A Computational Study on Novel Runner Extension Designs via 3D Sand-Printing to Improve Casting Performance

2021 ◽  
Author(s):  
Ryan Stebbins ◽  
Philip King ◽  
Guha Manogharan
Keyword(s):  
Computational Study ◽  
Metal Flow ◽  
Flow Characteristics ◽  
Air Entrainment ◽  
Sand Casting ◽  
Cfd Modeling ◽  
Reflected Waves ◽  
Casting Quality ◽  
Surge Control ◽  
Entrained Air

Abstract 3D sand-printing (3DSP) has become more popular in foundry applications due to its ability to create complex gating geometries. Since filling related defects, like entrained air and bi-films, are most commonly caused by high melt velocity and turbulence, recent 3DSP research has focused on designing gating systems to reduce melt velocity and turbulence. However, there have been no reported efforts on advancements in the design of runner extensions as a method to improve casting quality, despite its tremendous impact on the initial metal flow characteristics. The ability to fabricate 3DSP molds allow for unique runner extension designs that aid in improving casting quality. This paper is the first study known to the authors that investigates novel 3D runner extension designs to determine the most effective design for reducing sand casting defects. Based on literature review and design principles developed for 3D sprue geometries, six different runner extensions were studied using Computational Fluid Dynamics (CFD) modeling for foundry pouring conditions. The designs were evaluated on their ability to reduce defects like entrained air and bubbles, as well as to prevent backflow and reflected waves. An unweighted ranking matrix and comparison matrix against the control (straight runner extension) has been established based on air entrainment, tracer, voids, and extension volume. The results showed that the by-pass principal and surge control systems are effective at reducing reflective waves and controlling the ingate flow. The novel 3D duckbill trap extension proposed in this study had the best overall performance based on a 16% reduction in entrained air and a 71% reduction in void particles in the casting volume compared to the control extension design. These results provide a framework to further optimize runner extensions, utilize the advantages of 3D Sand-Printing technology to improve mechanical strength and reduce filling defects in sand-casting.

The effects of flue-wall design modifications on combustion and flow characteristics of an aluminum anode baking furnace-CFD modeling

2018 ◽  
Vol 230 ◽  
pp. 207-219 ◽  
Author(s):  
Abdul Raouf Tajik ◽  
Tariq Shamim ◽  
Mouna Zaidani ◽  
Rashid K. Abu Al-Rub
Keyword(s):  
Flow Characteristics ◽  
Cfd Modeling ◽  
Aluminum Anode

scholarly journals Investigation of Flow through a Labyrinth Seal

2021 ◽  
Vol 13 (2) ◽  
pp. 51-58
Author(s):  
Marius ENACHE ◽  
Razvan CARLANESCU ◽  
Andreea MANGRA ◽  
Florin FLOREAN ◽  
Radu KUNCSER
Keyword(s):  
Gas Turbines ◽  
Flow Characteristics ◽  
Labyrinth Seal ◽  
Cfd Modeling ◽  
Gas Temperature ◽  
Continuous Increase ◽  
Seal Design ◽  
Air Temperatures ◽  
Flow Through ◽  
Gas Leaks

Growing performance requirements for gas turbines have led to a continuous increase in gas temperature and pressure ratios. Together with the resulting increase in cooling flows, this requires more and more minimization and control of internal gas leaks. To meet future performance goals, the application of a new seal design and an improved understanding of leakage flow characteristics are of particular importance. The air mass flow through a labyrinth seal designed for a low-pressure turbine has been determined both through analytical calculus and CFD modeling. Different radial clearances and different air temperatures have been considered. In the next stage, the results will be validated through experiments.

scholarly journals Adverse Hemodynamic Conditions Associated with Mechanical Heart Valve Leaflet Immobility

2018 ◽  
Vol 5 (3) ◽  
pp. 74 ◽  
Author(s):  
Fardin Khalili ◽  
Peshala Gamage ◽  
Richard Sandler ◽  
Hansen Mansy
Keyword(s):  
Heart Valve ◽  
Heart Valves ◽  
Computational Study ◽  
Cell Damage ◽  
Mechanical Heart Valve ◽  
Flow Characteristics ◽  
Maximal Velocity ◽  
Valve Dysfunction ◽  
Promising Tool ◽  
Artificial Heart Valves

Artificial heart valves may dysfunction, leading to thrombus and/or pannus formations. Computational fluid dynamics is a promising tool for improved understanding of heart valve hemodynamics that quantify detailed flow velocities and turbulent stresses to complement Doppler measurements. This combined information can assist in choosing optimal prosthesis for individual patients, aiding in the development of improved valve designs, and illuminating subtle changes to help guide more timely early intervention of valve dysfunction. In this computational study, flow characteristics around a bileaflet mechanical heart valve were investigated. The study focused on the hemodynamic effects of leaflet immobility, specifically, where one leaflet does not fully open. Results showed that leaflet immobility increased the principal turbulent stresses (up to 400%), and increased forces and moments on both leaflets (up to 600% and 4000%, respectively). These unfavorable conditions elevate the risk of blood cell damage and platelet activation, which are known to cascade to more severe leaflet dysfunction. Leaflet immobility appeared to cause maximal velocity within the lateral orifices. This points to the possible importance of measuring maximal velocity at the lateral orifices by Doppler ultrasound (in addition to the central orifice, which is current practice) to determine accurate pressure gradients as markers of valve dysfunction.

scholarly journals Computational study on the aerodynamics of a long-shrouded contra-rotating rotor in hover

2019 ◽  
Vol 11 ◽  
pp. 175682931983368
Author(s):  
Chao Huo ◽  
Peng Lv ◽  
Anbang Sun
Keyword(s):  
Flow Field ◽  
Opposite Direction ◽  
Computational Study ◽  
Flow Characteristics ◽  
The Other ◽  
Complex Flow ◽  
Sliding Mesh ◽  
Global Performance ◽  
Mesh Method ◽  
Downstream Flow

This paper aims to investigate the aerodynamics including the global performance and flow characteristics of a long-shrouded contra-rotating rotor by developing a full 3D RANS computation. Through validations by current experiments on the same shrouded contra-rotating rotor, the computation using sliding mesh method and the computational zone with an extended nozzle downstream flow field effectively works; the time-averaged solution of the unsteady computation reveals that more uniform flow presents after the downstream rotor, which implies that the rear rotor rotating at opposite direction greatly compensates and reduces the wake; the unsteady computations further explore the flow field throughout the whole system, along the span and around blade tips. Complex flow patterns including the vortices and their interactions are indicated around the blade roots and tips. For further identifying rotor configurations, the rotor–rotor distance and switching two rotor speeds were studied. The computation reveals that setting the second rotor backwards decreases the wake scale but increases its intensity in the downstream nozzle zone. However, for the effect of switching speeds, computations cannot precisely solve the flow when the rear rotor under the windmill because of the upstream rotor rotating much faster than the other one. All the phenomena from computations well implement the experimental observations.

Air Entrainment and Bubble Generation by a Hydrofoil in a Turbulent Channel Flow

2019 ◽  
Author(s):  
Ichiro Kumagai ◽  
Kakeru Taguchi ◽  
Chiharu Kawakita ◽  
Tatsuya Hamada ◽  
Yuichi Murai
Keyword(s):  
Channel Flow ◽  
Flow Rate ◽  
High Speed ◽  
Air Flow ◽  
Air Entrainment ◽  
Air Bubbles ◽  
Air Flow Rate ◽  
Bubble Generation ◽  
Gas Liquid Flow ◽  
Entrained Air

Abstract Air entrainment and bubble generation by a hydrofoil bubble generator for ship drag reduction have been investigated using a small high-speed channel tunnel with the gap of 20 mm in National Maritime Research Institute (NMRI). A hydrofoil (NACA4412, chord length = 40 mm) was installed in the channel and an air induction pipe was placed above the hydrofoil. The flow rate of the entrained air was quantitatively measured by thermal air flow sensors at the inlet of the air induction pipe. The gas-liquid flow around the hydrofoil was visualized by a backlight method and recorded by a high-speed video camera. As the flow velocity in the channel increased, the negative pressure generated above the suction side of the hydrofoil lowered the hydrostatic pressure in the channel, then the atmospheric air was entrained into the channel flow. The entrained air was broken into small air bubbles by the turbulent flow in the channel. The threshold of air entrainment, the air flow rate, and gas-liquid flow pattern depends on Reynolds number, angle of attack (AOA), and hydrofoil type. We identified at least three modes of air entrainment behavior: intermittent air entrainment, stable air entrainment, and air entrainment with a ventilated cavity. At high flow speed in our experimental condition (9 m/s), a large volume of air bubbles was generated by this hydrofoil system (e.g. air flow rate was 50 l/min for NACA4412 at AOA 16 degrees), which has a high potential to reduce ship drag.

scholarly journals Numerical investigation of flow characteristics over stepped spillways

2020 ◽  
Author(s):  
Aytaç Güven ◽  
Ahmed Hussein Mahmood
Keyword(s):  
Numerical Model ◽  
Turbulent Flow ◽  
Flow Characteristics ◽  
Air Entrainment ◽  
Stepped Spillway ◽  
Stepped Spillways ◽  
Entrainment Velocity ◽  
Fluid Flow Characteristics ◽  
3D Package ◽  
Good Agreement

Abstract Spillways are constructed to evacuate the flood discharge safely not to let the flood wave overtop the dam body. There are different types of spillways, ogee type being the conventional one. Stepped spillway is an example of nonconventional spillways. The turbulent flow over stepped spillway was studied numerically by using the Flow-3D package. Different fluid flow characteristics such as longitudinal flow velocity, temperature distribution, density and chemical concentration can be well simulated by Flow-3D. In this study, the influence of slope changes on flow characteristics such as air entrainment, velocity distribution and dynamic pressures distribution over the stepped spillway was modelled by Flow-3D. The results from the numerical model were compared with the experimental study done by others in the literature. Two models of the stepped spillway with different discharge for each model was simulated. The turbulent flow in the experimental model was simulated by the Renormalized Group (RNG) turbulence scheme in the numerical model. A good agreement was achieved between the numerical results and the observed ones, which were exhibited in terms of graphics and statistical tables.

scholarly journals The effect of nozzle diameter on the flow characteristics of air entrainment phenomenon in vertical plunging jets

2019 ◽  
Author(s):  
Warjito ◽  
Budiarso ◽  
Irvanda Adam Pramono ◽  
Mario Laurensus Samosir ◽  
Dendy Adanta
Keyword(s):  
Flow Characteristics ◽  
Air Entrainment ◽  
Nozzle Diameter ◽  
Plunging Jets

Effect of Entrained Air on Cavitation Damage

1974 ◽  
Vol 1 (1) ◽  
pp. 97-107 ◽  
Author(s):  
S. O. Russell ◽  
G. J. Sheehan
Keyword(s):  
High Velocity ◽  
Additional Data ◽  
Air Entrainment ◽  
Test Facility ◽  
Hydraulic Structures ◽  
Cavitation Damage ◽  
Water Flows ◽  
Velocity Flow ◽  
High Head ◽  
Entrained Air

When water flows at high velocity over a surface, quite small boundary irregularities may trigger cavitation which can, in turn, cause extensive damage. Concrete surfaces downstream from high head outlet gates are particularly vulnerable to cavitation damage.Operating experience and previous experimental work suggest that cavitation damage can be greatly reduced and, in some cases, eliminated by entrained air in the water.Experiments were carried out with a special high head test facility in Vancouver to obtain additional data on the effect of air entrainment. These tests confirmed its effectiveness. In this paper, previous evidence is reviewed, the experiments are described, and the results presented. Finally suggestions are made about the design of hydraulic structures which involve high velocity flow.

scholarly journals Universal mechanism for air entrainment during liquid impact

2016 ◽  
Vol 789 ◽  
pp. 708-725 ◽  
Author(s):  
Maurice H. W. Hendrix ◽  
Wilco Bouwhuis ◽  
Devaraj van der Meer ◽  
Detlef Lohse ◽  
Jacco H. Snoeijer
Keyword(s):  
Experimental Data ◽  
Air Entrainment ◽  
Stokes Number ◽  
Liquid Pool ◽  
Boundary Integral ◽  
Boundary Integral Method ◽  
Rigid Sphere ◽  
Entrained Air ◽  
The Impact ◽  
Universal Mechanism

When a millimetre-sized liquid drop approaches a deep liquid pool, both the interface of the drop and the pool deform before the drop touches the pool. The build-up of air pressure prior to coalescence is responsible for this deformation. Due to this deformation, air can be entrained at the bottom of the drop during the impact. We quantify the amount of entrained air numerically, using the boundary integral method for potential flow for the drop and the pool, coupled to viscous lubrication theory for the air film that has to be squeezed out during impact. We compare our results with various experimental data and find excellent agreement for the amount of air that is entrapped during impact onto a pool. Next, the impact of a rigid sphere onto a pool is numerically investigated and the air that is entrapped in this case also matches with available experimental data. In both cases of drop and sphere impact onto a pool the numerical air bubble volume $V_{b}$ is found to be in agreement with the theoretical scaling $V_{b}/V_{drop/sphere}\sim \mathit{St}^{-4/3}$, where $\mathit{St}$ is the Stokes number. This is the same scaling as has been found for drop impact onto a solid surface in previous research. This implies a universal mechanism for air entrainment for these different impact scenarios, which has been suggested in recent experimental work, but is now further elucidated with numerical results.

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