Fluid-solid coupling numerical simulation of charge process in variable-mass thermodynamic system

Abstract： A joint solution model of variabk：-mass flow in two-phase region and fluid-solid coupling heat transfer, concerned about the charge process of variable-mass thermodynamic system, is built up and calculated by the finite element method （FEM）. The results are basically consistent with relative experimental data. The calculated average heat transfer coefficient reaches 1.7~105 W/（m2. K）. When the equal percentage valve is used, the system needs the minimum requirements of valve control, but brings the highest construction cost. With the： decrease of initial steam pressure, the heat transfer intensity also weakens but the steam flow increases. With the initial water filling coefficient increasing or the temperature of steam supply decreasing, the amount of accumulative steam flow increases with the growth of steam pressure. When the pressure of steam supply drops, the steam flow gradient increases during the maximum opening period of control valve, and causes the maximum steam flow to increase.

Numerical simulation study on the mold strength of magnetic mold casting based on a coupled electromagnetic-structural method

The properties of the magnetic mold in magnetic mold casting directly determine the quality of the final cast parts.In this study,the magnetic mold properties in magnetic mold casting,were studied utilizing a coupled electromagnetic-structural method through numerical simulation.This study investigated key factors including equivalent stress,the distribution of tensile and compressive stresses,and the area ratio of tensile stress.It compared molds made entirely of magnetic materials with those made partially of magnetic materials.Simulation results indicate that as current increases from 4 A to 8 A,both the initial magnetic mold and the material-replaced magnetic mold initially show an increasing trend in equivalent stress,tensile-compressive stress,and the area ratio of tensile stress,peaking at 6 A before declining.After material replacement,the area ratio of tensile stress at 6 A decreases to 19.84%,representing a reduction of 29.72%.Magnetic molds comprising a combination of magnetic and non-magnetic materials exhibit sufficient strength and a reduced area ratio of tensile stress compared to those made entirely from magnetic materials.This study provides valuable insights for optimizing magnetic mold casting processes and offers practical guidance for advancing the application of magnetic molds.

Coupled Numerical Simulation of Electromagnetic and Flow Fields in a Magnetohydrodynamic Induction Pump

Magnetohydrodynamic(MHD)induction pumps are contactless pumps able to withstand harsh environments.The rate of fluid flow through the pump directly affects the efficiency and stability of the device.To explore the influence of induction pump settings on the related delivery speed,in this study,a numerical model for coupled electromagnetic and flow field effects is introduced and used to simulate liquid metal lithium flow in the induction pump.The effects of current intensity,frequency,coil turns and coil winding size on the velocity of the working fluid are analyzed.It is shown that the first three parameters have a significant impact,while changes in the coil turns have a negligible influence.The maximum increase in working fluid velocity within the pump for the parameter combination investigated in this paper is approximately 618%.As the frequency is increased from 20 to 60 Hz,the maximum increase in the mean flow rate of the working fluid is approximately 241%.These research findings are intended to support the design and optimization of these devices.

Numerical Simulation and Experimental Study of Heat-fluid-solid Coupling of Double Flapper-nozzle Servo Valve

The double flapper-nozzle servo valve is widely used to launch and guide the equipment. Due to the large instantaneous flow rate of servo valve working under specific operating conditions, the temperature of servo valve would reach 120℃ and the valve core and valve sleeve deform in a short amount of time. So the control precision of servo valve significantly decreases and the clamping stagnation phenomenon of valve core appears. In order to solve the problem of degraded control accuracy and clamping stagnation of servo valve under large temperature difference circumstance, the numerical simulation of heat-fluid-solid coupling by using finite element method is done. The simulation result shows that zero position leakage of servo valve is basically impacted by oil temperature and change of fit clearance. The clamping stagnation is caused by warpage-deformation and fit clearance reduction of the valve core and valve sleeve. The distribution roles of the temperature and thermal-deformation of shell, valve core and valve sleeve and the pressure, velocity and temperature field of flow channel are also analyzed. Zero position leakage and electromagnet＇s current when valve core moves in full-stroke are tested using Electro-hydraulic Servo-valve Characteristic Test-bed of an aerospace sciences and technology corporation. The experimental results show that the change law of experimental current at different oil temperatures is roughly identical to simulation current. The current curve of the electromagnet is smooth when oil temperature is below 80℃, but the amplitude of current significantly increases and the hairy appears when oil temperature is above 80℃. The current becomes smooth again after the warped valve core and valve sleeve are reground. It indicates that clamping stagnation is caused by warpage-deformation and fit clearance reduction of valve core and valve sleeve. This paper simulates and tests the heat-fluid-solid coupling of double flapper-nozzle servo valve, and the obtained results provide the reference value for the design of double flapper-nozzle force feedback servo valve.

Simulation of Underground Reservoir Stability of Pumped Storage Power Station Based on Fluid-Structure Coupling

Based on global initiatives such as the clean energy transition and the development of renewable energy,the pumped storage power station has become a new and significant way of energy storage and regulation,and its construction environment is more complex than that of a traditional reservoir.In particular,the stability of the rock strata in the underground reservoirs is affected by the seepage pressure and rock stress,which presents some challenges in achieving engineering safety and stability.Using the advantages of the numerical simulation method in dealing deal with nonlinear problems in engineering stability,in this study,the stability of the underground reservoir of the Shidangshan(SDS)pumped storage power station was numerically calculated and quantitatively analyzed based on fluid-structure coupling theory,providing an important reference for the safe operation and management of the underground reservoir.First,using the COMSOL software,a suitablemechanicalmodel was created in accordance with the geological structure and project characteristics of the underground reservoir.Next,the characteristics of the stress field,displacement field,and seepage field after excavation of the underground reservoir were simulated in light of the seepage effect of groundwater on the nearby rock of the underground reservoir.Finally,based on the construction specifications and Molar-Coulomb criterion,a thorough evaluation of the stability of the underground reservoir was performed through simulation of the filling and discharge conditions and anti-seepage strengthening measures.The findings demonstrate that the numerical simulation results have a certain level of reliability and are in accordance with the stress measured in the project area.The underground reservoir excavation resulted in a maximum displacement value of the rock mass around the caverns of 3.56 mm in a typical section,and the safety coefficient of the parts,as determined using the Molar-Coulomb criterion,was higher than 1,indicating that the project as a whole is in a stable state.

Numerical simulation on fault water-inrush based on fluid-solid coupling theory

About 75% water-inrush accidents in China are caused by geological structure such as faults, therefore, it is necessary to investigate the water-inrush mechanism of faults to provide references for the mining activity above confined water. In this paper, based on the fluid-solid coupling theory, we built the stress-seepage coupling model for rock, then we combined with an example of water-inrush caused by fault, studied the water-inrush mechanism by using the numerical software COMSOL Mutiphysics, analyzed the change rule of shear stress, vertical stress, plastic area and water pressure for stope with a fault, and estimated the water-inrush risk at the different distances between working faces and the fault. The numerical simula- tion results indicate that： （1） the water-inrush risk will grow as the decrease of the distance between working face and the fault; （2） the failure mode of the rock in floor with fault is shear failure; （3） the rock between water-containing fault and working face failure is the reason for water-inrush.

Numerical simulation of aluminum holding furnace with fluid-solid coupled heat transfer

To predict three-dimensional temperature distribution of molten aluminum and its influencing factors inside an industrial aluminum holding furnace,a fluid-solid coupled method was presented.The fluid-solid coupled mathematics models of aluminum holding furnace in the premixed combustion processing were established based on mass conservation,moment conservation,momentum conservation,energy conservation and chemistry species conservation.Computational results agree well with the test data of the typical condition.The maximum combustion temperature is 1 850 K.The average temperature of the molten aluminum is 1 158 K,and the maximum temperature difference is about 240 K.The average temperature increases 0.3 ℃ while the temperature of combustion air increases 1 ℃.The optimal excess air ratio is 1.25-1.30.

Numerical simulation of compound media coupling mechanism of deep mining overburden strata

Aiming at the regularity of deep mining strata movement, through the application of plate theory and discrete medium theory in establishing the coupling model of the deep mining strata composite medium, the continuum media and the non-continuum media were coupled into the compound media giant system, and the stress of compound layer and strain coupling relationship were established. The accuracy of forecasting surface subsidence in deep mining conditions was improved. The deep mining was simulated through 3-D numerical value by the FLAC3D finite difference software, and the coupling relationship and coupling layer in the strata composite layer were analyzed. The results show that, under the deep mining condition, the coupling zone is in the position of coal seam roof with the thickness of 15-20 times, on which, the stress-strain has much difference on the coupling zone. Considering interlayer effect of coupling zone can improve the prediction precision of surface subsidence.

Numerical simulation research on dynamical variation of permeability of coal around roadway based on gas-solid coupling model for gassy coal

Due to the change of initial stress state caused by roadway excavation, the permeability of the coal body may be changed during the excavation process. In this paper, according to the different stress states, the coal around the roadway was divided into the seepage open zone, seepage orientation zone, seepage decay zone and original seepage zone along the radial direction of the roadway. The loaded gassy coal was treated as a viscoelastic and plastic softened medium, and the mechanical behaviors of the viscoelastic zone, plastic softened zone and broken zone around the roadway were analyzed with the consideration of the loading creep, softening and expansion effect of the gassy coal. According to the law of conservation of mass and the Darcy law, the flow-solid coupled model for the gas transportation of the coal around the roadway was established considering the dynamic evolution of the adsorption characteristics, porosity and permeability of the coal, and the simulation software COMSOL was utilized to numerically simulate the stress state and gas flow regularity around the coal, which provided meaningful reference for investigating the stability of the coal and rock around the roadway.

Non-Linear Numerical Simulation of Coal and Gas Outburst as a Coupling Instability Problem of Solid-Fluid Biphase Media

Based on the theory of continuum mechanics of multi-pbase media, a mathematical model and non-linear FEM equation of the coupling instability problem of solid-fluid biphase media for coal-methane outburst under finite deformation are established. The critical conditions of the surface instability are presented as the singularity of the total stiffness matrices of the coal body for coal-methaue outburst. That means the deformtion or the coal body emerges bifurcatiou phenomena. The numerical simulation of a typical outburst is made.

Fully coupled fluid-solid productivity numerical simulation of multistage fractured horizontal well in tight oil reservoirs

A mathematical model, fully coupling multiple porous media deformation and fluid flow, was established based on the elastic theory of porous media and fluid-solid coupling mechanism in tight oil reservoirs. The finite element method was used to determine the numerical solution and the accuracy of the model was verified. On this basis, the model was used to simulate productivity of multistage fractured horizontal wells in tight oil reservoirs. The results show that during the production of tight oil wells, the reservoir region close to artificial fractures deteriorated in physical properties significantly, e.g. the aperture and conductivity of artificial fractures dropped by 52.12% and 89.02% respectively. The simulations of 3000-day production of a horizontal well in tight oil reservoir showed that the predicted productivity by the uncoupled model had an error of 38.30% from that by the fully-coupled model. Apparently, ignoring the influence of fluid-solid interaction effect led to serious deviations of the productivity prediction results. The productivity of horizontal well in tight oil reservoir was most sensitive to the start-up pressure gradient, and second most sensitive to the opening of artificial fractures. Enhancing the initial conductivity of artificial fractures was helpful to improve the productivity of tight oil wells. The influence of conductivity, spacing, number and length of artificial fractures should be considered comprehensively in fracturing design. Increasing the number of artificial fractures unilaterally could not achieve the expected increase in production.

Numerical simulation of thermodynamics coupling in hot forming process of elliptical head used in power station

To reduce the time of getting an ideal elliptical heat used in power station through repairing and testing a die repeatedly according to experience,finite element software Deform-3D was used to research the simulation of deformation-heat transfer coupling in hot forming process of elliptical head with the size of Φ1200 mm ×100 mm. The variations of stress,stain,temperature,thickness and strain rate in forming process were gotten,and the forming quality was evaluated from roundness,thinning rate and thermal contraction. The results show that the maximum thinning rate of the elliptical head is 7. 31% ,it is close to the orthographic place; and the inner diam- eter obtained from simulation is 1200. 6 - 1202. 977 mm,it is in the range of inner diameter tolerance required; all the data fit well with the practical dimension data of processing head.

Numerical simulation of fixed bed reactor for oxidative coupling of methane over monolithic catalyst

A three-dimensional geometric model was set up for the oxidative coupling of methane(OCM) fixed bed reactor loaded with Na_3PO_4-Mn/SiO_2/cordierite monolithic catalyst,and an improved Stansch kinetic model was established to calculate the OCM reactions using the computational fluid dynamics method and Fluent software.The simulation conditions were completely the same with the experimental conditions that the volume velocity of the reactant is 80 ml·min^(-1) under standard state,the CH_4/O_2 ratio is 3 and the temperature and pressure is800 ℃ and 1 atm,respectively.The contour of the characteristic parameters in the catalyst bed was analyzed,such as the species mass fractions,temperature,the heat flux on side wall surface,pressure,fluid density and velocity.The results showed that the calculated values matched well with the experimental values on the conversion of CH4 and the selectivity of products(C_2H_6,C_2H_4,CO,CO_2 and H_2) in the reactor outlet with an error range of±4%.The mass fractions of CH_4 and O_2 decreased from 0.600 and 0.400 at the catalyst bed inlet to 0.445 and0.120 at the outlet,where the mass fractions of C_2H_6,C_2H_4,CO and CO_2 were 0.0245,0.0460,0.0537 and 0.116,respectively.Due to the existence of laminar boundary layer,the mass fraction contours of each species bent upwards in the vicinity of the boundary layer.The volume of OCM reaction was changing with the proceeding of reaction,and the total moles of products were greater than reactants.The flow field in the catalyst bed maintained constant temperature and pressure.The fluid density decreased gradually from 2.28 kg·m^(-3) at the inlet of the catalyst bed to 2.18 kg·m^(-3) at the outlet of the catalyst bed,while the average velocity magnitude increased from 0.108 m·s-1 to 0.120 m·s^(-1).

Numerical Simulation of Liquid-Solid Coupling in Multi-Angle Fractures in Pressure-Sensitive Reservoirs

This study clarifies the seepage characteristics of complex fractured pressure-sensitive reservoirs,and addresses a common technological problem,that is the alteration of the permeability degree of the reservoir bed(known to be responsible for changes in the direction and velocity of fluid flows between wells).On the basis of a new pressuresensitive equation that considers the fracture directional pressure-sensitive effect,an oil-gas-water three-phase seepage mathematical model is introduced,which can be applied to pressure-sensitive,full-tensor permeability,ultralow-permeability reservoirs with fracture-induced anisotropy.Accordingly,numerical simulations are conducted to explore the seepage laws for ultralow-permeability reservoirs.The results show that element patterns have the highest recovery percentage under a fracture angle of 45°.Accounting for the pressure-sensitive effect produces a decrease in the recovery percentage.Several patterns are considered:inverted five-seven-and nine-spot patterns and a cross-row well pattern.Finally,two strategies are introduced to counteract the rotation of the direction of the principal permeability due to the fracture directional pressure-sensitive effect.

Numerical simulation and analysis of moisture-heat coupling of soft rock tunnels in the cold regions

With the western development in China, more problems with rock and soil engineering in cold regions will be encountered. To study the stability of rock mass under the frost and thaw condition is of far significance. We attempt to simulate and analyze the temperature and moisture field in the surrounding rock of Dabanshan tunnel at its exit KI06＋025 in the cold region by software Femlab. First, introduced the common numerical solution to the moisture and heat coupled about the soft rock in tunnels of cold region. Then gave emphasis on simulation of the law of temperature distribution coupled temperature-moisture field and draw a parallel between temperature fields with different coefficient of percolation. In the course of simulation we considered the problem of caloric receptivity, thermal conductivity and critical heat varying with temperature.

Numerical simulation of oil shale in-situ mining using fluid-thermo-solid coupling

For the in-situ gas-injection mining technology of oil shale by process,a numerical simulation method with flow-thermo-solid coupling is proposed in this paper.This method adopts separate simulations and step-by-step coupling simulation ideas combined with the advantages of the finite element method and the finite volume method.The numerical simulation of flow-thermo-solid coupling is decomposed into two parts:flow-solid coupling and thermo-solid coupling.Considering the Fuyu oil shale in-situ production test area in Songliao Basin as an example,it is concluded that the oil shale has undergone four heating stages:a rapid temperature rise,a steady temperature rise,a slow temperature rise,and heat preservation.It takes about 10 years for the stress-strain state of the oil shale layer to reach a steady-state through the thermo-solid coupling.The main strain zones of the oil shale layer are distributed near the fracturing fractures connected to the gas injection well and at the edge of the fracturing fractures.The areas with the plastic deformation in the oil shale layer predominantly appear near the gas injection wells,production wells,and fracturing channels.The areas with the largest fracture strength are mostly distributed near the edge of the fracturing fractures with low flow velocity and low temperature.

AN ADAPTIVE EFG-FE COUPLING METHOD FOR THE NUMERICAL SIMULATION OF EXTRUSION PROCESSES

An adaptive EFG-FE coupling method is proposed and developed for the numerical simulation of lateral extrusion and forward-backward extrusion. Initially, the simulation has been implemented by using a conventional FE model. During the deforming process, mesh quality is checked at every incremental step. Distorted elements are automatically converted to EFG nodes, whereas, the less distorted elements are reserved. A new algorithm to generate EFG nodes and interface elements is presented. This method is capable of dealing with large deformation and has higher computational efficiency than using an EFG method wholly. Numerical results demonstrate that the adaptive EFG-FE coupling method has reasonable accuracy and is effective for local bulk metal forming such as extrusion processes.

Numerical simulation of packed-bed reactor for oxidative coupling of methane

A three-dimensional geometric model of the oxidative coupling of methane （OCM） packed-bed reactor loaded with Na2WO4-Mn/SiO2 partic- ulate catalyst was set up, and an improved Stansch kinetic model was established to calculate the OCM reactions using the computational fluid dynamics method and Fluent software. The simulation conditions were completely the same with the experimental conditions that the volume velocity of the reactant was 80 mL/min under standard state, the ratio of CH4/O2 was 3, the temperature and pressure were 800 ℃ and 1 atm, respectively. The contour of the characteristics parameters in the catalyst bed was analyzed, such as the species mass fractions, temperature, the heat flux on side wall surface, pressure, fluid density and velocity. The results showed that the calculated values matched well with the experimental values on the conversion of CH4 and the selectivity to products （C2H6, C2H4, CO2, CO） in the reactor outlet with an error range of 4-2%. The mass fractions of CH4 and O2 decreased from 0.6 and 0.4 in the catalyst bed inlet to 0.436 and 0.142 in the outlet, where the mass fractions of C2H6, C2H4, CO and CO2 were 0.035, 0.061, 0.032 and 0.106, respectively. Due to the existence of laminar boundary layer, the contours of each component bent upwards in the vicinity of the boundary layer. This OCM reaction was volume increase reaction and the total moles of products were greater than those of reactants. The flow field in the catalyst bed maintained constant temperature and pressure. The fluid density decreased gradually from 2.28 kg/m3 in the inlet of the catalyst bed to 2.22 kg/m3 in the outlet of the catalyst bed, while the velocity increased from 0.108 m/s to 0.115 m/s.

Numerical Simulation of Thermo-Hydro-Mechanical-Chemical Response Caused by CO_(2)Injection into Saline Geological Formations:A Case Study from the Ordos Project,China

Thermo-hydro-mechanical-chemical(THMC)interactions are prevalent during CO_(2)geological sequestration(CGS).In this study,a sequential coupling THMC numerical simulation program was constructed,which can be used to explore the following issues of CGS:fluid and heat flow,solute transport;stresses,displacements and rock failures related to geo-mechanical effects;equilibrium and kinetic chemical reactions;chemical damage to mechanical properties of the rock.Then,the coupling program was applied to the Ordos CGS Project to study the formation response under the multifield interaction caused by CO_(2)injection.The simulation results show that the mechanical process dominates the short CO_(2)injection period.Specifically,the formation’s permeability near the injection well increases by 43%,due to the reduction of effective stress,which significantly promotes the lateral migration of CO_(2).When the injection rate exceeds 0.15 million tons per year,the cohesion of the reservoir rock is not enough to resist the shear force inside the rock and rock failure may occur.During the subsequent long-term sequestration period(200 years),the influence of mineral reactions gradually increases.Due to calcite dissolution,the shear modulus of caprock is predicted to decrease by 7.6%,which will to some extent increase the risk of rock failure.

Numerical simulation for influences of pressure solution on T-H-M coupling in aggregate rock

The pressure solution model of granular aggregates was introduced into a FEM code which was developed for the analysis of thermo-hydro-mechanical(T-H-M) coupling in porous medium. Aimed at creating a hypothetical model of nuclear waste disposal in unsaturated quartz aggregate rock mass with laboratory scale, two 4-year computation cases were designed: 1) The porosity and permeability of rock mass are functions of the pressure solution; 2) The porosity and the permeability are constants. Calculation results show that the magnitude and distribution of stresses in the rock mass of these two calculation cases are roughly the same. And, the porosity and the permeability decrease to 43%-54% and 4.4%-9.1% of their original values after case 1 being accomplished; but the negative pore water pressures in cases 1 and 2 are respectively 1.0-1.25 and 1.0-1.1 times of their initial values under the action of nuclear waste. Case 1 exhibits the obvious effect of pressure solution.