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Previous studies have demonstrated the benefits of the log-conformation formulation to model viscoelastic fluids; it increases stability at high Weissenberg numbers and ensures that the conformation tensor remains positive-definite. Many studies have applied the log-conformation tensor formulation to benchmark cases; however, relatively few studies investigate using the formulation on more complex flows. In this paper, we extend the log-conformation formulation to the manufacturing-relevant flow of blade coating. We first verify the log-conformation formulation on the benchmark problem of flow past a cylinder using the finite element method, and then apply it to the blade-coating process, in which a viscoelastic fluid entrained by a moving substrate passes under a blade at a constant web speed. We investigate various rheological effects and the resulting film thickness for the blade-coating problem, and compare the results from the log-conformation formulation to those of the original stress formulation. We show that the log-conformation formulation agrees well with other established methods, and also increases the maximum achievable web speed in the blade-coating problem.

When the core is breached during a severe nuclear accident, a molten mixture of nuclear fuel, cladding, and structural supports is discharged from the reactor vessel. This molten mixture of ceramic and metal is often referred to as “corium”. Predicting the flow and solidification of corium poses challenges for numerical models due to the presence of large Peclet numbers when convective transport dominates the physics. Here, we utilize a control volume finite-element method (CVEM) discretization to stabilize the advection dominated flow and heat transport. This CVFEM approach is coupled with the conformal decomposition finite-element method (CDFEM), which tracks the corium/air interface on an existing background mesh. CDFEM is a sharp-interface method, allowing the direct discretization of the corium front. This CVFEM-CDFEM approach is used to model the spreading of molten corium in both two- and three-dimensions. The CVFEM approach is briefly motivated in a comparison with a streamwise upwind/Petrov-Galerkin (SUPG) stabilized finite-element method, which was not able to suppress spurious temperature oscillations in the simulations. Our model is compared directly with the FARO L26 corium spreading experiments and with previous numerical simulations, showing both quantitative and qualitative agreement with those studies.

Polyurethane foams are used widely for encapsulation and structural purposes because they are inexpensive, straightforward to process, amenable to a wide range of density variations (1–50 lb/ft3), and able to fill complex molds quickly and effectively. Computational models of the filling and curing process are needed to reduce defects such as voids, out-of-specification density, density gradients, foam decomposition from high temperatures due to exotherms, and incomplete filling. This paper details the development of a computational fluid dynamics model of a moderate density PMDI structural foam, PMDI-10. PMDI is an isocyanate-based polyurethane foam, which is chemically blown with water. The polyol reacts with isocyanate to produce the polymer. PMDI-10 is catalyzed giving it a short pot life, meaning that the foam is liquid and flowable only for a short-time; it foams and polymerizes to a solid within 5 min during normal processing. To achieve a higher density, the foam is over-packed to twice or more of its free-rise density of 10 lb/ft3. The goal for modeling is to represent the expansion, filling of molds, and the polymerization of the foam. This model will be used to reduce defects, optimize the mold design, understand processing parameter sensitivities, and predict the final foam properties. A homogenized continuum model for foaming and curing was developed based on reaction kinetics, documented in a recent paper; it uses a simplified mathematical formalism that decouples these two reactions. The chemo-rheology of PMDI is measured experimentally and fit to a generalized-Newtonian viscosity model that is dependent on the extent of cure, gas volume fraction, and temperature. The conservation equations, including the equations of motion, an energy balance, and three rate equations are solved using a stabilized finite element method. The equations are combined with a level set method to determine the location of the foam-gas interface as it evolves to fill the mold. Understanding the thermal history and loads on the foam due to exothermicity and oven curing is very important to the results, since the kinetics, viscosity, and other material properties are all sensitive to temperature. Results from the model are compared to experimental flow visualization data to understand the interface evolution with time and post-test X-ray computed tomography (CT) data for the density prediction validation. Several geometries are investigated including two configurations of a mock structural part and a bar geometry to specifically test the density model. We have found that the model predicts both average density and filling profiles well. However, it under predicts density gradients, especially in the gravity direction. Further model improvements are also discussed for future work.

We generate a wide range of models of proppant-packed fractures using discrete element simulations, and measure fracture conductivity using finite element flow simulations. This allows for a controlled computational study of proppant structure and its relationship to fracture conductivity and stress in the proppant pack. For homogeneous multi-layered packings, we observe the expected increase in fracture conductivity with increasing fracture aperture, while the stress on the proppant pack remains nearly constant. This is consistent with the expected behavior in conventional proppant-packed fractures, but the present work offers a novel quantitative analysis with an explicit geometric representation of the proppant particles. In single-layered packings (i.e. proppant monolayers), there is a drastic increase in fracture conductivity as the proppant volume fraction decreases and open flow channels form. However, this also corresponds to a sharp increase in the mechanical stress on the proppant pack, as measured by the maximum normal stress relative to the side crushing strength of typical proppant particles. We also generate a variety of computational geometries that resemble highly heterogeneous proppant packings hypothesized to form during channel fracturing. In some cases, these heterogeneous packings show drastic improvements in conductivity with only moderate increase in the stress on the proppant particles, suggesting that in certain applications these structures are indeed optimal. We also compare our computer-generated structures to micro computed tomography imaging of a manually fractured laboratory-scale shale specimen, and find reasonable agreement in the geometric characteristics.

Using a multiscale blood flow solver, the complete diffusion tensor of nanoparticles (NPs) in sheared cellular blood flow is calculated over a wide range of shear rate and haematocrit. In the short-time regime, NPs exhibit anomalous dispersive behaviors under high shear and high haematocrit due to the transient elongation and alignment of the red blood cells (RBCs). In the long-time regime, the NP diffusion tensor features high anisotropy. Particularly, there exists a critical shear rate (${\sim}100~\text{s}^{-1}$) around which the shear-rate dependence of the diffusivity tensor changes from linear to nonlinear scale. Above the critical shear rate, the cross-stream diffusivity terms vary sublinearly with shear rate, while the longitudinal term varies superlinearly. The dependence on haematocrit is linear in general except at high shear rates, where a sublinear scale is found for the vorticity term and a quadratic scale for the longitudinal term. Through analysis of the suspension microstructure and numerical experiments, the nonlinear haemorheological dependence of the NP diffusion tensor is attributed to the streamwise elongation and cross-stream contraction of RBCs under high shear, quantified by a capillary number. The RBC size is shown to be the characteristic length scale affecting the RBC-enhanced shear-induced diffusion (RESID), while the NP submicrometre size exhibits negligible influence on the RESID. Based on the observed scaling behaviours, empirical correlations are proposed to bridge the NP diffusion tensor to specific shear rate and haematocrit. The characterized NP diffusion tensor provides a constitutive relation that can lead to more effective continuum models to tackle large-scale NP biotransport applications.

A theory is presented for the transition between the coflowing and the drop-generation regimes observed in microfluidic channels with a rectangular cross section. This transition is characterized by a critical ratio of the dispersed- to continuous-phase volume flow rates. At flow-rate ratios higher than this critical value, drop generation is suppressed. The critical ratio corresponds to the fluid cross section where the dispersed-phase fluid is just tangent to the channel walls. The transition criterion is a function of the ratio of the fluid viscosities, the three-phase contact angle formed between the fluid phases and the channel walls, and the aspect ratio of the channel cross section; the transition is independent of interfacial tension. Hysteretic behavior of drop generation with respect to the flow-rate ratio is predicted for partially wetting dispersed-phase fluids. Experimental data are consistent with this theory.

Continuous jets of non-Newtonian fluids impinging on a fluid surface exhibit instabilities from jet buckling and coiling at low Reynolds numbers to delayed die swell, mounding, and air entrainment at higher Reynolds numbers. Filling containers with complex fluids is an important process for many industries, where the need for high throughput requires operating at high Reynolds numbers. In this regime, air entrainment can produce a visually unappealing product, causing a major quality control issue. Just prior to the onset of air entrainment, however, there exists an ideal filling regime which we term “planar filling,” as it is characterized by a relatively flat free surface that maintains its shape over time. In this paper, we create a steady-state, 2-D axisymmetric finite element model to study the transition from planar filling to the onset of air entrainment in a container filling process with generalized-Newtonian fluids. We use this model to explore the operating window for Newtonian and shear-thinning (or, more generally, deformation-rate-thinning) fluids, demonstrating that the flow behavior is characterized by a balance between inertial, viscous, and gravitational forces, as characterized by the Reynolds and Froude numbers. A scaling analysis suggests that the relevant parameters for calculating these dimensionless numbers are located where the jet impacts the liquid surface, and simulations show that the transition from planar filling to air entrainment often occurs when Re ∼ O ( 10 ) . We found that the bottom and side surfaces of the container drastically influence this transition to entrainment, stabilizing the flow.

SUMMARY We have developed a production-level foam processing computational model suitable for predicting the self-expansion of foam in complex geometries. The model is based on a finite element representation of the equations of motion, with the movement of the free surface represented using the level set method. An empirically based time-dependent and temperature-dependent density model is used to encapsulate the complex physics of foam nucleation and growth in a numerically tractable manner. The evolving density drives the dynamics of foam self-expansion. This continuum-level model uses a homogenized description of foam, which does not include the gas explicitly, but allows varying local fields, such as temperature and gas volume fraction, and material models. In addition, material models vary with the location of the level set interface, taking properties of the displaced air phase in the negative level set region and the foam in the positive region. The level set zero describes the location of the interface, where surface forces are applied using the continuous surface force treatment. The variation from foam to gas properties is handled with a diffuse interface method using a smooth Heaviside function and equation averaging. Material model development was guided and populated by careful experiments. Results from the model are compared with temperature-instrumented flow visualization experiments giving the location of the foam front as a function of time for a physically blown, epoxy foam. Good qualitative agreement is seen between simulations and experiments, although some of the subtleties of the filling process are lost to the model. Published 2011. This article is a US Government work and is in the public domain in the USA.

The practical implementation of several thixotropic rheological models has been evaluated for a prototypical industrial application. We have studied the ability of the models to predict both steady and transient rheology of a suspension of alumina particles and the suitability of those models for full transient finite element calculations. The constitutive models for thixotropic materials examined include the Carreau-Yasuda model and first and second-order indirect structure models. While all of these models were able to predict the shear-thinning behavior of the steady viscosity, the first and second-order structure models were also able to capture some aspects of the transient structure formation and fluid history. However, they were not able to predict some more complex transient behavior observed in step shear experiments. For most thixotropic suspensions, the time constant required to form structure is longer than the time constant to break it down. For this suspension, the time constant at a given shear rate was also dependent on the previous shear rate. If the previous shear rate was high, the time required to reach equilibrium was longer than if the previous shear rate was lower. This behavior was not captured by the simple initial structure dependence in the previous models. By adding an additional dependence on the initial suspension structure, the prediction of the transient rheology was substantially improved while maintaining an excellent agreement with the steady shear viscosity. Finite element results are presented for extrusion of a suspension to form a fiber. This model two-dimensional problem contains many of the same complexities as practical three-dimensional mold filling simulations (i.e., nonviscometric and mobile free surface). Our results show that these direct structure models exhibit oscillations near the stick-slip point in finite element calculations similar to many polymeric constitutive equations, but are otherwise suitable for implementation in complex industrial modeling applications.The practical implementation of several thixotropic rheological models has been evaluated for a prototypical industrial application. We have studied the ability of the models to predict both steady and transient rheology of a suspension of alumina particles and the suitability of those models for full transient finite element calculations. The constitutive models for thixotropic materials examined include the Carreau-Yasuda model and first and second-order indirect structure models. While all of these models were able to predict the shear-thinning behavior of the steady viscosity, the first and second-order structure models were also able to capture some aspects of the transient structure formation and fluid history. However, they were not able to predict some more complex transient behavior observed in step shear experiments. For most thixotropic suspensions, the time constant required to form structure is longer than the time constant to break it down. For this suspension, the time constant at a given s...

Batch sedimentation of non-colloidal particle suspensions is studied with nuclear magnetic resonance flow visualization and continuum-level numerical modelling of particle migration. The experimental method gives particle volume fraction as a function of time and position, which then provides validation data for the numerical model. A finite element method is used to discretize the equations of motion, including an evolution equation for the particle volume fraction and a generalized Newtonian viscosity dependent on local particle concentration. The diffusive-flux equation is based on the Phillips model (Phys. Fluids A 1992; 4:30–40) and includes sedimentation terms described by Zhang and Acrivos (Int. J. Multiphase Flow 1994; 20:579–591). The model and experiments are utilized in three distinct geometries with particles that are heavier and lighter than the suspending fluid, depending on the experiment: (1) sedimentation in a cylinder with a contraction; (2) particle flotation in a horizontal cylinder with a horizontal rod; and (3) flotation around a rectangular inclusion. Secondary flows appear in both the experiments and the simulations when a region of higher density fluid is above a lower density fluid. The secondary flows result in particle inhomogeneities, Rayleigh–Taylor-like instabilities, and remixing, though the effect in the simulations is more pronounced than in the experiments. Published in 2007 by John Wiley & Sons, Ltd.

A Galerkin/least-squares stabilization technique is applied to a discrete Elastic Viscous Stress Splitting formulation of for viscoelastic flow. From this, a possible viscoelastic stabilization method is proposed. This method is tested with the flow of an Oldroyd-B fluid past a rigid cylinder, where it is found to produce inaccurate drag coefficients. Furthermore, it fails for relatively low Weissenberg number indicating it is not suited for use as a general algorithm. In addition, a decoupled approach is used as a way separating the constitutive equation from the rest of the system. A Pressure Poisson equation is used when the velocity and pressure are sought to be decoupled, but this fails to produce a solution when inflow/outflow boundaries are considered. However, a coupled pressure-velocity equation with a decoupled constitutive equation is successful for the flow past a rigid cylinder and seems to be suitable as a general-use algorithm.

Shear-induced migration of particles is studied during the slow flow of suspensions of neutrally buoyant spheres, at 50% particle volume fraction, in an inelastic but shear-thinning, suspending fluid. The suspension is flowing in between a rotating inner cylinder and a stationary outer cylinder. The conditions are such that nonhydrodynamic effects are negligible. Nuclear magnetic resonance (NMR) imaging demonstrates that the movement of particles away from the high shear rate region is more pronounced than for a Newtonian suspending liquid. We test a continuum constitutive model for the evolution of particle concentration in a flowing suspension proposed by Phillips et al., but extended to shear-thinning, suspending fluids. The fluid constitutive equation is Carreau-like in its shear-thinning behavior but also varies with the local particle concentration. The model captures many of the trends found in the experimental data, but does not yet agree quantitatively. In fact, quantitative agreement with a diffusive flux constitutive equation would be impossible without the addition of another fitting parameter that may depend on the shear-thinning nature of the suspending fluid. Because of this, we feel that the Phillips model may be fundamentally inadequate for simulating flows of particles in non-Newtonian suspending fluids without the introduction of a normal stress correction or other augmenting terms.

A suspension of non-neutrally buoyant, large, nearly monodisperse spheres is studied both in batch sedimentation and in shear between concentric rotating cylinders. We apply a continuum constitutive equation based on the diffusive flux model augmented with buoyancy terms derived by Acrivos and coworkers and discretize the resulting equation set with the finite element method. We simulate batch sedimentation using this method and obtain a reasonable match with experiment. Next used two-dimensional NMR imaging to measure the evolution of solid fraction profiles in the same suspension undergoing flow between rotating concentric cylinders with two different initial conditions. Here, both gravity-induced and shear-induced particle migration are significant. Under these conditions, we have found that simulating the correct initial condition is critical to matching the experimental results. When this is done, the model results compare well with the experiments. Copyright © 2002 John Wiley & Sons, Ltd.

To date, few researchers have solved three-dimensional free-surface problems with dynamic wetting lines. This paper extends the free-surface finite element method described in a companion paper [Cairncross, R.A., P.R. Schunk, T.A. Baer, P.A. Sackinger, R.R. Rao, "A finite element method for free surface flows of incompressible fluid in three dimensions, Part I: Boundary-Fitted mesh motion.", to be published (1998)] to handle dynamic wetting. A generalization of the technique used in two dimensional modeling to circumvent double-valued velocities at the wetting line, the so-called kinematic paradox, is presented for a wetting line in three dimensions. This approach requires the fluid velocity normal to the contact line to be zero, the fluid velocity tangent to the contact line to be equal to the tangential component of web velocity, and the fluid velocity into the web to be zero. In addition, slip is allowed in a narrow strip along the substrate surface near the dynamic contact line. For realistic wetting-line motion, a contact angle which varies with wetting speed is required because contact lines in three dimensions typically advance or recede a different rates depending upon location and/or have both advancing and receding portions. The theory is applied to capillary rise of static fluid in a corner, the initial motion of a Newtonian droplet down an inclined plane, and extrusion of a Newtonian fluid from a nozzle onto a moving substrate. The extrusion results are compared to experimental visualization. Subject Categories

Filling processes occur in a wide range of industries, ranging from packaging of consumer products to manufacturing processes for making polymeric, metal and ceramic components. These processes involve the complex interplay of extrusion of a viscous liquid into a mould or container where it displaces a gas phase. Numerical modelling based on computational fluid dynamics can be useful for understanding the filling process. However, complexity arises in that the fluid dynamics in both the viscous liquid and gas phase must be resolved while concurrently determining the location of the fluid-gas interface and the interaction of this interface with the solid surface, i.e., the wetting behaviour. Determining the free surface location and wetting behaviour is an integral part of the numerical method.

In this report, we summarize our work on developing a production level foam processing computational model suitable for predicting the self-expansion of foam in complex geometries. The model is based on a finite element representation of the equations of motion, with the movement of the free surface represented using the level set method, and has been implemented in SIERRA/ARIA. An empirically based time- and temperature-dependent density model is used to encapsulate the complex physics of foam nucleation and growth in a numerically tractable model. The change in density with time is at the heart of the foam self-expansion as it creates the motion of the foam. This continuum-level model uses an homogenized description of foam, which does not include the gas explicitly. Results from the model are compared to temperature-instrumented flow visualization experiments giving the location of the foam front as a function of time for our EFAR model system.

A series of experiments has been performed to allow observation of the foaming process and the collection of temperature, rise rate, and microstructural data. Microfocus video is used in conjunction with particle image velocimetry (PIV) to elucidate the boundary condition at the wall. Rheology, reaction kinetics and density measurements complement the flow visualization. X-ray computed tomography (CT) is used to examine the cured foams to determine density gradients. These data provide input to a continuum level finite element model of the blowing process.

SUMMARY Little adaptive finite element work has been done in the area of viscoelastic flow in complex geometries. In this paper an adaptive finite element mesh refinement study is carried out on a Newtonian fluid and a Maxwell fluid in an axisymmetric 4: 1 contraction. The error indicator used for the refinement is the local norm of the residual in an element. For the Newtonian fluid, steady improvement with refinement is seen, though this is not the case for the Maxwell fluid, which never achieves a solution of good quality.

To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we modelmore » the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.« less

Solidification and blood flow seemingly have little in common, but each involves a fluid in contact with a deformable solid. In these systems, the solid-fluid interface moves as the solid advects and deforms, often traversing the entire domain of interest. Currently, these problems cannot be simulated without innumerable expensive remeshing steps, mesh manipulations or decoupling the solid and fluid motion. Despite the wealth of progress recently made in mechanics modeling, this glaring inadequacy persists. We propose a new technique that tracks the interface implicitly and circumvents the need for remeshing and remapping the solution onto the new mesh. The solid-fluid boundary is tracked with a level set algorithm that changes the equation type dynamically depending on the phases present. This novel approach to coupled mechanics problems promises to give accurate stresses, displacements and velocities in both phases, simultaneously.

Theoretical models describing the dynamic behavior of the expansion and contraction of polyelectrolyte gels present numerically challenging problems. This paper describes how a method of weighted residuals approach has been used to solve the two-dimensional governing system of equations by finite element analysis. The modulation of the imbibition/expulsion of solvent by a gel disk is studied as an example.