the naturally possible parameter space, flow phenomena such as phase-separation, longitudinal sorting, steep front surges, or front overtopping were observed. We group our observed flows regarding the flow properties and classify them into common flow types: (1) debris flood (hyperconcentrated flow), (2) debris flow, and (3) non-liquefied debris flow. To compare our results with natural events and other experimental results, we analyse the data with several dimensionless numbers. The flows were generally dominated by grain collision on the smooth surface. Naturally, frictional forces gain more influence on the rough surface but did not overrule collisional forces. Viscous forces played only a minor role in our experiments, due to the lack of highly viscous fluid. Overall, we infer, that our well-controlled experiments mimicked natural stony debris flow and give new profound insights into the causal relationship of how the initial and boundary conditions affect the flow evolution.

Submillimeter features on injected acrylonitrile butadiene styrene parts: Visualization of the flow and numerical simulation

AbstractNumerical simulation of classical dimension parts with micrometric textures on their surface is still difficult to master. The limit condition of the calculations, and in particular, the implemented values, characteristics of the polymer and thermal exchanges (polymer/mold) strongly impact the results. Starting from a model with a 370 μm wide rib, by means of a numerical simulation, a study was done on the evolution of the material flow front velocities and the flow lengths in both the macroscopic part and the microgroove. This innovative visualization mold design was used to determine the velocities from an experimental perspective and to discuss the calculation conditions. On the one hand, there are significant differences regarding the choice of the no flow temperature (~ 40 K) used in the calculation code, the analytical heat transfer equation as well as the experimental results. On the other hand, according to the no flow temperature, it may be necessary to consider, during the filling phase, a perfect mold/polymer thermal contact in the groove. Depending in particular on the injection velocity and the geometry of the micro textures, a characteristic time can be determined which defines an optimal operating point for the topographic texture of the part.

Inlet Condition for Mold Filling Simulation in Gravity Casting of Aluminum Alloy

The casting CAE is useful tool for casting design in order to obtain the sound castings without defects. It is very important to know the influence of casting conditions on the mold filling. In the present study, the inlet condition for the mold filling simulation in gravity casting of aluminum alloy is investigated to simulate the real phenomena changing with the difference in the casting shape. The direct observation experiment is carried out with six types of sprue designs using an aluminum alloy and sand mold. There are three types of sprues: the elbow, bend and stair-step shapes. The molten metal of Al–7%Si alloy is poured using the stopper ladle. The velocity change in accordance with the different casting condition is analyzed using images observed by the video camera. The velocity of flow front in the early stage of the mold filling is changed intensely. Then, the velocity after the middle stage of the mold filling is decreased calmly. It is difficult to simulate the present phenomena by the mold filling simulation using the velocity inlet boundary. In order to reproduce the difference of each filling behavior, new inlet condition, which is named to “OverFlow pouring Basin” (OFB), is proposed in this study. The mold filling behavior and filled-up time simulated using the inlet condition of OFB are more or less agreed with six real phenomena according with three sprue shapes and two sprue heights.

Flow-speed-controlled quality optimisation for one-shot-hybrid RTM parts

This work describes a model-based methodology to improve the bonding quality between the metal and composite constituents of one-shot-hybrid resin transfer moulding (OSH-RTM) parts. In order to reduce void induced defects in the interface an ideal flow front velocity needs to be achieved. This ideal flow front velocity is characterised by capillary rise experiments at the used carbon fibre textile. The flow front velocity during mould filling is controlled by the use of pressure sensors and Darcy’s law. Therefore, viscosity characterisation of the resin system and permeability measurements of the preform were carried out. The interface of the produced OSH-RTM roof bar for a car is tested on a component test rig imitating the load of a side impact at a car. A t-test was carried out to prove that the flow-speed-controlled injection strategy is advantageous compared to a constant mass flow injection by means of a higher maximum load transferable by the interface of the hybrid part.

Evaluación de los procesos superficiales de escorrentía en cárcavas originadas en olivares convencionales. Un apartado a tener en cuenta en la planificación territorial

Se analiza la respuesta hidrologica de una carcava efimera frente a un evento de lluvia equivalente de frecuencia “ordinaria” (≈1 ano) a partir de una simulacion de escorrentia en una cuenca experimental con olivar en Puente Genil, Cordoba (Espana). Mil litros de agua fueron bombeados durante 10 minutos y la descarga total, la velocidad superficial de avance de frente de flujo, la concentracion de sedimentos y los cambios morfologicos en el perfil transversal fueron calculados. Los resultados mostraron elevadas diferencias entre las tasas de escorrentia de hasta un 17% entre las condiciones “secas” y “humedas”. La concentracion de sedimentos instantanea llego a alcanzar valores de hasta 40 g l-1. Se concluye que las carcavas en olivares convencionales son capaces de registrar elevadas tasas de erosion y escorrentia, particularmente bajo condiciones de mayor humedad. Se requiere mas informacion y atencion a las medidas de control sobre la erosion por el flujo concentrado de la escorrentia en la planificacion agricola.

Determination of flow front velocity and optimal injection pressures for better impregnation of E-glass with polyester in resin transfer mold

Flow front velocity of resin plays a key role in yielding better impregnation of fiber reinforcement in resin transfer molding to fabricate quality composites. A video camera was used to capture the patterns of resin flowing below the grid lines drawn on the acrylic sheet of resin transfer mold and also to accurately measure the flow front velocity using an image conversion tool. The effect of flow front velocity, permeability, Reynolds number and void content at five different injection pressures on chopped strand E-glass/polyester composites consisting of 4, 5 and 6 layers has been studied. On the basis of Reynolds number of resin flow and void content present in the composite, optimal injection pressures are suggested for better impregnation of preform. Composites processed at these injection pressures gave superior properties in tension and flexure. Fractured parts of the specimens were examined on Scanning Electron Microscope to explain the causes of superior mechanical properties.

Load model for designing flexible steel barriers for debris flow mitigation

Light-weight flexible steel net barriers catch coarse debris, but let some of the fine material and water pass through the net. They are difficult to design so that they can withstand the impact pressures of both boulder-laden granular and water-saturated debris flows. Using results from laboratory and full-scale field tests, a debris flow load model has been developed for flexible barriers in torrent channels. The model accounts for the forces of initial impact as well as the filling process discretized stepwise over time (barriers in the field and laboratory fill continuously). Laboratory tests with fast debris flow front velocities revealed a run-up behaviour that was not observed in the field (“pile-up”). The load model divides the flow forces into a hydrostatic component and a dynamic part depending on a pressure coefficient, the flow velocity, and the density of the flow. This dynamic part, which is more complex to quantify, accounts for the wide-ranging debris flow characteristics from watery and muddy debris floods to granular friction-dominated mass flows.