Wall-resolved large-eddy simulation of turbulent channel flows with rough walls

Turbulent flows over rough surfaces widely exist in nature and industry.Investigating its mechanism is of theoretical and practical significance.In this work we simulate the turbulent channel flow with rough walls using large-eddy simulation with rough elements resolved using the curvilinear immersed boundary method and compare the results obtained in this work with those in the paper by Yuan and Piomelli(J.Fluid Mech.,vol.760,pp.R1,2014),where the volume of fluid method was employed for modeling rough elements.The mean streamwise velocity profiles predicted by the two methods agree well with each other.Differences in Reynolds stresses and dispersive stresses are observed,which are attributed to the different approaches in dealing with the complex geometry of the rough surface.

Large Eddy Simulation of Turbulent Channel Flows over Rough Walls with Stochastic Roughness Height Distributions

This paper studies the 3-D turbulent channel flows over rough walls with stochastic roughness height distributions by using the large eddy simulation and the immersed boundary method. The obtained mean and fluctuating velocity profiles for the smooth and rough channel flows agree well with the available numerical and experimental results. The stochastic surface roughness is found to have a more significant influence than the uniform surface roughness on the turbulent velocity statistics and the coherent structures, with the same average roughness height. With a greater variation in the roughness height, the mean velocity and the streamwise fluctuating velocity is decreased and the spanwise velocity and the wall-normal fluctuating velocity are increased. In addition, one observes larger and more profuse quasi-streamwise vortices, hairpin vortices and elongated structures above the crest plane of the roughness array in cases of highly stochastic rough walls. However, the low-speed streaky structures are broken up locally and the ejection and sweep events are depressed by the stochastic roughness below the average roughness height. The results of this study support Townsend’s wall-similarity hypothesis for both stochastic and uniform rough wall turbulences, demonstrating that in both cases the effects of the surface roughness on the turbulent flow are limited to the rough sub-layer.

SIMULATION OF SUDDEN-EXPANSION AND SWIRLING GAS-PARTICLE FLOWS USING A TWO-FLUID PARTICLE-WALL COLLISION MODEL WITH CONSIDERATION OF THE WALL ROUGHNESS

A two-fluid particle-wall collision model with consideration of wall roughness is pro- posed.It takes into account the effects of the friction,restitution and in particular the wall roughness, and hence the redistribution of Reynolds stress in different directions,the absorption of turbulent en- ergy from the mean motion and the attenuation of particle motion by the wall.The proposed model is used to simulate sudden-expansion and swirling gas-particle flows and is validated by comparing with experimental results.The results show that the proposed model gives better results than those obtained by the presently used zero-gradient condition.Hence,it is suggested that the proposed model should be used as the wall boundary condition for the particle phase in place of the presently used boundary condition.

Boundary-layer receptivity under interaction of free-stream turbulence and localized wall roughness

The boundary-layer receptivity under the interaction of free-stream turbu- lence （FST） and localized wall roughness is studied by the direct numerical simulation （DNS） and the fast Fourier transform. The results show that the Tollmien-Schlichting （T-S） wave packets superposed by a group of stability, neutral, and instability T-S waves are generated in the boundary layer. The propagation speeds of the T-S wave packets are calculated. The relation among the boundary-layer receptivity response, the amplitude of the FST, the roughness height, and the roughness width is determined. The results agree well with Dietz＇s experiments. The effect of the roughness geometries on the receptivity is also studied.

Experimental Studies of the Effect of Wall Roughness on Particle Behavior in Gas-Particle Flows

The effect of wall roughness on particle behavior in two-phase flows in a horizontal backward-facing step is studied using a phase-Doppler particle anemometer. The results show that the wall roughness widens the particle velocity probability density distribution, enhances the redistribution of particle velocity into different directions, reduces the particle longitudinal mean velocity and increases the longitudinal and transverse fluctuation velocities and Reynolds shear stress. The effect of roughness on particle motion in the recirculation zone is weaker than that in the fully developed flow region. The effect of roughness for small particles is restricted only in the near-wall region, while that for large particles diffuses to the whole flow field.

Modeling for Collapsing Cavitation Bubble near Rough Solid Wall by Mulit-Relaxation-Time Pseudopotential Lattice Boltzmann Model

Cavitation bubble collapse near rough solid wall is modeled by the multi-relaxation-time (MRT) pseudopotential lattice Boltzmann (LB) model. The modified forcing scheme, which can achieve LB model’s thermodynamic consistency by tuning a parameter related with the particle interaction range, is adopted to achieve desired stability and density ratio. The bubble collapse near rough solid wall was simulated by the improved MRT pseudopotential LB model. The mechanism of bubble collapse is studied by investigating the bubble profiles, pressure field and velocity field evolution. The eroding effects of collapsing bubble are analyzed in details. It is found that the process and the effect of the interaction between bubble collapse and rough solid wall are affected seriously by the geometry of solid boundary. At the same time, it demonstrates that the MRT pseudopotential LB model is a potential tool for the investigation of the interaction mechanism between the collapsing bubble and complex geometry boundary.

CO_(2)液滴在粗糙固体壁面上的润湿特性

CO_(2)在粗糙固体壁面上的润湿行为对CO_(2)冷凝捕集技术具有重要意义。采用分子动力学方法探究微结构、势能及温度对CO_(2)液滴润湿的影响。结果表明:相较于平板壁面,微结构壁面提高了CO_(2)液滴的接触角;在微结构壁面上势能参数影响CO_(2)液滴的润湿状态,在栏栅结构壁面上CO_(2)液滴从Cassie-Baxter状态转向Wenzel状态,而在三角和斜坡结构壁面上CO_(2)液滴均保持Wenzel状态,3种壁面上CO_(2)液滴的接触角均随势能参数的增大而减小;此外随着体系温度升高,CO_(2)分子克服界面能垒由液相转向气相,使得液滴尺寸变小,液滴的接触角稍有减小。

激光沉积制造零件表面粗糙度预测及控制方法研究

针对激光沉积制造(LDM)成形零件表面粗糙度高、成形质量差,以及打印后必须进行机加工等后处理的问题,自主搭建成形平台,使用“小光斑、小层厚、小粉末粒径”的工艺方法打印具有不同倾斜角度的薄壁零件,并考虑熔道搭接、层间抬升量及成形角度的影响,基于增材制造分层切片原理,给出了不同几何特征下典型薄壁零件的理论表面粗糙度预测模型,通过实际打印薄壁零件对其进行三维共聚焦观测表面形貌和粗糙度,测量验证了所提出的表面粗糙度预测模型的正确性,并在此基础上提出了激光沉积制造零件表面粗糙度的控制策略。

考虑铣削振动的薄壁件表面加工质量试验研究

薄壁件刚性较低,其铣削时产生的振动是加工中不可忽略的因素。为保证加工精度和表面加工质量,合理选用铣削参数是十分重要的。在考虑铣削振动的基础上,将7075铝合金薄壁件铣削时产生的加速度作为分析铣削振动的依据,以工件的表面粗糙度为最终指标,通过试验综合分析切削深度、每齿进给量和主轴转速等铣削参数对薄壁件表面加工质量的影响。试验结果表明:随着这3个铣削参数值增大,铣削振动和表面粗糙度均会增大。其中每齿进给量对工件振动的幅度,以及表面粗糙度的影响最为显著,因此,减小每齿进给量能有效降低铣削振动,减小表面粗糙度,从而保证薄壁件的加工质量。

考虑基质渗透性的粗糙单裂隙非达西流动特性研究

粗糙单裂隙及其周围岩石基质是组成复杂岩体裂隙网络的基本单元,了解其中发生的流体流动行为具有重要意义。通过直接求解Navier-Stokes(N-S)方程开展三维粗糙单裂隙和裂隙-孔隙双重介质模型的渗流模拟工作,研究了裂隙表面粗糙度、匹配性和基质渗透性对粗糙单裂隙中发生的非达西流动的影响规律。结果表明:Forchheimer方程可以准确描述双重介质模型中粗糙单裂隙流体流量与压力梯度间的非线性关系;表面粗糙度和不匹配性的增大会加剧裂隙内部开度分布的不均匀性,增大裂隙的流动阻力而促进非达西流动的发生;可渗透基质会使得裂隙过流能力增强,通过粗糙单裂隙的流量最多可增大约14%,这会抑制非达西流动的发生;基质渗透性对裂隙过流能力增长的影响程度与表面粗糙度和不匹配性呈正相关。

Numerical Simulation of Proppant Dynamics in a Rough Inclined Fracture

Although the dynamics of proppant(small ceramic balls used to prevent opened fractures from closing on the release of pressure)have been the subject of several numerical studies over recent years,large-scale inclined fractures exist in unconventional reservoirs for which relevant information is still missing.In the present study,this problem is investigated numerically considering the influence of several relevant factors such as the fracture roughness,inclination,the proppant particle size,the injection rate and the fluid viscosity.The results show that a rough wall enables the proppant to travel farther and cover larger areas.The inclination angle has little effect on the dune but a significant influence on the suspension zone.The area of this zone increases with a decrease in the inclination angle,and its value for an inclination of 15°is 20 times that at 90°.Small particle size,high injection rate,and high fracturing fluid viscosity have a beneficial influence on proppant transport;vice versa they hinder settling phenomena.

基于均值孔隙介质层的阻尼孔壁面摩擦效应研究

阻尼孔广泛用于各种液压机械系统,其孔径通常在0.3 mm到2 mm之间,这种微小流道的流动不同于常规管道,壁面粗糙度对其流动特性有重要的影响。针对这一问题,以安装在液压电磁换向阀中的阻尼孔为研究对象,采用均值孔隙介质层(PML)模拟了阻尼孔的壁面粗糙度。首先,建立了阻尼孔的物理模型,使用ICEM CFD软件对模型进行了网格划分;然后,构建了流体控制方程以及PML动量方程,求解出了黏性阻力系数和惯性阻力系数;最后,采用了流体仿真软件Fluent,分析了壁面粗糙度对阻尼孔流体流动特性、流体完全发展距离长度以及流体温升的影响。研究结果表明:仿真所得阻力特性与文献中实验所得阻力特性结果一样,采用PML表征壁面粗糙度的方法可行;由于壁面粗糙度,阻尼孔中的流体受到的阻力增大,导致从阻尼孔入口至出口压降增加了2.25%;相同边界条件下,含PML的阻尼孔比光滑阻尼孔的完全发展距离长0.1 mm左右;壁面的发热量平均提高了1.5%。

基于直驱机床的航空整体叶轮加工效率优化方法研究

为解决航空叶轮在复杂五轴联动加工过程中的效率和精度控制难题,本文基于直驱机床围绕加工参数对表面粗糙度和加工时间的影响进行了深入分析。首先通过与传统机床进行加工对比,证明了直驱机床的精度与速度方面的优势;其次针对原点坐标的研究揭示了原点位置对加工效率的影响,尤其是当原点接近A、C轴中心时,加工效率显著提高;最后通过正交试验法研究了转速、每齿进给量、切宽这3个关键因素,并发现每齿进给量是影响表面粗糙度的主导因素,其次是切宽,而转速的影响较小。在保证粗糙度小于1.6μm的前提下,以转速20000 r/mim、每齿进给量0.03 mm、切宽0.6 mm的参数组合获得最优结果。基于优化的工艺参数不仅提升了加工效率,节约了43.3%的加工时间,还确保了加工质量,为航空叶轮的精密加工提供了重要的技术参考,同时为基于直驱机床的复杂零件高效加工提供实践指导和理论依据。

喷浆支护过程回弹率敏感性模拟研究

以蓬莱金矿侯各庄巷道喷浆支护为模拟对象,基于喷浆接触参数,建立了PFC2D喷射模型。针对喷射距离、喷射速度、巷道锯齿数目、锯齿高度和角度进行模拟试验,通过分析不同参数下回弹率的变化特征,得出最佳喷射速度为10m/s,喷射距离为1.2m,此时回弹率最低为29.53%。回弹率随着锯齿角度减少,高度增加而逐渐增大。

关于改善液体流量标准装置微小流量稳定性的方法探讨

流量作为工业生产中的重要参数,具有测量动态性、不稳定性的特点,是过程控制中最难准确测量的参数之一。根据JJG164-2000《液体流量标准装置》检定规程,其稳定性是衡量液体标准装置不确定度的重要指标。为提高装置计量性能,本文主要从装置出口压力、管道壁粗糙度、管道中水溶解气和介质洁净度,对微小流量稳定性的影响因素进行分析,并制定加装二次稳压装置、更换管道材质、增加排气阀和杂质过滤装置等可行性改造方案。

激光辅助铣削AerMet100超高强度钢薄壁件变形与表面粗糙度研究

采用激光参数优化实验对AerMet100超高强度钢的激光辅助铣削进行激光参数优化,并进行激光辅助铣削AerMet100超高强度钢的温度单因素实验和正交试验,分析了适合AerMet100超高强度钢加工温度场及各铣削参数对薄壁工件变形、表面粗糙度的影响,采用极差分析的方法得到影响工件变形和表面粗糙度的铣削参量排序。从工件变形量和表面粗糙度两个方向进行参数优化,为激光辅助铣削Aermet100超高强度钢提供了指导。

Numerical simulation on proppant migration and placement within the rough and complex fractures

Hydraulic fracturing is a key technology for the development of unconventional hydrocarbon resources.The proppant placement morphology determines the fracture conductivity,thus affecting the reservoir stimulation effect.In this paper,the proppant migration and placement within complex fractures was studied by considering the fracture wall roughness through computational fluid mechanics-discrete element method(CFD-DEM)in numerical simulation,which is a key approach to study the proppant migration and placement.The results show that the proppant placement non-uniformity,proppant migration capacity,and proppant volume filled in the far-end and the secondary branched fracture are enhanced within the rough fracture compared with those within smooth fractures.The proppant migration capacity is increased within the fracture at low inclination angles(<60°)and low approach angles(<90°),and the proppant placement area is larger in the inclined fracture than that in the vertical fracture.The rise of injection rate and fracturing fluid viscosity causes more proppants migrate to far-end or secondary fractures,resulting in a non-proppant area within the near-wellbore fracture.An increase by 1.3 times in the injection rate and 3 times in the fracturing fluid viscosity leads to a decrease by 26.6%and 27%,respectively,in the proppant placement area within the near-wellbore fracture.The staged injection with small size proppants followed by large size proppants increases the proppant placement area in the primary fracture by 13%-26%,and that with large size proppants followed by small size proppants increases the proppant placement area by 19%-25%,which is due to that the latter method facilitates filling of the secondary branched fracture.The injection location mainly affects the proppant filling degree within the near-wellbore fractures.Compared with the upper injection,the middle and lower injection is not beneficial to filling of proppants within the near-wellbore fracture.

Fabrication of low-loss SiO2/Si channel waveguides by roughness reduction

An experimental study of the dependence of SiO2 waveguide side wall roughness on the etch condi- tions and etch masks in CHF3/O2 based reactive ion etching plasma was reported. When working under standard low-pressure （20mtorr） etching conditions, a novel etch roughening phenomenon has been observed in the plasma, that is, the roughness of the etched front surface increases with the amount of material etched, independent of etch rate, RF power, and gas composition. Besides, the etched underlying side wall will be tapered as the upper SU-8 resist pattern degradation transfers downward. A process using double-layered mask, consisting of SU-8 resist and thin Chromium film, was developed for improving the side wall smoothness. Based on the studies, SiO2/Si channel waveguides with the propagation loss less than 0. 07dB/cm were fabricated at last.

粗糙壁面螺旋溜槽中矿浆流场参数及颗粒分离行为演变特性

借助于RNG k-ε湍流模型、VOF多相流模型及Eulerian Multi-fluid VOF模型对螺旋溜槽内的流场及颗粒运动行为进行数值模拟,系统考察了光滑壁面和粗糙壁面条件下的清水流场参数、赤铁矿-石英矿浆流场参数、颗粒分布、分离效率随过流圈数的演变特性。结果表明:相较于清水体系,矿浆流膜存在局部凸起,内缘区域的矿浆流体切向速度变大,中部和外缘矿浆流体的切向速度降低,其径向速度分布具有明显波动特性;与光滑壁面条件相比,粗糙壁面条件下的矿浆流膜凸起高度降低,矿浆切向速度整体偏高,内缘矿浆切向流速差异较小,内环流强度减弱,外环流强度增大;当流体纵向行程达到第3圈时,各流场参数径向分布的差异缩小并接近一致;相比于光滑壁面,粗糙壁面中的赤铁矿颗粒在内半槽的分布减少,随过流圈数增多向内迁移量增大,但在外缘最外微区的停留量也增大,石英颗粒则随流场演变逐渐在第3圈槽面中部区域形成较多分布;赤铁矿和石英的最大分离效率随过流圈数增多而升高且逐渐平衡,粗糙壁面条件下赤铁矿和石英的最大分离效率降低。本文研究范围内粗糙壁面对螺旋溜槽矿浆流场及颗粒分离行为影响显著,研究结果可以为螺旋溜槽壁面粗糙度设计及过程调控提供参考。

Research on the Influence of Cutting Condition on the Surface Microstruct ure of Ultra-thin Wall Parts in Ultrasonic Vibration Cutting

In many fields of high-tech industry the ultra-t hi n wall parts are employed. In this paper the experiments were carried out to dis cuss the surface microstructure of the camera’s guided drawtube by applying ult rasonic vibration cutting device to the traditional lathe. The influence rule of the cutting condition on the surface roughness was put forward, which was drawn by comparing the ultrasonic cutting with the common cutting by use of the cemen ted carbide tool and the polycrystalline diamond (PCD) tool. The test results sh owed that the ultrasonic cutting performs better than the common cutting in the same condition. According to the test results analyzing, the surface characteriz ation is influenced clearly by the rigidity of the acoustic system and the machi ne tool, as well the setting height of the tool tip. Otherwise, the dense regula r low frequency vibration ripples will be scraped on the machined surface. When the tool tip is set higher than the rotating center of the work piece by three t imes of the amplitude of ultrasonic vibration, the vibration ripples behave alig ht; they turn light and shade alternatively when the tool tip is lower than the rotating center of the work piece by three times of the amplitude of ultrasonic vibration. According to the test result analyzing, the following conclusions are put forward: 1) The surface roughness in ultrasonic cutting is better than that in common cutting. Under a one third critical cutting velocity, the value of th e surface roughness in ultrasonic cutting rise slightly along with the cutting v elocity, while in common cutting it decreases contrast to the cutting velocity; the curves of the surface roughness in ultrasonic cutting and common cutting see m to be alike, both increase along with the feed rate and the cutting depth, but the value in ultrasonic cutting is smaller in the same condition.2) The influen ce of the coolant on the surface roughness cannot be ignored. The kerosene can b e employed to improve the surface roughness in ultrasonic machining.3) In ultras onic cutting process of aluminum alloy ultra-thin wall work piece, the PCD tool performs better than the cemented carbide tools.4) The vibration ripples result from the not enough rigidity of the acoustic system and the improper setting he ight of the tool tip. The departure of the tool tip from the rotating center of the work piece to some extent causes the vibration ripples on the machined surfa ce.