MACHINE LEARNING FOR THE DEVELOPMENT OF DATA DRIVEN TURBULENCE CLOSURES IN COOLANT SYSTEMS

This work shows the application of Gene Expression Programming to augment RANS turbulence closure modelling, for flows through complex geometry designed for additive manufacturing. Specifically, for the design of optimised internal cooling channels in turbine blades. One of the challenges in internal cooling design is the heat transfer accuracy of the RANS formulation in comparison to higher fidelity methods, which are still not used in design on account of their computational cost. However, high fidelity data can be extremely valuable for improving current lower fidelity models and this work shows the application of data driven approaches to develop turbulence closures for an internally ribbed duct. Different approaches are compared and the results of the improved model are illustrated; first on the same geometry, and then for an unseen predictive case. The work shows the potential of using data driven models for accurate heat transfer predictions even in non-conventional configurations and indicates the ability of closures learnt from complex flow cases to adapt successfully to unseen test cases.

Determination of the Near-Wellbore Pressure Drop for Dual Casing in Hydraulic Fracturing and Refracturing Applications

Due to the increases in completion costs demand for production improvements, fracturing through double casing in upper reservoirs for mature wells and refracturing early stimulated wells to change the completion design, has become more and more popular. One of the most common technologies used to re-stimulate previously fracked wells, is to run a second, smaller casing or tubular inside of the existing and already perforated pipes of the completed well. The new inner and old outer casing are isolated from each other by a cement layer, which prevents any hydraulic communication between the pre-existing and new perforations, as well as between adjacent new perforations. For these smaller inner casing diameters, specially tailored and designed re-fracturing perforation systems are deployed, which can shoot casing entrance holes of very similar size through both casings, nearly independent of the phasing and still capable of creating tunnels reaching beyond the cement layer into the natural rock formation. Although discussing on the API RP-19B section VII test format has recently been initiated and many companies have started to test multiple casing scenarios and charge performance, not much is known about the complex flow through two radially aligned holes in dual casings. In the paper we will look in detail at the parameters which influence the flow, especially the Coefficient of Discharge of such a dual casing setup. We will evaluate how much the near wellbore pressure drop is affected by the hole's sizes in the first and second casing, respectively the difference between them and investigate how the cement layer is influenced by turbulences, which might build up in the annulus. The results will enhance the design and provide a better understanding of fracturing or refracturing through double casings for hydraulic fracturing specialists and both operation and services companies.

Analysis of Thermal Performances in a Ventilated Room Using LBM-MRT: Effect of a Porous Separation

This article demonstrates the feasibility of porous separation on the performance of displacement ventilation in a rectangular enclosure. A jet of fresh air enters the cavity through an opening at the bottom of the left wall and exits through an opening at the top of the right wall. The porous separation is placed in the center of the cavity and its height varies between 0.2 and 0.8 with three values of thickness, 0.1, 0.2, and 0.3. The heat transfer rate was calculated for different intervals of Darcy (10−6 ≤ Da ≤ 10), Rayleigh (10 ≤ Ra ≤ 106), and Reynolds (50 ≤ Re ≤ 500) numbers. The momentum and the energy equations were solved by the lattice Boltzmann method with multiple relaxation times (LB-MRT). Schemes D2Q9 and D2Q5 were chosen for the velocity and temperature fields, respectively. For porous separation, the generalized Darcy–Brinkman–Forchheimer model was adopted. It is represented by a term added in the standard LB equations. For the dynamic domain, numerical simulations revealed complex flow structures depending on all control parameters. The results showed that the thermal field, mainly in the second compartment, is very dependent on the size and permeability of the porous separation. However, they have no influence on the transfer rate.

Numerical Simulation of Solids Conveying in Grooved Feed Sections of Single Screw Extruders

For plastic processing extruders with grooved feed sections, the design of the feed section by means of analytical calculation models can be useful to reduce experimental costs. However, these models include assumptions and simplifications that can significantly decrease the prediction accuracy of the throughput due to complex flow behavior. In this paper, the accuracy of analytical modeling for calculating the throughput in a grooved barrel extruder is verified based on a statistical design of experiments. A special focus is placed on the assumptions made in the analytics of a backpressure-independent throughput, the assumption of a block flow and the differentiation of the solids conveying into different conveying cases. Simulative throughput tests with numerical simulation software using the discrete element method, as well as experimental throughput tests, serve as a benchmark. Overall, the analytical modeling already shows a very good calculation accuracy. Nevertheless, there are some outliers that lead to larger deviations in the throughput. The model predominantly overestimates the throughputs, whereby the origin of these deviations is often in the conveying angle calculation. Therefore, a regression-based correction factor for calculating the conveying angle is developed and implemented.

Investigation of Flowback Behaviours in Hydraulically Fractured Shale Gas Well Based on Physical Driven Method

Due to the complex microscope pore structure of shale, large-scale hydraulic fracturing is required to achieve effective development, resulting in a very complicated fracturing fluid flowback characteristics. The flowback volume is time-dependent, whereas other relevant parameters, such as the permeability, porosity, and fracture half-length, are static. Thus, it is very difficult to build an end-to-end model to predict the time-dependent flowback curves using static parameters from a machine learning perspective. In order to simplify the time-dependent flowback curve into simple parameters and serve as the target parameter of big data analysis and flowback influencing factor analysis, this paper abstracted the flowback curve into two characteristic parameters, the daily flowback volume coefficient and the flowback decreasing coefficient, based on the analytical solution of the seepage equation of multistage fractured horizontal Wells. Taking the dynamic flowback data of 214 shale gas horizontal wells in Weiyuan shale gas block as a study case, the characteristic parameters of the flowback curves were obtained by exponential curve fittings. The analysis results showed that there is a positive correlation between the characteristic parameters which present the characteristics of right-skewed distribution. The calculation formula of the characteristic flowback coefficient representing the flowback potential was established. The correlations between characteristic flowback coefficient and geological and engineering parameters of 214 horizontal wells were studied by spearman correlation coefficient analysis method. The results showed that the characteristic flowback coefficient has a negative correlation with the thickness × drilling length of the high-quality reservoir, the fracturing stage interval, the number of fracturing stages, and the brittle minerals content. Through the method established in this paper, the shale gas flowback curve containing complex flow mechanism can be abstracted into simple characteristic parameters and characteristic coefficients, and the relationship between static data and dynamic data is established, which can help to establish a machine learning method for predicting the flowback curve of shale gas horizontal wells.

Numerical Study on Flow and Heat Transfer Characteristics of Trapezoidal Printed Circuit Heat Exchanger

Printed circuit heat exchanger (PCHE) is a promising regenerative device in the sCO2 power cycle, with the advantages of a large specific surface area and compact structure. Its tiny and complex flow channel structure brings enhanced heat transfer performance, while increasing pressure drop losses. It is, thus, important to balance heat transfer and flow resistance performances with the consideration of sCO2 as the working agent. Herein, three-dimensional models are built with a full consideration of fluid flow and heat transfer fields. A trapezoidal channel is developed and its thermal–hydraulic performances are compared with the straight, the S-shape, and the zigzag structures. Nusselt numbers and the Fanning friction factors are analyzed with respect to the changes in Reynolds numbers and structure geometric parameters. A sandwiched structure that couples two hot channels with one cold channel is further designed to match the heat transfer capacity and the velocity of sCO2 flows between different sides. Through this novel design, we can reduce the pressure drop by 75% and increase the regenerative efficiency by 5%. This work can serve as a solid reference for the design and applications of PCHEs.

Investigating the Level of Fidelity of an Actuator Line Model in Predicting Loads and Deflections of Rotating Blades under Uniform Free-Stream Flow

In this paper, the accuracy of an in-house Actuator Line (AL) model is tested on aeroelastic simulations of a Wind Turbine (WT) rotor and a helicopter Main Rotor (MR) under uniform free-stream flow. For the scope of aeroelastic analyses, the AL model is coupled with an in-house multibody dynamics code in which the blades are modeled as beams. The advantage from the introduction of CFD analysis in rotorcraft aeroelasticity is related to its capability to account in detail for the interaction of the rotor wake with the boundary layer developed on the surrounding bodies. This has proven to be of great importance in order to accurately estimate the aerodynamic forces and thus the corresponding structural loads and deflections of the blades. In wind turbine applications, a good example of the above is the rotor/ground interaction. In helicopter configurations, the interaction of MR with the ground or the fuselage and the interaction of tail rotor with the duct in fenestron configurations are typical examples. Furthermore, CFD aerodynamic analysis is an obvious modeling option in which the above mentioned asset can be combined with the consideration of the mutual interaction of the rotor with the ambient turbulence. A WT rotor operating inside the atmospheric boundary layer under turbulent free-stream flow is such a case. In the paper, AL results are compared against Blade Element Momentum (BEM) and Lifting Line (LL) model results in the case of the WT, whereas LL and measured data are considered in the helicopter cases. Blade loads and deflections are mainly compared as azimuthal variations. In the helicopter MR cases, where comparison is made against experimental data, harmonic analysis of structural loads is shown as well. Overall, AL proves to be as reliable as LL in the canonical cases addressed in this paper in terms of loads and deflections predictions. Therefore, it can be trusted in more complex flow conditions where viscous effects are pronounced.

Characterization of the Microflow Through 3D Synthetic Niche Microenvironments Hosted in a Millifluidic Bioreactor

Background: Development of new medicines is a lengthy process with high risk of failure since drug efficacy measured in vitro is difficult to confirm in vivo. Intended to add a new tool aiding drug discovery, the MOAB-NICHOID device was developed: a miniaturized optically accessible bioreactor (MOAB) housing the 3D engineered scaffold NICHOID. The aim of our study was to characterize the microflow through the 3D nichoid microenvironment hosted in the MOAB-NICHOID device.Methods: We used computational fluid dynamics (CFD) simulations to compute the flow field inside a very fine grid resembling the scaffold microenvironment.Results: The microflow inside the multi-array of nichoid blocks is fed and locally influenced by the mainstream flow developed in the perfusion chamber of the device. Here we have revealed a low velocity, complex flow field with secondary, backward, or local recirculation micro-flows induced by the intricate architecture of the nichoid scaffold.Conclusion: Knowledge of the microenvironment inside the 3D nichoids allows planning of cell experiments, to regulate the transport of cells towards the scaffold substrate during seeding or the spatial delivery of nutrients and oxygen which affects cell growth and viability.

Numerical Investigation of Segregation Evolution during the Vacuum Arc Remelting Process of Ni-Based Superalloy Ingots

Segregation defects greatly affect the service performance and working life of castings during the vacuum arc remelting (VAR) process. However, the corresponding research on the prediction of segregation defects is still not comprehensive. Through considering the influence of water-cooled crucible on the electromagnetic field inside an ingot, a full-scale model for the comprehensive prediction of freckles and macrosegregation defects during the VAR process is developed in this paper. The macroscopic solute transport phenomenon and the segregation behavior of Ni-5.8 wt% Al-15.2 wt% Ta alloy are predicted. The results indicate that the freckles are mainly concentrated in the lower region of the ingot. With the growth of the ingot, the solute enrichment channels gradually develop into solute enrichment regions, and the channel segregation evolves into macrosegregation. The Lorentz force mainly affects the flow pattern at the top of the molten pool, while the complex flow of multiple vortices is dominated by thermosolutal buoyancy. The maximum and minimum relative segregation ratio inside the ingot can reach 290% and −90%, respectively, and the positive segregation region accounts for about 79% of the total volume. This paper provides a new perspective for understanding the segregation behavior inside the ingot by studying the segregation evolution during the VAR process.