Simulation Analysis of Torsion Beam Hydroforming Based on the Fluid-Solid Coupling Method

Hydroformed parts are widely used in industrial automotive parts because of their higher stiffness and fatigue strength and reduced weight relative to their corresponding cast and welded parts.This paper reports a hydraulicforming experimental platform for rectangular tube fittings that was constructed to conduct an experiment on the hydraulic forming of rectangular tube fittings.A finite element model was established on the basis of the fluid–solid coupling method and simulation analysis.The correctness of the simulation analysis and the feasibility of the fluid–solid coupling method for hydraulic forming simulation analysis were verified by comparing the experimental results with the simulation results.On the basis of the simulation analysis of the hydraulic process of the torsion beam using the fluid–solid coupling method,a sliding mold suitable for the hydroforming of torsion beams was designed for its structural characteristics.The effects of fluid characteristics,shaping pressure,axial feed rate,and friction coefficient on the wall thicknesses of torsions beams during formation were investigated.Fluid movement speed was related to tube deformation.Shaping pressure had a significant effect on rounded corners and straight edges.The axial feed speed was increased,and the uneven distribution of wall thicknesses was effectively improved.Although the friction coefficient had a nonsignificant effect on the wall thickness of the ladder-shaped region,it had a significant influence on a large deformation of wall thickness in the V-shaped area.In this paper,a method of fluid-solid coupling simulation analysis and sliding die is proposed to study the high pressure forming law in torsion beam.

Application of the generalized quasi-complementary energy principle to the fluid-solid coupling problem

The fluid-solid coupling theory, an interdisciplinary science between hydrodynamics and solid mechanics, is an important tool for response analysis and direct design of structures in naval architecture and ocean engineering. By applying the corresponding relations between generalized forces and generalized displacements, convolutions were performed between the basic equations of elasto-dynamics in the primary space and corresponding virtual quantities. The results were integrated and then added algebraically. In light of the fact that body forces and surface forces are both follower forces, the generalized quasi-complementary energy principle with two kinds of variables for an initial value problem is established in non-conservative systems. Using the generalized quasi-complementary energy principle to deal with the fluid-solid coupling problem and to analyze the dynamic response of structures, a method for using two kinds of variables simultaneously for calculation of force and displacement was derived.

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.

Fully fluid-solid coupling dynamic model for seismic response of underground structures in saturated soils

The seismic response characteristics of underground structures in saturated soils are investigated.A fully fluid-solid coupling dynamic model is developed and implemented into ABAQUS with a user-defined element to simulate the dynamic behavior of saturated soils.The accuracy of the model is validated using a classic example in literature.The performance of the model is verified by its application on simulating the seismic response characteristics of a subway station built in saturated soils.The merits of the model are demonstrated by comparing the difference of the seismic response of an underground structure in saturated soils between using the fully coupling model and a single-phase medium model.The study finds that the fully coupling model developed herein can simulate the dynamic response characteristics of the underground structures in saturated soils with high accuracy.The seismic response of the underground structure tends to be underestimated by using the single-phase medium model compared with using the fully coupling model,which provides a weaker confining action to the underground structure.

FLUID-SOLID COUPLING MATHEMATICAL MODEL OF CONTAMINANT TRANSPORT IN UNSATURATED ZONE AND ITS ASYMPTOTICAL SOLUTION

The process of contaminant transport is a problem of multicomponent and multiphase flow in unsaturated zone. Under the presupposition that gas existence affects water transport, a coupled mathematical model of contaminant transport in unsaturated zone has been established based on fluid_solid interaction mechanics theory. The asymptotical solutions to the nonlinear coupling mathematical model were accomplished by the perturbation and integral transformation method. The distribution law of pore pressure, pore water velocity and contaminant concentration in unsaturated zone has been presented under the conditions of with coupling and without coupling gas phase. An example problem was used to provide a quantitative verification and validation of the model. The asymptotical solution was compared with Faust model solution. The comparison results show reasonable agreement between asymptotical solution and Faust solution, and the gas effect and media deformation has a large impact on the contaminant transport. The theoretical basis is provided for forecasting contaminant transport and the determination of the relationship among pressure_saturation_permeability in laboratory.

Fluid-solid coupling model for studying wellbore instability in drilling of gas hydrate bearing sediments

As the oil or gas exploration and development activities in deep and ultra- deep waters become more and more, encountering gas hydrate bearing sediments （HBS） is almost inevitable. The variation in temperature and pressure can destabilize gas hydrate in nearby formation around the borehole, which may reduce the strength of the formation and result in wellbore instability. A non-isothermal, transient, two-phase, and fluid-solid coupling mathematical model is proposed to simulate the complex stability performance of a wellbore drilled in HBS. In the model, the phase transition of hydrate dissociation, the heat exchange between drilling fluid and formation, the change of mechanical and petrophysical properties, the gas-water two-phase seepage, and its interaction with rock deformation are considered. A finite element simulator is developed, and the impact of drilling mud on wellbore instability in HBS is simulated. Results indicate that the re- duction in pressure and the increase in temperature of the drilling fluid can accelerate hydrate decomposition and lead to mechanical properties getting worse tremendously. The cohesion decreases by 25% when the hydrate totally dissociates in HBS. This easily causes the wellbore instability accordingly. In the first two hours after the formation is drilled, the regions of hydrate dissociation and wellbore instability extend quickly. Then, with the soaking time of drilling fluid increasing, the regions enlarge little. Choosing the low temperature drilling fluid and increasing the drilling mud pressure appropriately can benefit the wellbore stability of HBS. The established model turns out to be an efficient tool in numerical studies of the hydrate dissociation behavior and wellbore stability of HBS.

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.

Fluid-solid coupling numerical simulation of micro-disturbance grouting treatment for excessive deformation of shield tunnel

Micro-disturbance grouting is a recovery technique to reduce the excessive deformation of operational shield tunnels in urban areas.The grout mass behaves as a fluid in the ground before hardening to form a grout–soil mixture,which highlights the necessity of using fluid–solid coupling method in the simulation of grouting process.Within a discrete element modeling environment,this paper proposes a novel fluid-solid coupling method based on the pore density flow calculation.To demonstrate the effectiveness of this method,it is applied to numerical simulation of micro-disturbance grouting process for treatment of large transverse deformation of a shield tunnel in Shanghai Metro,China.The simulation results reveal the mechanism of recovering tunnel convergence by micro-disturbance grouting in terms of compaction and fracture of soil,energy analysis during grouting,and mechanical response of soil-tunnel interaction system.Furthermore,the influence of the three main grouting parameters(i.e.,grouting pressure,grouting distance,and grouting height)on tunnel deformation recovery efficiency is evaluated through parametric analysis.In order to efficiently recover large transverse deformation of shield tunnel in Shanghai Metro,it is suggested that the grouting pressure should be about 0.55 MPa,the grouting height should be in the range of 6.2–7.0 m,and the grouting distance should be in the range of 3.0–3.6 m.The results provide a valuable reference for grouting treatment projects of over-deformed shield tunnel in soft soil areas.

Numerical Simulation of the Mass Movement Process of the 2018 Sedongpu Glacial Debris Flow by Using the Fluid-Solid Coupling Method

In the context of global warming and intensified human activities,glacier instability in plateau regions has increased,and glacier debris flows have become active,which poses a significant threat to the lives and property of people and socioeconomic development.The mass movement process of glacier debris flows is extremely complex,so this paper uses the 2018 Sedongpu glacier debris flow event on the Qinghai-Tibet Plateau as an example and applies a numerical simulation method to invert the whole process of mass movement.In view of the interaction between phases in the process of motion,we use the fluid-solid coupling method to describe the mass movement.The granular-flow model and drift-flux model are employed in FLOW3D software to study the mass movement process of glacier debris flows and explore their dynamic characteristics.The results indicate that the glacier debris flow lasted for 700 s,and the movement process was roughly divided into four stages,including initiation,scraping,surging and deposition;the depositional characteristics calculated by the fluid-solid coupling model are consistent with the actual survey results and have good reliability;strong erosion occurs during the mass movement,the clear volume amplification effect,and the first wave climbs 17.8 m across the slope.The fluid-solid coupling method can better simulate glacier debris flows in plateau regions,which is helpful for the study of the mechanism and dynamic characteristics of such disasters.

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 investigation on permeability evolution behavior of rock by an improved flow-coupling algorithm in particle flow code

Permeability is a vital property of rock mass, which is highly affected by tectonic stress and human engineering activities. A comprehensive monitoring of pore pressure and flow rate distributions inside the rock mass is very important to elucidate the permeability evolution mechanisms, which is difficult to realize in laboratory, but easy to be achieved in numerical simulations. Therefore, the particle flow code （PFC）, a discrete element method, is used to simulate permeability behaviors of rock materials in this study. Owe to the limitation of the existed solid-fluid coupling algorithm in PFC, an improved flow-coupling algorithm is presented to better reflect the preferential flow in rock fractures. The comparative analysis is conducted between original and improved algorithm when simulating rock permeability evolution during triaxial compression, showing that the improved algorithm can better describe the experimental phenomenon. Furthermore, the evolution of pore pressure and flow rate distribution during the flow process are analyzed by using the improved algorithm. It is concluded that during the steady flow process in the fractured specimen, the pore pressure and flow rate both prefer transmitting through the fractures rather than rock matrix. Based on the results, fractures are divided into the following three types： I） fractures link to both the inlet and outlet, II） fractures only link to the inlet, and III） fractures only link to the outlet. The type I fracture is always the preferential propagating path for both the pore pressure and flow rate. For type II fractures, the pore pressure increases and then becomes steady. However, the flow rate increases first and begins to decrease after the flow reaches the stop end of the fracture and finally vanishes. There is no obvious pore pressure or flow rate concentration within type III fractures.

Fluid solid coupling model based on endochronic damage for roller compacted concrete dam

According to the characteristics of thin-layer rolling and pouting construction technology and the complicated mechanical behavior of the roller compacted concrete dam （RCCD） construction interface, a constitutive model of endochronic damage was established based on the endochronic theory and damage mechanics. The proposed model abandons the traditional concept of elastic-plastic yield surface and can better reflect the real behavior of rolled control concrete. Basic equations were proposed for the fluid-solid coupling analysis, and the relationships among the corresponding key physical parameters were also put forward. One three-dimensional finite element method （FEM） program was obtained by studying the FEM type of the seepage-stress coupling intersection of the RCCD. The method was applied to an actual project, and the results show that the fluid-solid interaction influences dam deformation and dam abutment stability, which is in accordance with practice. Therefore, this model provides a new method for revealing the mechanical behavior of RCCD under the coupling field.

Flow Field and Temperature Field of Water-Cooling-Type Magnetic Coupling

At present, the water-cooling simulation of the water-cooled magnetic coupler is based on the water-cooled motor and the hydraulic coupler, which cannot accurately characterize the temperature distribution of the rotating watercooled coupling of the coupler. Focusing on rotating water cooling radiating, the present paper proposes simulating the water cooling temperature field as well as the flow field through the method of combining fluid-solid coupled heat transfer and MRF(Multiphase Reference Frame). In addition, taking an 800 kW magnetic coupling as an example, the paper optimizes the shape, number, cooling water inlet speed? and so on? of the cooling channel. Considering factors such as the complete machine’s temperature, and drag torque, it is proved that the cooling e ect is best when there are 36 involute curved channels and when the inlet speed is 3 m/s. Further, through experiments, the actual temperature values at six di erent positions when 50 kW and 70 kW thermal losses di er are measured. The measured values agree with the simulation results, proving the correctness of the proposed method. Further, data have been collected during the entire experimental procedure? and the variation in the coupling’s temperature is analyzed in depth, with the objective of laying a foundation for the estimation of the inner temperature rise as well as for the optimization of the structural design.

Nonlinear coupling analysis of coal seam floor during mining based on FLAC^3D

Based on the hydro-geological conditions of 1028 mining face in Suntuan Coal Mine, mining seepage strain mechanism of seam floor was simulated by a nonlinear coupling method, which applied fluid-solid coupling analysis module of FLAC^3D. The results indicate that the permeability coefficient of adjoining rock changes a lot due to mining. The maximum value reaches 1 379.9 times to the original value, where it is at immediate roof of the mined-out area. According to the analysis on the seepage field, mining does not destroy water resistance of the floor aquiclude. The mining fissure does not conduct lime-stone aquifer, and it is less likely to form damage. The plastic zone does not exactly correspond to the seepage area, and the scope of the altered seepage area is much larger than the plastic zone.

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.

Influence of Coolant on Chip Forming in Gun⁃Drill Based on Fluid⁃Solid Coupling Method

Chip shape is one of the important factors that affect the processing quality of the deep hole.The flow field of 17 mm standard gun-drill is simulated by taking the coolant pressure as a single factor variable,and the influence of coolant pressure on chip forming is discussed by combining with experiments in this paper.The results show that at the initial stage of chip forming,the flow of cutting fluid will intensify the lateral crimp of chips,and then affect the crimp radius of the chip and the number of turns of the crimp screw.The lateral crimp degree increases first and then decreases with the increase of coolant pressure,and the crimp degree is the smallest at 3 MPa.In addition,during the chip removal process,the stream shrinking in the flow field is the main influencing factor that drive and force the chip to break again,and their influence on the chip removal and chip breaking is proportional to the coolant pressure.

Rigid block characteristics on subaerial landslide-tsunamis using a 3D coupled Eulerian-Lagrangian model

To quantitatively reveal how rock blocks falling into water affect the impulse waves,the influence of a rigid block on induced first wave and second wave is systematically investigated.The block characteristics include the initial velocity,density,volume,and incident angle,and the investigated wave behavior characteristics include the maximum kinetic energy of the water,the transformation ratio of the kinetic energy from the block to the waves,the duration of the waves,the maximum movement speed,and the maximum height and width of the waves.The coupled Eulerian-Lagrangian method(CEL)is introduced to establish the numerical models of the fluid-solid coupling,and a laboratory test of a rigid wedge sliding into water demonstrates that it can reasonably describe the dynamic behavior of a landslide-induced wave.A typical process of a block entering water and its energy variation are described and analyzed in detail.Further,the relationship between each characteristic parameter of the block and the waves is quantitatively investigated and fitted.The simulation results show that energy exchange between the block and the water is very rapid after the block collides with the water.The maximum kinetic energy,maximum velocity,duration,and side dimension of the waves mainly increase non-linearly with the above characteristic parameters of the block.The transformation ratio of the kinetic energy from the block to the water,the first wave,and the second wave are usually below 60%,45%,and 30%,respectively.The velocity of the block first decreases and then maintains a constant speed after entering the water.The displacement of the block increases linearly with the initial velocity and density of the block and exponentially increases with the block volume at different times.With the increase in the incident angle of the block,the kinetic energy and scale of the second wave increase correspondingly.

Transient Analysis of a Reactor Coolant Pump Rotor Seizure Nuclear Accident

The reactor coolant pump(RCP)rotor seizure accident is defined as a short-time seizure of the RCP rotor.This event typically leads to an abrupt flow decrease in the corresponding loop and an ensuing reactor and turbine trip.The significant reduction of core coolant flow while the reactor is being operated at full load can have very negative consequences.This potentially dangerous event is typically characterized by a complex transient behavior in terms of flow conditions and energy transformation,which need to be analyzed and understood.This study constructed transient flow and rotational speed mathematical models under various degrees of rotor seizure using the test data collected from a dedicated transient rotor seizure test system.Then,bidirectional fluid-solid coupling simulations were conducted to investigate the flow evolution mechanism.It is found that the influence of the impeller structure size and transient braking acceleration on the unsteady head(Hu)is dominant in rotor seizure accident events.Moreover,the present results also show that the rotational acceleration additional head(Hu1)is much higher than the instantaneous head(Hu2).

Optimizing the Diameter of Plugging Balls in Deep Shale Gas Wells

Deep shale gas reserves that have been fractured typically have many relatively close perforation holes. Due to theproximity of each fracture during the formation of the fracture network, there is significant stress interference,which results in uneven fracture propagation. It is common practice to use “balls” to temporarily plug fractureopenings in order to lessen liquid intake and achieve uniform propagation in each cluster. In this study, a diameteroptimization model is introduced for these plugging balls based on a multi-cluster fracture propagationmodel and a perforation dynamic abrasion model. This approach relies on proper consideration of the multiphasenature of the considered problem and the interaction force between the involved fluid and solid phases. Accordingly,it can take into account the behavior of the gradually changing hole diameter due to proppant continuousperforation erosion. Moreover, it can provide useful information about the fluid-dynamic behavior of the consideredsystem before and after plugging. It is shown that when the diameter of the temporary plugging ball is1.2 times that of the perforation hole, the perforation holes of each cluster can be effectively blocked.