Chapter 5

NUMERICAL MODELING
5.1Numerical Approach in CFD optimization
Computational Fluid Dynamics (CFD) is a standard tool in industry for analyzing external and internal flows of industrial devices. It is a powerful numerical tool which is becoming widely used to simulate many thermal systems and fluid flow system. The accuracy of the calculations depend on a number of parameters including the choice of turbulence model and the treatment of the boundary layer since this largely dictates the nature of the heat transfer. The converged values of temperature and fluid flow parameters enabled to find heat transfer and fluid flow characteristics. Prior to a CFD-analysis, several

parameters should be considered and some decisions should be made. In CFD calculations, there are three main steps: 1. Pre-Processing Geometry creation, meshing, solver setting 2. Solver Execution Compute and monitor the solution 3. Post-Processing - Examine the results Consider revisions to the model 5.1.1 Pre-Processor Pre-processing consists of a flow problem to a CFD program by means of an user friendly interface and the subsequent transformation of this input into a form suitable for use by the solver. The user activities at the pre-processing stage involve: Definition of the geometry of the region of interest: the computational domain. Grid generation: the sub-division of the domain into a number of smaller, nonoverlapping sub-domains: a grid (mesh) of cells (or control volumes or elements). Selection of the physical and chemical phenomenon that need to be modeled. Definition of fluid properties. Specification of appropriate boundary conditions at cells, which coincide with or touch the domain boundary.

5.1.2 Solver The method used for numerical solution in the commercial CFD code Fluent is finite volume method. Basically the solver performs the following steps: Approximation of the unknown flow variables by means of simple functions. Discretization by substitution of the approximations into the governing flow equations and subsequent mathematical manipulations. Solution of the algebraic equations.

5.1.3 Post - Processor As in pre-processing a huge amount of development work has recently taken place in the post-processing field. Owing to the increased popularity of engineering workstations, many of which have outstanding graphics capabilities, the leading CFD packages are now equipped with versatile data visualization tools. These include: Domain geometry and grid display Vectors plots Line and shaded contour plots 2D and 3d surface plots Particle tracking View manipulation (translation, rotation, scaling etc) Color postscript output

5.1.4 Optimization The design and operation of a system or process to make it as good as possible in some defined sense The main purpose of design exploration is to identify the relationship between the performance of the product (maximum stress, mass, fluid flow, velocities, etc.) and the design variables (dimensions, loads, material properties, etc.). Based on these results, the analyst will be able to influence the design so as to meet the products requirements. He will be able to identify the key parameters of the design and how they influence the performance.

Design exploration does provide tools to analyze a parametric design with a reasonable number of parameters. The Response Surface methods described here are suitable for problems using about 10 to 15 input parameters. So typical steps followed includes: Analysis of product under all operating conditions. Identify design candidates. Assess the robustness of design candidate. Determine the number of parameters. Increase the response surface accuracy.

5.2 Turbulence Modeling

Solving CFD problem usually consists of four main components: geometry and grid generation, setting-up a physical model, solving it and post-processing the computed data. The way geometry and grid are generated, the set problem is computed and the way acquired data is presented is very well known. Precise theory is available. Unfortunately, that is not true for setting-up a physical model for turbulence flows. The problem is that one tries to model very complex phenomena with a model as simple as possible. Therefore an ideal model should introduce the minimum amount of complexity into the modeling equations, while capturing the essence of the relevant physics. A key item in all CFD analyses is to obtain accurate and reliable solutions. Most industrial flows include turbulent flow structures that cannot be resolved numerically on available computers. To overcome the resolution limitations, CFD codes usually solve the Reynolds-Averaged Navier-Stokes equations augmented by turbulence models to compute the averaged turbulent stresses. These models are often the limiting aspect in the accuracy of numerical simulations. Modeling the turbulence and heat transfer at impinging jet is a challenging task. All physical details of jet impingement turbulent flow structures and heat transfer can be captured only by using the Direct Numerical Simulation (DNS) approach (Tiselj et al., 2004). Using DNS for turbulent jet simulation is however very expensive as it requires a vast amount of computational time and resources. Large Eddy Simulation (LES) (Niceno et al., 2002) seems to be more appealingonly larger spatial scales are resolved directly whereas closure models are used at the smaller scales. As reported by Hadziabdic and Hanjalic (2008) the existing

DNS and LES simulations of impinging jets are limited to a relatively low Reynolds numbers (less than 10,000) and mostly deal with simpler plane jets, which are computationally less demanding (no radial spreading of the jet). More practical approach most commonly used to model the realistic turbulent flows with sufficient accuracy is the use of Reynolds Averaged Navier Stokes (RANS) equations combined with two equation turbulence models. In this work the local heat transfer and flow characteristics of a single axis-symmetric impinging jet are analyzed using the RANS approach. A two-equation Shear Stress Transport (SST) turbulence model (Menter, 1993) is used to resolve the turbulence. Its formulation assures that it can be used for free shear and boundary flows. Turbulence in a free shear region is modulated with a k model, while in the near-wall region a k turbulence model is used. Turbulence models and heat transfer predictions are validated on a simple jet impingement test case, where jet is flowing out of a long circular pipe and impinges on the heated plate (Baughn and Shimizu, 1989). The standard SST model has difficulties to accurately predict the heat transfer and turbulent kinetic energy near the stagnation point of the jet impingement flow field, but considering all the aspect of design SST model is said to be optimum choice over the others. 5.2.1 Governing equations in SST Since transport processes of averaged quantities are considered to be in steady-state the Reynolds Averaged Navier Stokes (RANS) equations can be used to describe the fluid flow and the heat transfer. The turbulence is resolved by using a two-equation eddy viscosity type SST turbulence model (Menter, 1993)[30]. It has been reported (Hadziabdicand Hanjalia, 2008) that the SST model over predicts the turbulent production in regions with large normal strain, i.e. regions with strong fluid flow acceleration or deceleration. There are a few proposals in the literature on how to modify the production term. One of them is Kato Launder modification (Kato and Launder, 1993), which is also used in the current study. Production term P is involved in transport equation for the turbulent kinetic energy (ANSYS, 2006).

The turbulent production is given by the following equation:

Where

is the turbulent shear stress tensor. Since the SST turbulent model is an

eddy viscosity type model, the boussinesq eddy viscosity assumption is used:

The parameter

is the eddy viscosity given by the turbulence model and

is the

trace-less viscous strain rate defined by ( )

Since the fluid is considered incompressible, the production term can be rewritten as ( )( )

Where,

The proposal by Kato and Launder is to replace one of the strain rates in the turbulent production term with the vorticity . The kato-Launder modified production then becomes: , where ( )

P=

5.3 Numerical model for CFD solver

In this work the flow field is numerically examined by using ANSYS CFX. Geometry creation and meshing was performed in ANSYS ICEM CFD. A mesh file is imported in the

CFX-Pre where boundary conditions applied and setting of the turbulence module and other setting for CFX-Pre is done. The flow and turbulent fields have to be accurately solved to obtain reasonable heat transfer predictions. Higher resolution scheme is used for all terms that affect heat transfer. Higher order discretization scheme is used for the pressure; momentum, turbulent kinetic energy, specific dissipation rate, and the energy. Flow, turbulence, and energy equations have been solved. To simplify the solution, the variation of thermal and physical properties of air with temperature is neglected. Finally the CFX-Post is used to generate various textual and graphical results. 5.3.1 Geometry and meshing The geometry is created in ANSYS Design modeler and mesh in AnsysCFX(Workbench environment). ANSYS workbench provides advanced geometry

acquisition, mesh generation, optimization and post-processing tools to meet requirement for integrated mesh generation and post processing. ANSYS Workbench maintains close relationship with geometry during mesh generation and post processing. ANSYS Workbench provides direct link between geometry and analysis. In ANSYS Workbench, geometry can be input from just about any format from any CAD package or 3rd party universal database. In this case the geometry is created in ANSY ICEM CFD itself and Multoblock structured hexahedral mesh is created. As geometry is small enough so here we consider complete geometry for the CFD analyses (Fig.5.3). All geometrical dimensions are similar as that of test set up. As structured mesh used hence the orthogonality is maintained hence accurate prediction of heat transfer characteristics there. To capture the near wall flow phenomenon dense the hexahedral mesh at near wall region by means of using the linear mesh law algorithm and then bunching the all parallel edges as shown in Fig.5.4. This was not only capture the near wall flow phenomenon but also increases the smoothness of the mesh. Dense mesh also helps to control the y+ character. The Quality, Determinant, Aspect Ratio etc are maintained above the standard valued mentioned by ANSYS Workbench user guide. Grid independency on heat transfer characteristics was checked by changing the element size from 0.4 million to 0.8 million which follows that about 0.6 million was good enough for present analysis from view point of accuracy and computational time. The mesh statistics are given in Table 5.1

5.3.2 Governing equations ANSYS CFX uses an element based finite volume method, which first involves discretizing the spatial domain mesh. The mesh is used to construct finite volumes, which are used to conserve relevant quantities such as mass, momentum and energy. A control volume is constructed around each mesh node using the median dual. The governing equations are solved at each control volume. The analytical determination of the convection heat transfer coefficient requires the solution of the fluid conservation equations: mass, momentum and energy to obtain the temperature distribution in the fluid washing the heated solid. Once the temperature distribution is determined and if the fluid motion in the region immediately adjacent to the heated wall is laminar, the convection heat transfer coefficient is then determined using following set of governing equations: Conservation of mass ( Conservation of linear momentum ( ) ( ) (( )( )) )

Conservation of energy ( ) ( ( )) (( ) )

These equations are integrated over each control volume and Gauss divergence theorem is applied to convert volume integrals involving divergence and gradient operators to surface integrals. Many discrete approximations are developed for CFD based on series of expansion approximations of continuous functions. ANSYS CFX uses second order accurate approximation as much as possible.

Fig.5.1 Geometry specifying Air & Alluminium domain.

Fig.5.2 Structural (hexahedral) mesh of the Domain.

Table 5.1 Mesh statistics for flat plate heat sink Geometry AIR Elements AL Total AIR Nodes AL Total Min. Quality Max Avg. H/d=4 393581 170573 654453 427910 195638 591653 0.498 0.999 0.623 H/d=6 431037 180681 702539 466086 206258 638683 0.463 0.999 0.592 H/d=8 456392 191309 743830 493502 218390 676253 0.412 0.999 0.561

5.3.3 Boundary conditions In ANSYS CFX there are different boundary condition type present i.e. inlet, outlet, opening, wall, symmetry plane, profile boundary conditions these can be specified depending on our problem. Inlets are used predominantly for regions where inflow is expected, however, inlets also support outflow as a result of velocity specified boundary conditions. Outlets are used predominantly for regions where outflow is expected, however, outlets also support inflow as a result of velocity specified boundary conditions. An opening can be used at a boundary where you have information about some conditions at the boundary location but do not know whether the flow is into or out of the domain. The opening type boundary condition can therefore be used where there is simultaneous inflow and outflow at a single location. The opening boundary condition type is only available for subsonic boundaries. 5.3.3 Solver controls

The ANSYS CFX solver needs to be control or designed to get physical behavior of the problem. There are number of options to solve the equations but on which gives better results is adopted from trials. Table 5.2 Solver settings of the CFX simulation. Settings Features Advection scheme Turbulence Numeric Minimum Iterations Maximum Iterations Basic Settings Timescale Control Buoyancy Physical Timescale Residual Type Residual Target Details High Resolution Second order 250 1000 Physical Time Scale Non Buoyant 0.003 [s] RMS 1e-04

5.4 Solution strategy Staggered solvers employ a solution strategy where the momentum equations are first solved, using a guessed pressure, and equation for pressure correlation is obtained. Because of the guess and correct, nature of the linear system, a large number of iterations are typically required in addition to need for judiciously selecting rlaaxation parameters for the variables. ANSYS CFX uses SIMPLE algorithm for solving the equations which is the pressure velocity coupling. ANSYS CFX uses a coupled solver, which solves hydrodynamic equations as a single system. The solution approach uses the fully implicit discretization of equations at any given time step. Diffusion terms of all the governing equations are discretized using the central difference scheme. Convective terms of the momentum and energy equations are discretized using the third order QUICK interpolation scheme and convective terms of the turbulent

kinetic energy and turbulent dissipation rate equations are discretized using second-order upwind differencing scheme (Morris et al., 1996). Fig.5.3 shows the flow chart which illustrates the general field solution process used in ANSYS CFX solver.

Start Initialize all the variables at time t=0 Incorporate boundary conditions Solve the momentum equations Solve energy, turbulence equations

Converged? Yes Save values of all the variables Go to the next time step No

No

Is one cycle completed? Yes Stop

Fig. 5.3 Algorithm (solution strategy) of ANSYS CFX solver.

5.5 DesignXplorer strategy: