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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.

Blood flowing through microvascular bifurcations has been an active research topic for many decades, while the partitioning pattern of nanoscale solutes in the blood remains relatively unexplored. Here, we demonstrate a multiscale computational framework for direct numerical simulation of the nanoparticle (NP) partitioning through physiologically-relevant vascular bifurcations in the presence of red blood cells (RBCs). The computational framework is established by embedding a newly-developed particulate suspension inflow/outflow boundary condition into a multiscale blood flow solver. The computational framework is verified by recovering a tubular blood flow without a bifurcation and validated against the experimental measurement of an intravital bifurcation flow. The classic Zweifach-Fung (ZF) effect is shown to be well captured by the method. Moreover, we observe that NPs exhibit a ZF-like heterogeneous partition in response to the heterogeneous partition of the RBC phase. The NP partitioning prioritizes the high-flow-rate daughter branch except for extreme (large or small) suspension flow partition ratios under which the complete phase separation tends to occur. By analyzing the flow field and the particle trajectories, we show that the ZF-like heterogeneity in NP partition can be explained by the RBC-entrainment effect caused by the deviation of the flow separatrix preceded by the tank-treading of RBCs near the bifurcation junction. The recovery of homogeneity in the NP partition under extreme flow partition ratios is due to the plasma skimming of NPs in the cell-free layer. These findings, based on the multiscale computational framework, provide biophysical insights to the heterogeneous distribution of NPs in microvascular beds that are observed pathophysiologically.

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.

Transport of solid particles in blood flow exhibits qualitative differences in the transport mechanism when the particle varies from nanoscale to microscale size comparable to the red blood cell (RBC). The effect of microscale particle margination has been investigated by several groups. Also, the transport of nanoscale particles (NPs) in blood has received considerable attention in the past. This study attempts to bridge the gap by quantitatively showing how the transport mechanism varies with particle size from nano- to microscale. Using a three-dimensional (3D) multiscale method, the dispersion of particles in microscale tubular flows is investigated for various hematocrits, vessel diameters and particle sizes. NPs exhibit a nonuniform, smoothly-dispersed distribution across the tube radius due to severe Brownian motion. The near-wall concentration of NPs can be moderately enhanced by increasing hematocrit and confinement. Moreover, there exists a critical particle size ($\sim$1 $\mu$m) that leads to excessive retention of particles in the cell-free region near the wall, i.e., margination. Above this threshold, the margination propensity increases with the particle size. The dominance of RBC-enhanced shear-induced diffusivity (RESID) over Brownian diffusivity (BD) results in 10 times higher radial diffusion rates in the RBC-laden region compared to that in the cell-free layer, correlated with the high margination propensity of microscale particles. This work captures the particle size-dependent transition from Brownian-motion dominant dispersion to margination using a unified 3D multiscale computational approach, and highlights the linkage between the radial distribution of RESID and the margination of particles in confined blood flows.

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.

An ongoing Sandia National Laboratories’ (SNL) research study is evaluating a potential design of an injectable sacrificial material (SM) system that could contain and cool corium ejected from a reactor vessel lower head failure during a potential severe accident involving melting fuel at a commercial light water nuclear reactor (LWR). An injectable system could be installed at any existing LWR, without significant modification to the cavity or to the drywell pedestal region of the plant. The conceptual design under consideration is a passive system. The SM is being optimized to quickly cool the corium mixture while creating gas to form porosity in the solid, such that subsequent water flooding can penetrate the structure and provide additional cooling. The SM would form a barrier and limit corium-concrete interactions. This three-year project takes a joint experimental and computational approach. In this paper, we will first discuss the success of our small-scale experiments conducted on the interactions between the surrogate corium material (SCM) and SM, used to evaluate the injectable concept. A larger experimental study, currently underway, will further validate the injectable concept, with a focus on accurately measuring interactions. This paper details the modeling study and its progress, including modeling the experiments on a surrogate system and extending the model to bench-scale corium flow from validation experiments. The project’s modeling studies will use the SNL engineering code suite SIERRA Mechanics to understand the interaction of injectable SM and molten corium and predict corium spreading. Spreading is modeled using a level set method to track the front in conjunction with a pressure-stabilized finite element method on the fully three-dimensional mass, momentum, and energy conservation equations. Using this diffuse-interface method, the corium spreading front can be tracked and an appropriate pseudo-solidification viscosity models can be implemented to accurately model the corium spreading physics. Finally, an injectable SM delivery system is discussed along with its deployment to the six-common commercial LWR designs currently operating in the United States. At the end of this project, a simplified model based on SIERRA simulations will be developed for implementation into MELCOR, a severe reactor analysis code, developed at SNL for the U.S. Nuclear Regulatory Commission. This will allow us to demonstrate the ability of the injectable SM system to mitigate the ex-vessel corium spreading, provide containment and negate the release of radionuclides.

Multilayer coextrusion is applied to produce a tape containing layers of alternating electrical properties to demonstrate the potential for using coextrusion to manufacture capacitors. To obtain the desired properties, we develop two filled polymer systems, one for conductive layers and one for dielectric layers. We describe numerical models used to help determine the material and processing parameters that impact processing and layer stability. These models help quantify the critical ratios of densities and viscosities of the two layers to maintain stable layers, as well as the effect of increasing the flow rate of one of the two materials. The conducting polymer is based on polystyrene filled with a blend of low-melting-point eutectic metal and nickel particulate filler, as described by Mrozek et al. (2010). The appropriate concentrations of fillers are determined by balancing measured conductivity with processability in a twin screw extruder. Based on results of the numerical models and estimates of the viscosity of emulsions and suspensions, a dielectric layer composed of polystyrene filled with barium titanate is formulated. Despite the fact that the density of the dielectric filler is less than the metallic filler of the conductive phase, as well as rheological measurements that later showed that the dielectric formulation is not an ideal match to the viscosity of the conductive material, the two materials can be successfully coextruded if the flow rates of the two materials are not identical. A measurable capacitance of the layered structure is obtained.

The biotransport of the intravascular nanoparticle (NP) is influenced by both the complex cellular flow environment and the NP characteristics. Being able to computationally simulate such intricate transport phenomenon with high efficiency is of far-reaching significance to the development of nanotherapeutics, yet challenging due to large length-scale discrepancies between NP and red blood cell (RBC) as well as the complexity of NP dynamics. Recently, a lattice-Boltzmann (LB) based multiscale simulation method has been developed to capture both NP scale and cellular level transport phenomenon at high computational efficiency. The basic components of this method include the LB treatment for the fluid phase, a spectrin-link method for RBCs, and a Langevin dynamics (LD) approach to capturing the motion of the suspended NPs. Comprehensive two-way coupling schemes are established to capture accurate interactions between each component. The accuracy and robustness of the LB-LD coupling method are demonstrated through the relaxation of a single NP with initial momentum and self-diffusion of NPs. This approach is then applied to study the migration of NPs in a capillary vessel under physiological conditions. It is shown that Brownian motion is most significant for the NP distribution in capillary vessels. For 1~100 nm particles, the Brownian diffusion is the dominant radial diffusive mechanism compared to the RBC-enhanced diffusion. For ~500 nm particles, the Brownian diffusion and RBC-enhanced diffusion are comparable drivers for the particle radial diffusion process., Published on Computers & Fluids

A hybrid computational method coupling the lattice-Boltzmann (LB) method and a Langevin-dynamics (LD) method is developed to simulate nanoscale particle and polymer (NPP) suspensions in the presence of both thermal fluctuation and long-range many-body hydrodynamic interactions (HI). Brownian motion of the NPP is explicitly captured by a stochastic forcing term in the LD method. The LD method is two-way coupled to the non-fluctuating LB fluid through a discrete LB forcing source distribution to capture the long-range HI. To ensure intrinsically linear scalability with respect to the number of particles, an Eulerian-host algorithm for short-distance particle neighbor search and interaction is developed and embedded to LB-LD framework. The validity and accuracy of the LB-LD approach are demonstrated through several sample problems. The simulation results show good agreements with theory and experiment. The LB-LD approach can be favorably incorporated into complex multiscale computational frameworks for efficiently simulating multiscale, multicomponent particulate suspension systems such as complex blood suspensions., Comment: Published in International Journal for Numerical Methods in Fluids

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.

A model system was developed for enabling a multiscale understanding of centrifugal-contactor liquid–liquid extraction. The system consisted of Nd(III) + xylenol orange in the aqueous phase buffered to pH = 5.5 by KHP, and dodecane + thenoyltrifluroroacetone (HTTA) + tributyphosphate (TBP) in the organic phase. Diffusion constants were measured for neodymium in both the organic and aqueous phases, and the Nd(III) partition coefficients were measured at various HTTA and TBP concentrations. A microfluidic channel was used as a high-shear model environment to observe mass transfer on a droplet scale with xylenol orange as the aqueous-phase metal indicator; mass-transfer rates were measured quantitatively in both diffusion and reaction limited regimes on the droplet scale. The microfluidic results were comparable to observations made for the same system in a laboratory scale liquid–liquid centrifugal contactor, indicating that single drop microfluidic experiments can provide information on mass transfer in complicated flows and geometries. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3071–3078, 2014

Liquid-liquid extraction (LLE) is a widely used separation method for an extensive range of metals including actinides. The Gibbs energy minimization (GEM) method is used to compute the complex chemical equilibria for the LLE system HNO3–H2O–UO2(NO3)2–TBP plus diluent at 25°C. The nonelectrolyte phase is treated as an ideal mixture defined by eight tri-n-butyl phosphate (TBP) complexes plus the inert diluent. The Pitzer method is used to capture nonidealities in the concentrated electrolyte phase. The generated extraction isotherms are in very good agreement with reported experimental data for various TBP loadings and electrolyte concentrations demonstrating the adequacy of this approach to analyze complex multiphase multicomponent systems. The model is robust and yet flexible allowing for expansion to other LLE systems and coupling with computational tools for parameter analysis and optimization.

Polyurethane is a complex multiphase material that evolves from a viscous liquid to a system of percolating bubbles, which are created via a CO2 generating reaction. The continuous phase polymerizes to a solid during the foaming process generating heat. Foams introduced into a mold increase their volume up to tenfold, and the dynamics of the expansion process may lead to voids and will produce gradients in density and degree of polymerization. These inhomogeneities can lead to structural stability issues upon aging. For instance, structural components in weapon systems have been shown to change shape as they age depending on their molding history, which can threaten critical tolerances. The purpose of this project is to develop a Cradle-to-Grave multiphysics model, which allows us to predict the material properties of foam from its birth through aging in the stockpile, where its dimensional stability is important.

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.

Epoxy resins filled to a high solids loading (40–60% by volume) with noncolloidal particles are used to mitigate stress and vibration in electronic components. We perform continuum-level finite element method (Schunk et al., A Full-Newton Finite Element Program for Free and Moving Boundary Problems with Coupled Fluid/Solid Momentum, Energy, Mass, and Chemical Species Transport: User's Guide, Sandia National Laboratories) simulations of filler particle redistribution during the nonisothermal cure of the epoxy under both quiescent and bulk flow conditions. An extent of reaction is used to track the degree of cure. To determine the particle migration, we couple a diffusive flux suspension model (Zhang and Acrivos, Int J Multiphase Flow 1994, 20, 579.) with the curing model. The heat transfer, including the exothermic polymerization reaction, is also modeled. The result is a generalized Newtonian model that has viscosity as a function of temperature, cure and particle volume fraction. With x-ray computed tomography, we examine settling of the particulate phase in both flowing and quiescent curing systems and compare the experimental results to the model predictions. The model is also validated with temperature measurements. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011

Highly conductive polymers are difficult to process utilizing standard polymer approaches. This report describes a polymer composite loaded with a eutectic metal that is molten during melt processing along with a more traditional Nickel particulate filler. Conductivities over 300 S/cm were achieved, and 60 vol% metals loading was processable with a single screw extruder. The addition of the Nickel particulate was critical for maintaining eutectic dispersion. We anticipate that this approach will facilitate the implementation of conductive polymers into a broader variety of practical applications, due to the enhanced compatibility with standard polymer processing techniques such as extrusion, melt mixing, and resin transfer-molding operations.

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.

We are developing computational models to help understand manufacturing processes, final properties and aging of structural foam, polyurethane PMDI. Th e resulting model predictions of density and cure gradients from the manufacturing process will be used as input to foam heat transfer and mechanical models. BKC 44306 PMDI-10 and BKC 44307 PMDI-18 are the most prevalent foams used in structural parts. Experiments needed to parameterize models of the reaction kinetics and the equations of motion during the foam blowing stages were described for BKC 44306 PMDI-10 in the first of this report series (Mondy et al. 2014). BKC 44307 PMDI-18 is a new foam that will be used to make relatively dense structural supports via over packing. It uses a different catalyst than those in the BKC 44306 family of foams; hence, we expect that the reaction kineti cs models must be modified. Here we detail the experiments needed to characteriz e the reaction kinetics of BKC 44307 PMDI-18 and suggest parameters for the model based on these experiments. In additi on, the second part of this report describes data taken to provide input to the preliminary nonlinear visco elastic structural response model developed for BKC 44306 PMDI-10 foam. Wemore » show that the standard cu re schedule used by KCP does not fully cure the material, and, upon temperature elevation above 150 o C, oxidation or decomposition reactions occur that alter the composition of the foam. These findings suggest that achieving a fully cured foam part with this formulation may be not be possible through therma l curing. As such, visco elastic characterization procedures developed for curing thermosets can provide only approximate material properties, since the state of the material continuously evolves during tests.« less

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.

We are developing computational models to elucidate the expansion and dynamic filling process of a polyurethane foam, PMDI. The polyurethane of interest is chemically blown, where carbon dioxide is produced via the reaction of water, the blowing agent, and isocyanate. The isocyanate also reacts with polyol in a competing reaction, which produces the polymer. Here we detail the experiments needed to populate a processing model and provide parameters for the model based on these experiments. The model entails solving the conservation equations, including the equations of motion, an energy balance, and two rate equations for the polymerization and foaming reactions, following a simplified mathematical formalism that decouples these two reactions. Parameters for the polymerization kinetics model are reported based on infrared spectrophotometry. Parameters describing the gas generating reaction are reported based on measurements of volume, temperature and pressure evolution with time. A foam rheology model is proposed and parameters determined through steady-shear and oscillatory tests. Heat of reaction and heat capacity are determined through differential scanning calorimetry. Thermal conductivity of the foam as a function of density is measured using a transient method based on the theory of the transient plane source technique. Finally, density variations of the resulting solidmore » foam in several simple geometries are directly measured by sectioning and sampling mass, as well as through x-ray computed tomography. These density measurements will be useful for model validation once the complete model is implemented in an engineering code.« less

Computational fluid mechanics techniques for examining free surface problems in two-dimensional form are now well established. Extending these methods to three dimensions requires a reconsideration of some of the difficult issues from two-dimensional problems as well as developing new formulations to handle added geometric complexity. This paper presents a new finite element formulation for handling three-dimensional free surface problems with a boundary-fitted mesh and full Newton iteration, which solves for velocity, pressure, and mesh variables simultaneously. A boundary-fitted, pseudo-solid approach is used for moving the mesh, which treats the interior of the mesh as a fictitious elastic solid that deforms in response to boundary motion. To minimize mesh distortion near free boundary under large deformations, the mesh motion equations are rotated into normal and tangential components prior to applying boundary conditions. The Navier–Stokes equations are discretized using a Galerkin–least square/pressure stabilization formulation, which provides good convergence properties with iterative solvers. The result is a method that can track large deformations and rotations of free surface boundaries in three dimensions. The method is applied to two sample problems: solid body rotation of a fluid and extrusion from a nozzle with a rectangular cross-section. The extrusion example exhibits a variety of free surface shapes that arise from changing processing conditions. Copyright © 2000 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

An implicit, pseudo-solid domain mapping technique is described that facilitates finite element analysis of free and moving boundary problems. The technique is based on an implicit, full-Newton strategy, free of restrictions on mesh structure; this leads to many advantages over existing domain mapping techniques. The fully coupled approach using Newton's method is particularly effective for problems with strong coupling between the internal bulk physics and the governing physics at unknown free boundary locations. It is also useful when the distinguishing conditions which constrain the free boundary shape provide only an implicit dependence on the boundary location. Unstructured meshes allow for efficient resolution of internal and boundary layers and other regions of strong local variations in the solution and they also reduce the amount of user interaction required to define a problem since the meshes may be generated automatically. The technique is readily applied to steady or transient problems in complex geometries of two and three dimensions. Examples are shown that include free and moving boundary problems from solidification and capillary hydrodynamics.

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.

A thin flow-focusing microfluidic channel is evaluated for generating monodisperse liquid droplets. The microfluidic device is used in its native state, which is hydrophilic, or treated with OTS to make it hydrophobic. Having both hydrophilic and hydrophobic surfaces allows for creation of both oil-in-water and water-in-oil emulsions, facilitating a large parameter study of viscosity ratios (droplet fluid/continuous fluid) ranging from 0.05 to 96 and flow rate ratios (droplet fluid/continuous fluid) ranging from 0.01 to 2 in one geometry. The hydrophilic chip provides a partially-wetting surface (contact angle less than 90°) for the inner fluid. This surface, combined with the unusually thin channel height, promotes a flow regime where the inner fluid wets the top and bottom of the channel in the orifice and a stable jet is formed. Through confocal microscopy, this fluid stabilization is shown to be highly influenced by the contact angle of the liquids in the channel. Non-wetting jets undergo breakup and produce drops when the jet is comparable to or smaller than the channel thickness. In contrast, partially-wetting jets undergo breakup only when they are much smaller than the channel thickness. Drop sizes are found to scale with a modified capillary number based on the total flow rate regardless of wetting behavior.

The application of the finite element method to multiphase flow problems with interphase mass and heat transfer is described. A general forinulation is used that determines the position of the interfacial boundary and allows for multiple solvents, differential volatilities and concentration- and temperature-dependent thermophysical properties. Species phase change and the dramatic volume change that acompanies interphase mass transfer make implementation of the theory challening, since these events lead to discontinuous velocities and concentrations at phase boundaries. These discontinuities are especially large in processes involving rapid evaporation or condensation. As examples we examine the effects of rapid drying on film and fibre formation of sol--gel materials, which are often laden with volatile species.

Multilayer coextrusion has become a popular commercial process for producing complex polymeric products from soda bottles to reflective coatings. A numerical model of a multilayer coextrusion process is developed based on a finite element discretization and two different free-surface methods, an arbitrary-Lagrangian-Eulerian (ALE) moving mesh implementation and an Eulerian level set method, to understand the moving boundary problem associated with the polymer-polymer interface. The goal of this work is to have a numerical capability suitable for optimizing and troubleshooting the coextrusion process, circumventing flow instabilities such as ribbing and barring, and reducing variability in layer thickness. Though these instabilities can be both viscous and elastic in nature, for this work a generalized Newtonian description of the fluid is used. Models of varying degrees of complexity are investigated including stability analysis and direct three-dimensional finite element free surface approaches. The results of this work show how critical modeling can be to reduce build test cycles, improve material choices, and guide mold design.

The 4:1 axisymmetric contraction problems for Maxwell and Oldroyd-B fluids are solved using cubic finite-element interpolation for the stress field. Comparisons are made of results obtained using the explicitly elliptic momentum equation (EEME) and the inconsistent Petrov-Galerkin streamline upwinding method (SU) on unstructured triangular meshes and on structured quadrilateral meshes. Most solutions are confirmed by calculation on finer meshes, and the critical Deborah number may increase (for triangular meshes) or decrease slightly (for quadrilateral meshes) as the element size decreases.