Figure 3 Definition of physical geometry and flow parameters, FLOW-3D

Numerical Modelling of Flow over Single-Step Broad-Crested Weir Using FLOW-3D and HEC-RAS

FLOW-3D 및 HEC-RAS를 이용한 단일 계단형 광정수제 위를 흐르는 유동의 수치 모델링

1. 서론

  • 수치유체역학(CFD)의 발전으로 다양한 수리 구조물의 성능을 평가하는 연구가 활발하게 이루어짐.
  • 본 연구에서는 FLOW-3D(k-ε 모델)와 HEC-RAS(정상유동 모델)를 사용하여 단일 계단형 광정수제 위를 흐르는 유동을 모의함.
  • 실험 데이터를 활용하여 두 모델의 정확도를 비교 분석하며, 특히 정수제 전·후방 및 계단부에서의 유동 특성을 평가함.

2. 연구 방법

모델 설정 및 시뮬레이션 조건

  • FLOW-3D 모델
    • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
    • RNG k-ε 난류 모델을 적용하여 난류 해석 수행.
    • FAVOR(Fractional Area/Volume Obstacle Representation) 기법을 이용하여 복잡한 구조 형상 반영.
  • HEC-RAS 모델
    • Steady-Flow 모듈을 이용하여 정상유동 해석.
    • 수위 프로파일을 에너지 방정식을 이용하여 계산.
    • 수력 점프(hydraulic jump) 및 과도 흐름(supercritical flow) 예측.
  • 경계 조건 설정
    • 유입부: 부피 유량(Volume flow rate) 조건 적용.
    • 유출부: 자유 배출(Outflow) 조건 설정.
    • 벽면: No-slip 조건 적용.

3. 연구 결과

유동 패턴 분석

  • 정수제 상류부:
    • HEC-RAS와 FLOW-3D 모두 상류부에서의 수위 분포를 정확하게 예측(평균 오차: 0.52%, 0.59%).
  • 정수제 상부 흐름:
    • HEC-RAS는 점진적인 흐름을 정확히 계산하지 못하고 불연속적인 프로파일을 생성함.
    • FLOW-3D는 점진적인 흐름 변화를 보다 정확하게 시뮬레이션(평균 오차: 1.57%, HEC-RAS: 2.48%).
  • 낙수(nape flow) 및 수력 점프(hydraulic jump) 형성:
    • HEC-RAS는 수직면을 지나가는 흐름을 제대로 시뮬레이션하지 못함.
    • FLOW-3D는 수력 점프 위치를 보다 정확하게 예측.
  • 임계수심(yc) 및 전면수심(yb) 분석
    • FLOW-3D 예측 값(yc/yb 비율 = 1.5687)이 실험값(1.5)과 가장 유사.
    • HEC-RAS는 yb를 과대 예측하여 yc/yb 비율이 1.0193으로 나타남.

4. 결론 및 제안

결론

  • FLOW-3D는 점진적 흐름, 난류, 수력 점프의 위치 등을 보다 정밀하게 예측하는데 유리함.
  • HEC-RAS는 장거리 채널에서 정상유동을 빠르게 분석하는 데 효과적이나, 급격한 흐름 변화가 있는 경우 부정확할 수 있음.
  • 낙수 영역에서 HEC-RAS는 곡면 흐름을 제대로 재현하지 못하지만, FLOW-3D는 이를 보다 현실적으로 모의.

향후 연구 방향

  • 다양한 계단 형상 및 유량 조건에서의 추가 연구 필요.
  • 실제 현장 데이터를 이용한 모델 검증 연구 진행.
  • LES(Large Eddy Simulation) 모델과의 비교 연구 수행.

5. 연구의 의의

본 연구는 FLOW-3D와 HEC-RAS를 활용하여 단일 계단형 광정수제 위를 흐르는 유동을 수치적으로 분석하고, 두 모델의 성능을 비교하였다. FLOW-3D는 난류 흐름과 수력 점프를 보다 정밀하게 예측하는 데 유용하며, HEC-RAS는 정상 유동 조건에서 경제적인 해석이 가능함을 확인하였다.

6. 참고 문헌

  1. Akan, A. O. (2006), Open Channel Hydraulics, First edition, Elsevier.
  2. Akbar, Z.A.; Habib, M.J.S.; Hassan, L.: Simulation of Hydraulic Jump through Channels Junction Using the FLOW-3D and Flunent Models, Research Journal of Recent Sciences, 4(1), 129-134 (2015).
  3. Babaali, H.; Shamsai, A.; Vosoughifar, H.: Computational Modeling of the Hydraulic Jump in the Stilling Basin with Convergence Walls Using CFD Codes, Arabian Journal for Science and Engineering, 4(2), 381–395 (2015).
  4. Chanson, H.: The Hydraulics of Open Channel Flow: An Introduction, Second edition, Elsevier (2004).
  5. Chow, V.T.: Open-Channel Hydraulics, McGraw-Hill (1959).
  6. Cook, A.C.: Comparison of One-Dimensional HEC-RAS with Two-Dimensional FESWMS Model in Flood Inundation Mapping, MSc thesis, Purdue University, USA (2008).
  7. Crookston, B.M.; Paxson, G.S.; Savage, B.M.: Hydraulic Performance of Labyrinth Weirs for High Headwater Ratios, The 4th IAHR International Symposium on Hydraulic Structures, Porto, Portugal, 1-8 (2012).
  8. FLOW-3D Documentation, Release 10.1.0, Flow Science, Inc. (2012).
  9. Graebel, W.P.: Advanced Fluid Mechanics, Elsevier (2007).
  10. Gonzalez, N.S.: Two-Dimensional Modeling of the Red River Floodway, MSc thesis, University of Manitoba, Canada (1999).
  11. Hoseini, S.H.: 3D Simulation of Flow over a Triangular Broad-Crested Weir, Journal of River Engineering, 2(2), 1-7 (2014).
  12. Khazaee, I.; Mohammadiun, M.: Effect of flow field on open channel flow properties using numerical investigation and experimental comparison, International Journal of Energy and Environment, 3(4), 617-628 (2012).
  13. Mohammed, J.R.; Qasim, J.M.: Comparison of One-Dimensional HEC-RAS with Two-Dimensional ADH for Flow over Trapezoidal Profile Weirs, Caspian Journal of Applied Sciences Research, 1(6), 1-12 (2012).
  14. Rady, R.M.: 2D-3D Modeling of Flow over Sharp-Crested Weirs, Journal of Applied Sciences Research, 7(12), 2495-2505 (2011).
  15. Siddique-E-Akbor, A.H.M.; Hossain, F.; Lee, H.; Shum, C.K.: Inter-comparison study of water level estimates derived from hydrodynamic–hydrologic model and satellite altimetry for a complex deltaic environment, Remote Sensing of Environment, Vol. 115, 1522–1531 (2011).
  16. Subramanya, K.: Flow in Open Channels, McGraw-Hill (1986).
  17. Toombes, L.; Chanson, H.: Numerical Limitations of Hydraulic Models, The 34th International
    Association for Hydraulic Research World Congress, Brisbane, Australia, 2322-2329 (2011).
Fig. 6. Vector plot of turbulent energy.

FLOW-3D 모형을 이용한 용승류 모의

Fig. 6. Vector plot of turbulent energy.

1. 서론

  • 최근 일본과 한국에서 대규모 해양구조물을 이용하여 인공적으로 용승류를 발생시키는 연구가 활발히 진행되고 있음.
  • 용승류는 심층수의 영양염을 표층으로 이동시켜 어장 환경을 개선하는 효과를 가짐.
  • 본 연구에서는 FLOW-3D를 이용하여 용승류의 흐름을 수치적으로 모의하고, Marker 기법을 활용하여 영양염의 이동을 분석하는 방법을 탐색함.

2. 연구 방법

FLOW-3D 기반 CFD 모델링

  • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
  • RNG k-ε 난류 모델을 적용하여 유동 해석 수행.
  • FAVOR(Fractional Area/Volume Obstacle Representation) 기법을 활용하여 복잡한 해저 구조 반영.
  • 경계 조건 설정:
    • 유입부: 일정 유량(Volume flow rate) 조건 적용.
    • 유출부: 자유 배출(Outflow) 조건 설정.
    • 벽면: No-slip 조건 적용.
  • 검사단면(Observation section) 설정
    • 검사단면에서의 영양염 농도 변화를 추적하여 용승효과를 정량적으로 분석.

3. 연구 결과

용승류 흐름 분석

  • 용승 구조물 설치 전후 비교 결과, 구조물 설치 후 수직 유속이 증가하여 영양염이 상층으로 이동함.
  • 구조물 높이에 따른 용승류의 강도 변화 확인:
    • 높이 14m: 최대 연직 유속 0.204 m/s.
    • 높이 17m: 최대 연직 유속 0.210 m/s.
  • 난류 강도 및 유동 패턴
    • 용승류가 발생하는 위치에서 난류 에너지가 증가하며, 영양염이 효과적으로 이동하는 것으로 나타남.
  • Marker 기법을 이용한 영양염 이동 분석
    • 해저에 분포한 Marker가 구조물의 용승 효과로 인해 표층으로 이동하는 것을 확인함.

4. 결론 및 제안

결론

  • FLOW-3D 기반 수치 모델이 용승류 효과를 정성적으로 분석하는 데 유용함.
  • 구조물의 높이가 증가할수록 용승류가 강해지고, 영양염의 이동 효과가 뚜렷해짐.
  • 검사단면에서의 영양염 농도 변화를 분석하면 용승효과를 사전에 평가할 수 있음.

향후 연구 방향

  • 다양한 구조물 형상과 배치 조건에서 용승효과 최적화 연구.
  • LES(Large Eddy Simulation) 모델과의 비교 연구 수행.
  • 현장 데이터를 기반으로 실험적 검증 진행.

5. 연구의 의의

본 연구는 FLOW-3D를 활용하여 인공 용승류의 유동 특성을 수치적으로 분석하고, Marker 기법을 이용하여 영양염의 이동을 정량적으로 평가하였다. 이를 통해 어장 조성 사업의 효과를 사전에 예측할 수 있는 방법론을 제시한다.

6. 참고 문헌

  1. 신정교, 김규한, 편종근 (2004). 인공리프의 용승류 발생효과에 관한 연구, 대한토목학회 정기학술대회논문집, 5548-5551.
  2. 해양수산부 (2005). 인공용승류를 이용한 어장환경 개선 연구 1차년도 보고서.
  3. 해양수산부 (2006). 인공용승류를 이용한 어장환경 개선 연구 2차년도 보고서.
  4. 해양수산부 (2007). 인공용승류를 이용한 어장환경 개선 연구 3차년도 보고서.
  5. 金卷精一, 鈴木達雄 (2001). 沖合域における漁場造成の課題, 水産工學關係試驗硏究推進會議水産基盤部會報告書, 水産工學硏究所, 23-41.
  6. 武田眞典, 左タ木洋之 (2006). 人工海底山脈漁場造成現狀課題, 全國漁港漁場整備技術硏究發表會講演集, 5, 105-120.
  7. 中島敏光 (2002). 海洋深層水の利用, 綠書房.
Figure 10. Three-dimensional illustration of Froude number in various tailwaters. (a) 129.10 m, (b) 129.40 m, (c) 129.70 m, (d) 129.99 m, and (e) 130.30 m

Hydraulic Characteristic Analysis of Buoyant Flap Typed Storm Surge Barrier using FLOW-3D Model

FLOW-3D 모델을 이용한 부유 플랩형 폭풍 해일 방어벽의 수리 특성 분석

1. 서론

  • 본 연구는 부유 플랩형 폭풍 해일 방어벽의 수리학적 특성을 수치적으로 분석하는 것을 목적으로 함.
  • 폭풍 해일 제어 및 연안 홍수 완화에서 방어벽의 효과를 평가하기 위해 수행됨.
  • FLOW-3D 소프트웨어를 이용하여 방어벽의 유체역학적 거동을 모델링함.

2. 연구 방법

  • 전산유체역학(CFD) 기법을 적용하여 부유 플랩형 방어벽을 모델링함.
  • 수치 모델의 주요 구성 요소:
    • 레이놀즈 평균 나비에-스토크스(RANS) 방정식을 이용한 난류 모델링.
    • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
    • 실제 조석(tidal) 및 폭풍 해일(storm surge) 조건을 반영한 경계 조건 적용.
  • 기존 실험 데이터를 활용하여 모델 검증 수행.

3. 연구 결과

  • 주요 연구 결과:
    • 방어벽이 수위 감소 및 파랑 에너지 저감에 효과적임을 확인.
    • 방어벽 각도에 따라 와류(vortex) 형성 및 난류 강도가 변화함.
    • 파고, 방어벽 유연성, 유속에 따라 구조적 안정성이 영향을 받음.
  • 실험 데이터와의 비교를 통해 모델의 예측 정확성이 높음을 확인함.

4. 결론

  • 부유 플랩형 폭풍 해일 방어벽은 연안 홍수 완화에 효과적인 대안이 될 수 있음.
  • CFD 시뮬레이션을 통해 방어벽 설계 최적화에 유용한 정보를 제공할 수 있음.
  • 향후 연구에서는 장기적인 구조적 내구성 및 실제 환경에서의 적용 가능성을 중점적으로 다뤄야 함.
Figure 1. Location of the study area
Figure 1. Location of the study area

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Graphical Abstract

Flow-3D Numerical Modeling of Converged Side Weir

수렴형 측방 위어의 FLOW-3D 수치 모델링

연구 배경 및 목적

문제 정의

  • 측방 위어(side weir)는 수로 및 하천에서 홍수 조절, 유량 분배 및 관개 시스템에서 중요한 역할을 함.
  • 기존 연구는 주로 단순한 프리즘형(prismatic) 채널에서 수행되었으며, 수렴형(converged) 채널에서의 측방 위어 성능 연구는 부족함.
  • 수렴형 채널에서 위어의 효율성 증대 가능성을 검토하고, FLOW-3D를 이용한 정량적 분석이 필요함.

연구 목적

  • FLOW-3D를 사용하여 수렴형 채널에서 측방 위어의 유동 특성을 수치적으로 분석.
  • 실험 모델과 비교하여 FLOW-3D의 신뢰성을 검증.
  • 수렴각 및 하류 채널 폭 변화가 위어 성능(유량 분배, 수위 변화, 에너지 손실 등)에 미치는 영향 평가.

연구 방법

실험 및 수치 모델 개요

  • 실험 환경:
    • 실험실 규모 수로(길이 700mm, 폭 310mm, 높이 480mm).
    • 다양한 위어 길이(5개), 위어 크레스트 높이(4개), 수렴각(2개), 하류 채널 폭(3개) 조건에서 총 33개 실험 수행.
    • 유량 범위: 10~100m³/h.
  • FLOW-3D 기반 CFD 시뮬레이션 설정:
    • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
    • RNG k-ε 난류 모델 적용.
    • 격자(Grid) 설정: 메쉬 크기 1cm, 전체 셀 수 모델 크기에 따라 조정.
    • 경계 조건:
      • 유입: 부피 유량 조건(volume flow rate).
      • 유출: 자유 배출(outflow) 경계 조건.
      • 벽면: No-slip 조건 적용.

주요 결과

수렴형 vs. 프리즘형 채널 비교

  • 수렴형 채널에서 하류 폭을 감소시키면 위어 상류 수심이 증가하여 위어를 통한 유량 분배 증가.
  • 수렴각이 클수록 수위 및 특정 에너지가 증가하여 유출량(Qw/Q0) 비율 향상.
  • 프리즘형 채널 대비 수렴형 채널이 동일한 유량에서도 더 높은 위어 크레스트 수위를 형성하여 방류 효율성이 증가.

수위 및 유속 분포 분석

  • 위어 상류 및 중간부에서 수면 경사가 하강하는 경향, 그러나 위어 끝에서는 상승하는 패턴 확인.
  • 최대 유속이 수렴 채널에서 위어 시작점 근처에서 발생, 반면 횡방향 유속은 위어 중앙부에서 최대값 도달.
  • 에너지 손실 분석 결과, 하류 채널 폭 감소(b/B ↓)에 따라 에너지 손실 감소, 이는 유량 분배 효율 증가로 연결됨.

결론 및 향후 연구

결론

  • FLOW-3D 시뮬레이션 결과와 실험 데이터가 높은 일치도를 보이며(R² = 0.98), 수렴형 측방 위어의 유동 특성을 효과적으로 예측 가능.
  • 수렴형 채널에서 위어의 효율성이 증가하며, 하류 채널 폭이 줄어들수록 위어 상류 수위가 상승하여 방류량이 증가.
  • b/B 비율이 작을수록(즉, 하류 채널이 좁을수록) 위어의 성능이 개선됨.

향후 연구 방향

  • LES(Large Eddy Simulation) 모델과의 비교 분석 수행.
  • 다양한 채널 형상 및 유량 조건에서 추가적인 검증 수행.
  • 실제 하천 및 관개 시스템 적용을 위한 최적 설계 모델 연구.

연구의 의의

이 연구는 FLOW-3D를 활용하여 수렴형 측방 위어의 유동 및 에너지 특성을 분석하고, 실험 데이터를 통해 모델의 신뢰성을 검증하였다. 수렴형 채널 설계를 통해 위어 성능을 최적화할 수 있음을 입증하며, 실무 적용 가능성이 높음.

References

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Figure 5. Boundary conditions of the BRA weir model

Numerical Simulation for Flow over A Broad-Crested Weir Using FLOW-3D

FLOW-3D를 이용한 광정수로 위어 유동 수치 시뮬레이션

연구 배경 및 목적

문제 정의

  • 광정수로 위어(broad-crested weir)는 수위 조절, 유량 측정 및 에너지 감쇠에 널리 사용되는 수리학적 구조물임.
  • 기존 실험 연구는 비용이 높고 시간이 소요되므로 FLOW-3D를 이용한 CFD(전산유체역학) 기반 연구가 필요함.

연구 목적

  • FLOW-3D를 사용하여 다양한 상·하류 경사 조건에서 광정수로 위어의 유동 특성을 수치적으로 분석.
  • 방출 계수(discharge coefficient, Cd), 에너지 등고선(energy grade line, H1) 및 평균 유속을 계산하여 위어 형상의 영향을 평가.
  • 실험 데이터와 비교하여 FLOW-3D의 예측 정확도를 검증.

연구 방법

FLOW-3D 시뮬레이션 설정

  • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
  • Navier-Stokes 방정식 기반의 유체 거동 해석 수행.
  • 난류 모델: k-ε 모델 적용.
  • 경계 조건:
    • 유입: 부피 유량 조건(volumetric flow rate).
    • 유출: 지정 압력 조건(specified pressure).
    • 벽면: No-slip 조건 적용.
  • 메쉬 크기: FAVOR(Fractional Area/Volume Obstacle Representation) 기법을 활용하여 적절한 격자 크기 선정.

실험 및 검증 방법

  • 실험 모델: 수평 유량 수조(flume) 내 다양한 위어 형상 실험.
  • 위어 유형: 네 가지 형상(ARB, BRA, VRB, BRV) 비교 분석.
  • 유량(Q): 0.004~0.018 m³/s 범위에서 분석 수행.

주요 결과

방출 계수(Cd) 분석

  • 유입면의 경사가 증가할수록 방출 계수 Cd가 감소.
  • Cd 값의 변동 범위: Hager 공식 적용 시 높은 Cd 값, Bazin 공식 적용 시 Cd 값이 선형적으로 증가하는 경향 확인.
  • 유량 증가 시 Cd 값도 점진적으로 증가, 그러나 하류 경사는 Cd에 미미한 영향을 미침.

에너지 등고선(H1) 및 유속 분석

  • 유입 경사가 증가할수록 에너지 등고선(H1) 값이 증가하여 흐름 저항 증가.
  • 하류 경사는 H1 값에 거의 영향을 주지 않음.
  • 유속 분석 결과, 같은 유량에서 유입 경사가 작을수록 흐름 속도가 감소.

결론 및 향후 연구

결론

  • FLOW-3D는 광정수로 위어의 유동 특성을 정확하게 예측할 수 있음.
  • 유입 경사가 증가할수록 방출 계수 감소 및 유속 증가, 반면 하류 경사는 유동 특성에 거의 영향을 미치지 않음.
  • Cd 값은 Bazin 공식이 Hager 공식보다 실험값과 더 높은 일치도를 보임.

향후 연구 방향

  • LES(Large Eddy Simulation) 및 다른 난류 모델과 비교 연구.
  • 다양한 위어 형상 및 유량 조건에서 추가적인 검증 수행.
  • 실제 하천 환경에서의 적용 가능성 연구.

연구의 의의

이 연구는 FLOW-3D를 활용하여 광정수로 위어의 유동 및 방출 계수를 정량적으로 분석하고, CFD 모델의 신뢰성을 검증하였다. 수리학적 설계 최적화를 위한 데이터 및 분석 방법을 제공한다.

References

  1. Abid, S. R., Hilo, A. N., Ayoob, N. S. and Daek Y. H. (2019). “Underwater abrasion of steel fiber-reinforced self-compacting concrete”, Case Studies in Construction Materials, vol. 11, pp. 1-17.
  2. Abimbola, A. O. (2018). “Wave propagation and scour failure of coastal structures due to tsunamis”, Ph.D thesis.
  3. ACI Committee 210. (2003). “Erosion of concrete in hydraulic structure (ACI 210R-03)”, American concrete institute, USA, pp. 1-24.
  4. Arun, K. and Ritu, R. (2022). “CFD Study of Flow Characteristics and Pressure Distribution on Re-Entrant Wing Faces of L-Shape Buildings“. Civil Engineering and Architecture, vol. 10(1), pp. 289-304. DOI: 10.13189/cea.2022.100125.
  5. Azimi, A. H. and Rajaratnam, N. (2009). “Discharge characteristics of weirs of finite crest length”, Journal of Hydraulic Engineering, vol. 135(12), pp. 1081-1085.
  6. Bazin, H. (1898). “Experience nouvelles sur l’ ecoulement en deversoir”, Ann. Ponts chausses, vol. 68(2), pp. 151-265.
  7. BSI (1969b). Measurement of Liquid Flow in Open Channels: Weirs and Flumes, BS 3680, Part 4, British Standards Institution, London.
  8. Chow, V.T., 1959. Open-channel hydraulics, McGraw-Hill.
  9. Flow Science. (2014). “FLOW-3D version 11 user manual”.
  10. Fritz, H. M. and Hager, W. H. (1998). “Hydraulics of embankment weirs”, Journal of Hydraulic Engineering, vol. 124(9), pp. 963-971.
  11. Gonzalez, C. A. and Chanson, H. (2007). “Experimental measurements of velocity and pressure distribution on large broad-crested weir”, Flow measurement and Instrumentation, vol., pp. 107-113.
  12. Hager, W. H. and Schwalt, M. (1994). “Broad-crested weir”, Journal of Irrigation and Drainage Engineering, vol. 120(1), pp. 13-26.
  13. Haun, S., Olsen, N. R. B. and Feurich, R. (2011). “Numerical modeling of flow over trapezoidal broad-crested weir”, Engineering Applications of Computational Fluid Mechanics, vol. 5(3), pp. 397-405.
  14. Hilo, A. N., Ayoob, N. S. and Daek, Y. H. (2021). Numerical Simulation to Evaluate The Effect of The Stepped Chute on Abrasion Erosion of A Stilling Basin Type III. IOP Conference Series: Materials Science and Engineering, vol. 1090, pp. 1-11.
  15. Sargison, J. E. and Percy, A. (2009). “Hydraulics of broad-crested weirs with varying side slopes”, Journal of Irrigation and Drainage Engineering, vol. 135(1), pp. 115-118.
  16. Sarker, M. A. and Rhodes, D. G. (2004). “Calculation of free-surface profile over a rectangular broad-crested weir”, Flow Measurement and Instrumentation, vol. 15, pp. 215-219.
Figure 4 Simulated velocity magnitude

An Experimental and Numerical Study of Ski-Jump Spillway Using FLOW-3D

FLOW-3D를 이용한 스키점프형 여수로의 실험 및 수치적 연구

연구 배경 및 목적

문제 정의

  • 스키점프형 여수로는 유속이 20m/s를 초과할 때 사용되는 중요한 구조물이며, 에너지 소산을 위한 핵심 설계 요소임.
  • 기존의 물리 실험은 비용이 높고 시간이 많이 소요되므로 컴퓨터 기반 CFD(전산유체역학) 시뮬레이션을 통한 연구가 필요함.

연구 목적

  • FLOW-3D를 이용하여 스키점프형 여수로의 유동 특성을 수치적으로 분석.
  • 실험 데이터와 비교하여 FLOW-3D 모델의 정확성을 검증.
  • 여수로의 제트 궤적(jet trajectory), 압력 분포 및 에너지 소산 특성 분석.

연구 방법

실험 및 수치 모델 개요

  • 연구 대상: IS 7365 (2010) 표준을 따른 전통적인 스키점프형 여수로.
  • 실험 조건:
    • 수로 크기: 폭 0.30m, 깊이 0.30m, 길이 6m의 유리제 수리 실험 수로.
    • 연속된 곡면 립(lip) 각도 35°, 반경 0.0915m.
    • 유량(Q): 0.00431 ~ 0.00962 m³/s 범위.

FLOW-3D 기반 CFD 시뮬레이션 설정

  • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
  • RNG k-ε 난류 모델을 적용하여 난류 해석 수행.
  • FAVOR(Fractional Area/Volume Obstacle Representation) 기법을 적용하여 장애물 영역 설정.
  • 경계 조건:
    • 유입: 지정 속도 조건.
    • 유출: 지정 압력 조건.
    • 벽면: No-slip 조건 적용.

주요 결과

유동 및 에너지 소산 특성 분석

  • 스키점프형 여수로에서 유동이 곡면을 따라 흐르면서 에너지가 점진적으로 소산됨.
  • FLOW-3D 결과와 실험 데이터의 에너지 소산율 비교
    • 최대 오차율 15.69%로 나타났으며, 실험과 높은 일치도를 보임.
    • 유량이 증가할수록 에너지 소산율이 감소하는 경향 확인.
  • 제트 궤적 및 압력 분포 분석
    • 시뮬레이션 결과와 실험값이 3D 유동장 및 압력 분포에서 일치함을 확인.

결론 및 향후 연구

결론

  • FLOW-3D 기반 시뮬레이션이 실험 결과와 높은 일치도를 보이며, 스키점프형 여수로의 유동 및 에너지 소산 특성을 효과적으로 예측 가능.
  • 유량 변화에 따른 에너지 소산율 감소 경향을 확인하였으며, 추가적인 최적화 연구 필요.

향후 연구 방향

  • LES(Large Eddy Simulation) 난류 모델과 비교 분석 수행.
  • 다양한 여수로 형상 및 유량 조건에서 추가적인 검증 수행.
  • 실제 댐 적용 사례와 비교 연구 수행.

연구의 의의

이 연구는 FLOW-3D를 활용하여 스키점프형 여수로의 유동 및 에너지 소산 현상을 정량적으로 분석하고, 수치 모델의 정확성을 실험적으로 검증하였다. 댐 설계 및 홍수 방지 인프라 구축에 중요한 데이터와 분석 방법을 제공한다.

References

  1. High Overflow Dams, Hydraulic Design Criteria, U.S. Army Corps of Engineers, Waterways Experiment Station, 1970.
  2. R. Maitre, S. Obolensky, Etude de Quelques Caractéristiques de l’Ecoulement dans la Partie Aval des Evacuateurs de Surface, La Houille Blanche 4 (1954) 481–511.
  3. T.J. Rhone, A. J. Peterka, Improved tunnel spillway flip buckets, Journal of Hydraulic Engineering, ASCE 126 (1959) 1270–1291.
  4. A.C. WATERS, Terraces and coulees along the Columbia River near lake Chelan, Washington. Geological Society of America Bulletin 44 (1933) 783–820.
  5. R. Joun, W.H. Hager, Flip bucket without and with deflectors, Journal of Hydraulic Engineering, ASCE 126 (2000) 837–845.
  6. M. Jorabloo, R. Maghsoodi, H. Sarkardeh, 3D Simulation of flow over flip buckets at dams, Journal of American Science 7 (2011) 931–936.
  7. O. A. Yamini, M. R. Kavianpour, Experimental study of static and dynamic pressures over simple flip bucket, 5th symposium on advances in science and technology, Khavaran Highereducation Institute, Mashhad, Iran. May 12-14 (2011).
  8. O.A. Yamini, M.R. Kavianpour, S.H. Mousavi, A. Movahedi, . Bavandpour, Experimental investigation of pressure fluctuation on the bed of compound flip buckets, ISH Journal of Hydraulic Engineering 1 (2017) 1–8.
  9. P. Novak, C. Nalluri, R. Narayanan, Hydraulic Structures, Forth Edition, Taylor & Francis, New York (2007) 246–265.
  10. M.H. Chaudhry, Open-Channel Flow, Second Edition, Springer, 2008.
  11. L. Schmocker, M. Pfister, W.H. Hager, H. E. Minor, Aeration characteristics of ski jump jets, Journal of Hydraulic Engineering, ASCE 134 (2008) 90–97.
  12. M. R. Bhajantri, T.I. Eldho, P.B. Deolalikar, Hydrodynamic modelling of flow over a spillway using a two-dimensional finite volume-based numerical model, Sadhana 31 (2006) 743–754.
  13. F.A. Bombardelli, I. Meireles, J. Matos, Laboratory measurements and multi-block numerical simulation of the mean flow and turbulence in the non-aerated skimming flow region of steep stepped spillways, Environ Fluid Mech, Springer 11 (2011) 263–288.
  14. P.G. Chanel, J.C. Doering, An evaluation of computational fluid dynamics for spillway modelling, 16th Australian Fluid Mechanics Conference, Crown Plaza, Gold Coast, Australia, (2007).
  15. B. M. Savage, and M. C. Johanson, Flow over ogee spillway: physical and numerical model case study, J. of Hydraulic Engineering, ASCE 127 (2001) 640–649.
  16. G. Heidarinejad, and A. Najibi, Two-dimensional analysis of flow at the toe of a dam, Proceedings of Intl. Conf. on Hydraulic Structures, Shahid Bahonar Kerman University, Kerman, (2001).
  17. D.K. Ho, H.K.M. Boyes, S.M. Donohoo, Investigation of spillway behaviour under increased maximum flood by computational fluid dynamics technique, 14th Australian Fluid Mechanics Conference, Adelaide University, Adelaide, Australia, (2001).
  18. S. Eklund, CFD modelling of ski-jump spillway in Stornnforsen, Master’s Thesis, Royal Institute of Technology, Sweden, (2017).
Figure 4. Bed bathymetry of the developed scour hole at Q = 0.035 m3 s

Three Dimensional Simulation of Flow Field around Series of Spur Dikes

Spur Dikes 주변의 3차원 유동장 시뮬레이션

Figure 4. Bed bathymetry of the developed scour hole at Q = 0.035 m3 s
Figure 4. Bed bathymetry of the developed scour hole at Q = 0.035 m3 s

연구 배경 및 목적

문제 정의

  • Spur Dikes는 하천 제방 보호 및 유로 조절을 위해 사용되며, 국부적인 세굴(scour)과 유동장 변화가 발생함.
  • 기존의 물리 실험은 시간과 비용이 많이 소요되므로 컴퓨터 기반 CFD(전산유체역학) 시뮬레이션을 활용한 연구가 필요함.

연구 목적

  • FLOW-3D를 이용하여 Spur Dikes 주변 유동 특성을 3차원적으로 분석.
  • 실험 데이터와 비교하여 FLOW-3D 모델의 정확성을 검증.
  • 다양한 난류 모델(RNG k-ε, LES 등)의 성능을 비교하여 최적의 난류 모델 선정.

연구 방법

실험 및 수치 모델 개요

  • 연구 대상: 연속된 세 개의 Spur Dikes가 있는 수로.
  • 실험 조건:
    • 수로 길이 12.2m, 폭 0.6m, 깊이 1.2m.
    • Sontek ADV를 이용하여 유속 측정.
    • 실험 후 세굴 형상 측정 및 모델 검증 수행.

FLOW-3D 기반 CFD 시뮬레이션 설정

  • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 추적.
  • RNG k-ε, LES 및 표준 k-ε 난류 모델 비교.
  • 격자(Grid) 민감도 분석을 통해 최적의 격자 크기 결정(3mm).
  • 경계 조건:
    • 유입: 평균 속도 0.29m/s 적용.
    • 유출: 자유 배출(outflow) 경계 설정.
    • 바닥: No-slip 조건 적용, 이동 가능한 퇴적층 설정.

주요 결과

유동 및 세굴 특성 분석

  • Spur Dikes 전면에서 강한 와류(vortex) 발생 → 세굴 형성의 주요 원인.
  • RNG k-ε 모델이 실험 데이터와 가장 높은 정확도를 보임.
  • LES 모델은 고난류 영역에서 비교적 정확하지만 계산 비용이 높음.
  • 표준 k-ε 모델은 난류 에너지를 과대평가(50% 이상의 오차).

결론 및 향후 연구

결론

  • FLOW-3D 기반 시뮬레이션이 실험 결과와 높은 일치도를 보이며, Spur Dikes 주변의 유동 및 세굴 현상을 효과적으로 예측 가능.
  • RNG k-ε 모델이 가장 적합한 난류 모델로 평가됨.
  • 세굴 깊이는 초기 및 주요 세굴 단계에서 대부분 결정되며, 이후 큰 변화 없음.

향후 연구 방향

  • LES(Large Eddy Simulation) 적용 범위 확대 및 정확도 비교.
  • 실제 하천 환경과의 비교 연구 수행.
  • 세굴 예측 모델 개선을 위한 추가적인 실험 검증 수행.

연구의 의의

이 연구는 FLOW-3D를 활용하여 Spur Dikes 주변의 유동 및 세굴 현상을 정량적으로 분석하고, 수치 모델의 정확성을 실험적으로 검증하였다. 하천 관리 및 구조물 설계의 최적화에 기여할 수 있는 데이터와 분석 방법을 제공한다.

References

  1. F.D. Shields, Jr., C.M. Cooper, and S.S. Knight, Experiment in stream restoration, J. Hydraul. Eng., 121(6), 1995, 494–502.
  2. R.A. Kuhnle, Y. Jia, and C.V. Alonso, Measured and simulated flow near a submerged spur dike, J. Hydraul. Eng., 1348(7), 2008, 916–924.
  3. R.J. Garde, K. Subramanya, and K.D. Nambudripad, Study of scour around spur-dikes, J. Hydraul. Div., ASCE, 87(6), 1961, 23–37.
  4. E.M. Laursen, Analysis of relief bridge scour, J. Hydraul. Div., Am. Soc. Civ. Eng., 89(3), 1963, 93–118.
  5. M.A. Gill, Erosion of sand beds around spur dikes, J. Hydraul. Div., ASCE, 98(9), 1972, 1587–1602.
  6. T.F. Kwan, and B.W. Melville, Local scour and flow measurements at bridge abutments, J. Hydraul. Res., 32(5), 1994, 661–673.
  7. S.Y. Lim, Equilibrium clear water scour around an abutment, J. Hydraul. Eng., 123(3), 1997, 237–243.
  8. M.M. Rahman, N. Nagata, Y. Muramoto, and H. Murata, Effect of side slope on flow and scouring around spur-dike-like structures, Proc., 7th Int. Symp. on River Sedimentation, Hong Kong, China, 1998, 165–171.
  9. N. Nagata, T. Hosoda, T. Nakato, and Y. Muramoto, Three-dimensional numerical model for flow and bed deformation around river hydraulic structures, J. Hydraul. Eng., 131(12), 2005, 1074-1087.
  10. C.J. Posey, Why bridges fail in floods, Civ. Eng. (N.Y.), 19, 1949, 42–90.
  11. H.W. Shen, V.R. Schneider, and S. Karaki, Local scour around bridge piers, J. Hydraul. Div., Am. Soc. Civ. Eng., 95(6), 1969, 1919–1940.
  12. B. Dargahi, Flow field and local scouring around a pier. Bulletin No. TRITA-VBI-137, Hydraulic Laboratory, Royal Institute of Technology, Stockholm, Sweden, 1988.
  13. A. J. Raudkivi, Loose boundary hydraulics (3rd Ed., Pergamon, New York, 1990).
  14. F. Ahmed, and N. Rajaratnam, Flow around bridge piers, J. Hydraul. Eng., 124(3), 1998, 288 – 300.
  15. F. Ahmed, and N. Rajaratnam, Observations of flow around bridge abutment, J. Eng. Mech., 126(1), 2000, 51 – 59.
  16. B.W. Melville, Local scour at bridge abutments, J. Hydraul. Eng., ASCE, 118(4), 1992, 615–631.
  17. W.S. Uijttewaal, D. Lehmann, and A. van Mazijk, Exchange processes between a river and its groyne fields: model experiments, J. Hydraul. Eng., ASCE, 127(11), 2001, 928–936.
  18. V. Weitbrecht, W. Uijttewaal, and G.H. Jirka, 2D particle tracking to determine transport characteristics in rivers with dead zones, Proc., Int. Symp. Shallow Flows, Delft, The Netherlands, 2009, 103–110.
  19. M.A. Stevens, M.M. Gasser, and M.B.A.M. Saad, Wake vortex scour at bridge piers, J. Hydraul. Eng., 117(7), 1991, 891–904.

Fig. 12. Three-dimensional flow pattern plot (Q = 156.23 m3 s)

삼천포 화력발전소 방류 지역의 FLOW-3D 모델을 이용한 흐름 패턴 변화 예측

연구 배경 및 목적

  • 삼천포 화력발전소는 냉각수로 사용되고 방류되는 해수를 이용한 소수력 발전소를 건설 중
  • 소수력 발전소는 발전량을 최대화하기 위해 규모를 크게 하는 것이 바람직하지만, 방류수로의 기능을 저해하지 않는 범위 내에서 결정해야 함
  • 따라서 적정 규모를 결정하기 위해서는 수리학적 고려가 필요
  • 본 연구에서는 현재 방류수로의 흐름 특성 자료를 이용하여 3차원 흐름 모형인 FLOW-3D 모형을 구축하고, 구축된 모형을 이용하여 소수력 발전소의 규모에 따른 방류수로 상류 지점의 수위 증가 양상을 예측하고, 발전소 건설에 따른 흐름 변화 양상을 분석하는 것을 목적으로 함

연구 방법

  • 삼천포 소수력발전 실용화 기술사업의 일환으로 관측된 방류수로 및 방류해역의 흐름자료 및 선정된 대안에 대하여 댐의 규모(높이, 가동보 설치 규모)에 따른 방류수로의 수위변화를 예측하기 위하여 FLOW-3D 흐름 모형을 구축
  • 구축된 모형을 이용하여 다양한 설계조건(주로, 발전시설 우안에 설치되는 냉각수 방류량 월류를 위한 가동보의 높이 변화)에 대한 방류수로의 수위 및 유속변화 양상을 예측·분석했으며, 최적의 소수력 발전소 규모 결정에 필요한 검토자료로 이용
  • FLOW-3D 모형은 댐 여수로의 흐름 해석을 포함하여 다양한 수리 구조물에서의 흐름 해석에 널리 활용되고 있는 모형으로, 적절한 모형의 보정 및 검증만 수행된다면 매우 정확하게 흐름장을 재현할 수 있기 때문에 수리 실험 대체 수단으로의 가능성이 검토되고 있음

연구 결과

  • 삼천포 소수력발전소 건설은 상류의 수위 증가를 유발하며, 설계 유량 156톤/초, 발전소 가동보 높이 3.8m 기준에 대한 방류수로 Weir 상류지점의 수위는 4.97m로 현 상태 4.32m보다 65cm 정도 증가하는 것으로 파악됨

Reference

  1. 김남일 (2003). Investigation of Scale Effects of Hydraulic Model for Dam Spillway Using 3-D CFD Model. 박사학위논문, 서울대학교.
  2. 이길성, 이종현 (2003). CFD 모형을 이용한 여수로 수리모형의 축척효과 조사, 대한토목학회 정기학술대회 논문집, 대한토목학회, pp. 2700-2703.
  3. 한국수자원공사, 대우건설 (2004). 화북 다목적댐 건설공사 여수로 수치해석 보고서.
  4. 한국전력공사, 전력연구원 (2004). 화력발전소의 해수방류수를 이용한 수력발전시스템 타당성 조사 연구(최종보고서), 산업자원부.
  5. 한국전력공사 (1994). 삼천포화력 5,6호기 설계기술 용역, 배수구 구조물 기본설계보고서(최종분), 89700-C411-001 (9-287-C3411-001).
  6. 한국전력공사 (1996). 삼천포화력 5,6호기 설계기술 용역, 순환수계통 설계서 (최종분), 87900-C466-001 (0-280-C3316-001).
  7. 한국남동발전(주) (2005), 삼천포 소수력발전소 기본설계보고서.
Figure 3 Velocity Distribution from Plan View and Profile View (Case 2)-1

Power Intake Velocity Modeling Using FLOW-3D at Kelsey Generating Station

FLOW-3D를 활용한 Kelsey 발전소의 발전기 유입부 유속 모델링

연구 배경 및 목적

문제 정의

  • Manitoba Hydro는 기존 발전소의 효율성을 개선하는 Supply Efficiency Improvement Program을 진행 중임.
  • Kelsey 발전소(224MW)는 Upper Nelson River에 위치하며, 7개의 발전 유닛을 보유.
  • 발전소 입구 채널에는 암반 장애물(rock knob)이 존재하여 비균일한 유동을 발생시키며, 특히 유닛 6, 7의 효율에 영향을 미침.
  • 터빈 재설치(re-runnering) 후 유량이 1700m³/s에서 2200m³/s로 증가할 것으로 예상되므로, 최적의 유입 유동 조건 평가가 필요함.

연구 목적

  • FLOW-3D를 이용하여 Kelsey 발전소의 기존 및 개선된 유입 유동을 시뮬레이션.
  • 발전소 입구에서 발생하는 유속 분포를 분석하여 터빈 제조업체에 제공.
  • 암반 장애물의 영향을 평가하고, 재설치 후 유량 증가에 따른 유동 변화를 분석.

연구 방법

수치 모델링 및 시뮬레이션 설정

  • FLOW-3D를 사용하여 3차원 수치 모델을 구축.
  • 발전소 설계도면을 기반으로 주요 입구 구성 요소를 모델링, 단 작은 구조물(트래시 랙, 게이트 가이드 등)은 제외.
  • 세 가지 운영 시나리오(Case 1~3) 설정:
    1. Case 1: 유닛 1~7 전부 재설치 후 완전 개방(Full Gate, FG)
    2. Case 2: 유닛 1-5만 재설치, 유닛 67 기존 상태 유지(FG)
    3. Case 3: 유닛 1-5만 재설치, 유닛 67 기존 최적 게이트(Best Gate, BG)
  • 경계 조건:
    • 상류: 일정 수위 조건 적용
    • 하류: 질량 소모(mass sink) 방식 사용하여 발전기 유량 반영
  • 격자 설정:
    • 입구 채널은 상대적으로 큰 격자 사용, 발전소 입구는 세밀한 격자로 설정하여 정확도 향상.

주요 결과

유동 특성 분석

  • Case 1(전 유닛 재설치)에서 유속 분포가 가장 균일하게 나타남.
  • Case 2, 3에서는 암반 장애물로 인해 유닛 6, 7에서 강한 와류(vortex) 형성, 이는 효율 저하 가능성이 있음.
  • 실제 1990년 현장 실험과 비교 시, 모델링 결과가 높은 정확도로 일치.

결론 및 향후 연구

결론

  • FLOW-3D 모델이 Kelsey 발전소 유입부 유속 분포를 정확히 재현 가능함을 확인.
  • 암반 장애물이 유닛 6, 7의 유동을 왜곡하며, 터빈 효율을 저하시킬 가능성이 있음.
  • 터빈 제조업체가 최적 설계를 수행할 수 있도록 유속 데이터를 제공.

향후 연구 방향

  • 터빈 재설치 후 실측 데이터와 모델 비교 검증.
  • 암반 장애물 제거 또는 유동 개선 방안 연구.
  • 다른 발전소 적용을 위한 추가적인 CFD 해석 수행.

연구의 의의

본 연구는 FLOW-3D를 활용하여 발전소 유입부 유동을 분석하고, 터빈 재설치 후 유동 변화를 예측하는 기법을 제시하였다. 이를 통해 발전소 운영 효율을 극대화하고, 최적 설계를 지원할 수 있는 유용한 데이터를 제공하였다.

References

  1. Efrem Teklemariam and Joe L. Groeneveld. 2000. Solving Problems in Design and Dam Safety with Computational Fluid Dynamics, Hydro Review, Vol. 5: 48-52.
  2. Efrem Teklemariam, Brian W. Korbaylo, Joe L. Groeneveld and David M. Fuchs. 2002. Computational Fluid Dynamics: Diverse Applications in Hydropower Project’s Design and Analysis, CWRA 55th Annual Conference, Winnipeg, Manitoba, CA, pp: 1-20.
  3. Flow Science Inc. 2006. Flow 3D version 9.1 user manual.
  4. Fuamba, M., Role. 2006. Behavior of Surge Chamber in Hydropower: Case of the Robert Bourassa Hydro Power Plant in Quebec, Canada, Dams and Reservoir, Societies and Environment in the 21st Century- Berga et al (eds) @ 2006 Taylor & Francis Group, London, ISBN 0415 40423 1.
  5. Joe L. Groeneveld, Kevin M. Sydor, David M. Fuchs, Efrem Teklemariam and Brian W. Korbaylo. 2001. Optimization of Hydraulic Design using Computational Fluid Dynamics, Waterpower XII, July 9-11, Salt Lake City, Utah.
  6. Marc St. Laurent, Efrem Teklemariam, Paul Cooley and Joe Groeneveld. 2002. Application of Hydraulic Models for the Environmental Impact Assessment of the Proposed Wuskwatim Generating Station, June 11-14, CWRA 55th Annual Conference, Winnipeg, Manitoba, CA.
  7. Michael C. Johnson and Bruce M. Savage. 2006. Physical and Numerical Comparison of Flow over Ogee Spillway in the Presence of Tail water, Journal of Hydraulic Engineering, Vol. 312, pp: 1353-1357.
Fig. 3 Frictional heat generation rate

전산유체역학을 활용한 마찰교반용접의 해석적 접근에서 표면추적을 위한 알고리즘 연구

A Study on an Interface Tracking Algorithm in Friction Stir Welding Based on Computational Fluid Dynamics Analysis

Fig. 3 Frictional heat generation rate
Fig. 3 Frictional heat generation rate

연구 배경 및 목적

문제 정의

  • 마찰교반용접(Friction Stir Welding, FSW)은 고상 용접 기술로, 기존 용접 방법보다 결함이 적고 알루미늄과 같은 난용접 소재에도 적용 가능함.
  • 기존 CFD 해석에서는 툴과 모재 간의 마찰에 의한 열원을 정확히 모델링하지 못하고 소성변형에 의한 열원만 고려하는 경우가 많았음.

연구 목적

  • FLOW-3D를 활용하여 FSW 공정에서 툴과 모재 간의 마찰열원을 정밀하게 모델링할 수 있는 표면추적 알고리즘 개발.
  • 새로운 알고리즘을 통해 툴의 회전과 이동을 동시에 고려한 마찰열원 계산을 수행하고, 해석 결과를 이론적 계산값과 비교하여 검증.

연구 방법

표면추적 알고리즘 개발

  • 툴의 형상(숄더, 핀 측면, 핀 밑면) 및 이동 궤적을 반영한 인터페이스 추적 기법 적용.
  • 툴의 중심 좌표와 셀 중심 간의 거리를 계산하여 툴 표면 셀을 추적.
  • 표면적 평균값을 활용하여 마찰열원의 크기를 계산하는 방식 도입.

FSW 시뮬레이션 모델링

  • 유체역학 모델: 점성 유동(visco-plastic flow) 고려.
  • 열 전달 모델: 마찰열과 소성변형열을 포함한 3D 열원 모델 구축.
  • 경계 조건: 모재 하부의 받침판(backing plate)과의 열전달을 대류 경계조건으로 가정.
  • 수치해석 도구: Flow-3D 유저 서브루틴(user subroutine) 활용하여 해석 수행.

주요 결과

마찰열 모델 검증

  • 새로운 표면추적 알고리즘을 적용한 해석 결과, 이론적으로 계산한 마찰열원 값과 최대 3% 이내의 오차율을 보이며 높은 정확도 확인.
  • 해석 결과에서 숄더 > 핀 측면 > 핀 밑면 순으로 열 발생량이 많음, 이는 접촉면적과 속도의 영향 때문임.
  • 기존 연구들과 비교 시, 툴 이동과 회전을 동시에 고려하면서도 보다 정확한 마찰열원을 부여할 수 있음을 입증.

결론 및 향후 연구

결론

  • 제안된 표면추적 알고리즘이 FSW 공정에서 마찰열원을 정확히 반영할 수 있음을 확인.
  • 툴의 이동 및 회전을 동시에 고려하면서 마찰열원을 부여할 수 있는 새로운 접근법을 제시.
  • 기존 방법 대비 이론값과의 오차율이 3% 이내로 줄어들어, 해석 신뢰도가 향상됨.

향후 연구 방향

  • 다양한 툴 형상 및 재료에 대한 적용 연구.
  • 다층 용접 및 비대칭 툴 형상에서의 추가 검증.
  • 실제 실험 데이터를 활용한 모델의 보정 및 개선.

연구의 의의

본 연구는 전산유체역학(CFD)을 활용한 FSW 해석에서 마찰열원의 정밀한 모델링을 가능하게 하는 표면추적 알고리즘을 제안하였다. 이 접근법은 기존의 한계를 극복하며, FSW 공정 최적화 및 용접 품질 향상에 기여할 것으로 기대된다.

References

  1. W.M. Thomas, E.D. Nicholas, J.D. Needham, M.G. Murch, P. Templesmith, C. Dawes, G.B. Patent Application No. 9,125,978.8, Dec. 1991, U.S. Patent No. 5,460,317, Oct. 1995
  2. I.S. Chang, Y.J. Cho, H.S. Park, D.Y. So, Importance of Fundamental Manufacturing Technology in the Automotive Industry and the State of the Art Welding and Joining Technology, J.Welding and Joining, 34(1) (2016), 21-25
  3. D.G. Kim, H. Badarinarayan, J.H. Kim, C.M. Kim, K. Okamoto, R.H. Wagoner and K.S. Chung, Numerical simulation of friction stir butt welding process for AA5083-H18 sheets, European Journal of Mechanics-A/Solids, 29(2) (2013), 204-215
  4. G.Q. Chen, Q.Y. Shi, Y.J. Li, Y.J. Sun, Q.L. Dai, J.Y. Jia, Y.C. Zhu and J.J. Wu, Computational fluid dynamics studies on heat generation during friction stir welding of aluminum alloy, Computational Materials Science, 79 (2013), 540-546
  5. S.D. Ji, Q.Y. Shi, L.G. Zhang, A.L. Zou, S.S. Gao and L.V. Zan, Numerical simulation of material flow behavior of friction stir welding influenced by rotational tool geometry, Computational Materials Science, 63 (2012), 218-226
  6. T. Sheppard and D.S. Wright, Determination of flow stress : Part 1 constitutive equation for aluminium alloys at elevated temperatures, Metals Technology, 6(1) (1979), 215-223
  7. O.C. Zienkiewicz and I.C. Cormeau, Visco‐plasticity-plasticity and creep in elastic solids-a unified numerical solution approach, International Journal for Numerical Methods in Engineering, 8(4) (1974), 821-845
  8. G. Buffa, J. Hua, R. Shivpuri and L. Fratini, A continuum based fem model for friction stir welding-model development, Materials Science and Engineering: A, 419-1 (2005), 389-396
  9. R. Ayer, H.W. Jin, R.R. Mueller, S. Ling and S. Ford, Interface structure in a Fe–Ni friction stir welded joint, Scripta Materialia, 53(12) (2005), 1383-1387
  10. H.S. Carslaw and J.C. Jaeger, Conduction of heat in solids, Oxford(2nd Edition), Clarendon Press, 1959
  11. R. Nandan, G.G. Roy, T.J. Lienert and T. Deb-Roy, Three-dimensional heat and material flow during friction stir welding of mild steel, Acta Materialia, 55(3) (2007)
  12. J.H. Cho, D.E. Boyce and P.R. Dawson, Modeling strain hardening and texture evolution in friction stir welding of stainless steel, Materials Science and Engineering, A, 398(1) (2005), 146-163
  13. T. Sheppard and A. Jackson, Constitutive equations for use in prediction of flow stress during extrusion of aluminium alloys, Materials science and Technology, 13(3) (1997), 203-209
  14. H. Schmidt, J. Hattel and J. Wert, An analytical model for the heat generation in friction stir welding, Modelling and Simulation in Materials Science and Engineering, 12(1) (2003), 143-157
Figure 2 The temperature field and melt pools shape during L-PBF process

Thermal and Melting Track Simulations of Laser Powder Bed Fusion (L-PBF)

레이저 분말층 융합(L-PBF) 공정의 열 및 용융 트랙 시뮬레이션

Figure 2 The temperature field and melt pools shape during L-PBF process
Figure 2 The temperature field and melt pools shape during L-PBF process

연구 배경 및 목적

문제 정의

  • L-PBF 공정은 금속 분말층을 레이저로 용융 및 고화하여 적층 제조하는 기술로, 최종 제품의 밀도, 치수 정확도, 기계적 특성 등에 영향을 미침.
  • 용융 풀의 형상과 온도 분포는 공정 변수(레이저 출력, 주사 속도 등)에 의해 결정되며, 이를 최적화하는 것이 중요함.

연구 목적

  • Flow-3D(Flow-weld) 기반 CFD 시뮬레이션을 사용하여 공정 변수(레이저 출력, 주사 속도)가 온도장 및 용융 풀 형상에 미치는 영향을 분석.
  • 단일 용융 트랙(single melting track)의 특성을 평가하여 L-PBF 공정의 품질 개선을 위한 기초 데이터 제공.

연구 방법

수치 모델링 및 시뮬레이션 설정

  • 열 전달 모델: 전도, 대류, 복사를 포함한 열 전달 해석 수행.
  • 유체 역학 모델: VOF(Volume of Fluid) 기법을 활용하여 용융 풀의 형상 변화 추적.
  • 공정 변수 설정:
    • 레이저 출력: 120W, 140W
    • 주사 속도: 0.4m/s, 0.6m/s, 0.8m/s
    • 레이저 빔 직경: 80µm
    • 적층 두께: 50µm
  • 재료: AISI 420 마르텐사이트계 스테인리스강 분말(평균 입자 크기 20µm) 사용.

주요 결과

온도장 및 용융 풀 형상 변화

  • 낮은 주사 속도에서는 넓은 열 분포 영역이 형성되며, 높은 주사 속도에서는 좁고 깊은 용융 풀이 형성됨.
  • 주사 속도가 증가함에 따라 타원형(Ellipse) 용융 풀이 눈물방울(Tear-drop) 형태로 변화.

용융 트랙 특성 분석

  • 레이저 출력 증가 및 주사 속도 감소 시 용융 풀의 폭과 깊이가 증가.
  • 주사 속도가 0.4m/s에서 0.6m/s로 증가하면 용융 트랙 하부에 기공(void) 발생 가능성 증가.
  • 시뮬레이션 결과는 실험 데이터와 높은 일치도를 보이며, 경미한 차이만 존재.

결론 및 향후 연구

결론

  • Flow-3D 기반 시뮬레이션을 통해 L-PBF 공정의 용융 풀 형상 및 온도 분포를 효과적으로 예측 가능.
  • 낮은 주사 속도에서 넓은 열 분포 및 깊은 용융 풀이 형성되며, 높은 주사 속도에서는 용융 풀이 좁아짐.
  • 공정 변수 최적화를 통해 미세 기공 및 불완전 용융 문제를 방지할 수 있음.

향후 연구 방향

  • 다양한 재료 및 공정 변수에 대한 추가 연구 진행.
  • 다층 적층 공정에서의 열 누적 및 변형 분석.
  • 실제 제조 환경에서의 실험적 검증 강화.

연구의 의의

이 연구는 L-PBF 공정에서 용융 풀 형상을 제어하기 위한 핵심 공정 변수를 도출하고, Flow-3D 기반 CFD 시뮬레이션의 유효성을 입증하였다. 향후 금속 적층 제조의 품질 개선 및 최적 설계에 기여할 수 있을 것으로 기대된다.

References

  1. ASTM Standard F-2792- 12a. Standard Terminology for Additive Manufacturing Technologies, ASTM International
  2. W. E. Frazier 2014 Metal Additive Manufacturing: A Review, Journal of Materials Engineering and Performance Vol 23, pp. 1917–1928
  3. V. Bhavar, P. Kattire, V. Patil, S. Khot, K. Gujar and R. Singh 2014 A Review on Powder Bed Fusion Technology of Metal Additive Manufacturing, International conference and exhibition on Additive Manufacturing Technologies-AM-2014, September 1 & 2, 2014, Bangalore, India.
  4. T. Wohlers 2010 Additive Manufacturing State of the Industry, Wohlers report, pp. 1-26
  5. C. H. Fu and Y. B. Guo, 3-dimension finite element modelling of selective laser melting Ti-6AL-4V alloy, 25th Annual International Solid Freeform, pp. 1129-1144
  6. Y. S. Lee and W. Zhang 2015 Mesoscopic Simulation of Heat Transfer and Fluid Flow in Laser Powder Bed Additive Manufacturing, International Solid Free Form Fabrication Symposium Austin, pp. 1154-1165
  7. Y. Li and D. Gu 2014 Thermal behavior during selective laser melting of commercially pure titanium powder: Numerical simulation and experimental study, Additive Manufacturing Vol 1–4, pp. 99–109
  8. X. Zhao, Q. Wei, B. Song, Y. Liu, X. Luo, S. Wen, and Y. Shi 2015 Fabrication and Characterization of AISI 420 Stainless Steel Using Selective Laser Melting, Materials and Manufacturing Processes, pp. 1–7
  9. K. Zeng, D. Pal and B. Stucker 2012 A review of thermal analysis methods in Laser Sintering and Selective Laser Melting, Journal of Heat Transfer, pp. 796-814
  10. A. M. Kamara, W. Wang, S. Marimuthu, and L. Li 2010 Modelling of the melt pool geometry in the laser deposition of nickel alloys using the anisotropic enhanced thermal conductivity approach, Proc. IMechE Vol. 225, pp. 87-99
  11. A. Srivastava, Moving heat Source Version 4.1, Technical document, https://appstore.ansys.com, ANSYS, Inc, accessed on 1 Aug 2017
Flow 3D outputs of flow depth and velocity of H =0.15m

Numerical Analysis of Hydraulic Behavior of Vertical Drop Structures Using FLOW-3D

FLOW-3D를 활용한 수직 낙차 구조물의 수리학적 거동 수치 해석

FIG8FL~4
Figure 8.FLOW-3D outputs of flow depth and velocity of H =0.15m

연구 목적

  • 본 연구는 수직 낙차 구조물(vertical drop structure)의 유동 특성을 분석하기 위해 CFD(Computational Fluid Dynamics) 모델을 활용함.
  • FLOW-3D 소프트웨어를 이용하여 자유 표면 흐름을 시뮬레이션하고, 실험 데이터와 비교하여 모델의 정확성을 검증함.
  • 수로 경사, 유입 속도, 난류 모델 선택이 낙차 구조 내 유동 패턴 및 에너지 손실에 미치는 영향을 평가함.
  • 수치 해석 결과를 기반으로 낙차 구조물의 최적 설계 조건을 도출하여 수력학적 효율성을 개선하고자 함.

연구 방법

  1. FLOW-3D 기반 수치 모델링
    • VOF(Volume of Fluid) 기법을 적용하여 자유 표면 흐름을 추적하고, 표준 k-ε 난류 모델을 사용하여 난류 효과를 분석함.
    • 격자(grid) 크기 최적화를 통해 해석 정확도를 향상시킴.
    • 수직 낙차 구조물의 유동 특성을 분석하기 위해 다양한 수로 길이 및 낙차 높이 조건을 설정함.
  2. 실험 데이터와 비교 검증
    • 실제 실험에서 측정된 하류 수심 및 에너지 손실 데이터를 CFD 결과와 비교하여 모델의 신뢰성을 평가함.
    • 낙차 구조 내 유동 속도 분포 및 충격력(impact force)을 수치적으로 분석함.
    • 다양한 격자 크기 및 난류 모델을 비교하여 최적 해석 방법을 도출함.

주요 결과

  1. 유동 거동 분석
    • 낙차 구조물에서 수류가 낙하하면서 난류 강도가 증가하며, 하류에서 수심이 증가하는 패턴을 보임.
    • 낙차 높이가 증가할수록 충격력이 증가하고, 이에 따른 에너지 손실도 커짐.
    • 하류 채널 길이가 충분할 경우 난류 효과가 감소하며, 유동이 안정화되는 경향을 보임.
  2. CFD 시뮬레이션과 실험 데이터 비교
    • FLOW-3D 모델이 실험 결과와 높은 일치도를 보이며, 평균 오차율이 5% 이하로 나타남.
    • 격자 크기가 20,000개 이상일 때 모델 정확도가 최적화됨.
    • 낙차 구조의 형상 및 유입 조건에 따라 난류 강도가 다르게 나타남.
  3. 에너지 손실 및 하류 유동 특성
    • 수로 길이가 증가할수록 에너지 손실이 감소하며, 하류 수심이 증가함.
    • 낙차 구조 설계에 따라 난류 강도가 달라지며, 이를 고려한 최적 설계가 필요함.
    • 낙차 구조 후단부에 역류(backflow)가 발생할 수 있으며, 이를 방지하기 위한 추가 설계가 요구됨.

결론

  • FLOW-3D를 활용한 수치 해석이 수직 낙차 구조물의 유동 특성을 정확하게 예측할 수 있음을 확인함.
  • 하류 수심, 유입 속도 및 난류 모델이 유동 특성 및 에너지 손실에 미치는 영향을 분석함.
  • CFD 시뮬레이션 결과와 실험 데이터가 높은 상관관계를 보이며, 낙차 구조물 설계 최적화를 위한 유용한 도구임을 입증함.
  • 향후 연구에서는 다양한 수리학적 조건을 반영한 추가적인 검증이 필요함.

Reference

  1. RAND, W.: Flow Geometry at Straight Drop Spillways. In Proceedings of the Proceedings ofthe American Society of Civil Engineers; ASCE, 1955; Vol. 81, pp. 1–13.
  2. Akram Gill, M.: Hydraulics of Rectangular Vertical Drop Structures. Journal of HydraulicResearch 1979, 17, 289–302.
  3. RAJARATNAM, N. – CHAMANI, M.R.: Energy Loss at Drops. Journal of Hydraulic Research1995, 33, 373–384.
  4. ESEN, I.I. – ALHUMOUD, J.M.; HANNAN, K.A.: Energy Loss at a Drop Structure with a Step atthe Base. Water international 2004, 29, 523–529.
  5. HONG, Y.-M. – HUANG, H.-S. – WAN, S.: Drop Characteristics of Free-Falling Nappe forAerated Straight-Drop Spillway. Journal of hydraulic research 2010, 48, 125–129.
  6. FAROUK, M. – ELGAMAL, M.: Investigation of the Performance of Single and Multi-DropHydraulic Structures. International Journal of Hydrology Science and Technology 2012, 2, 48–74.
  7. LIU, S.I. – CHEN, J.Y. – HONG, Y.M. – HUANG, H.S. – RAIKAR, R. V.: Impact Characteristics ofFree Over-Fall in Pool Zone with Upstream Bed Slope. Journal of Marine Science andTechnology 2014, 22, 9.
  8. AL-SHAIKHLI, H.I. – KHASSAF, S.I.: CFD Simulation of Waves over Mound Breakwater.Journal of Global Scientific Research 2022, 7, 2283–2291.
  9. KHASSAF, S.I. – ABBAS, H.A. Study of the Local Scour around L-Shape Groynes in ClearWater Conditions. International Journal of Engineering & Technology 2018, 7, 271–276.
  10. GESSLER, D. CFD Modeling of Spillway Performance. In Impacts of Global Climate Change;2005; pp. 1–10.
  11. RAJAB, H. – Elgizawy, A. Design of Spill Tube with Features for Controlling Air BubbleGenerated for Aircraft Applicaitons. Mechanical and Aerospace Engineering presentations2012.
  12. BERGA, L. – BUIL, J.M. – BOFILL, E. – DE CEA, J.C. – PEREZ, J.A.G.; MAÑUECO, G. -POLIMON, J. – SORIANO, A. – YAGÜE, J. Dams and Reservoirs, Societies and Environment inthe 21st Century, Two Volume Set: Proceedings of the International Symposium on Dams inthe Societies of the 21st Century, 22nd International Congress on Large Dams (ICOLD),Barcelona, Spain, 18 June 2006; CRC Press, 2006; ISBN 1482262916.
  13. AL SHAIKHLI, H.I. – KHASSAF, S.I. Using of Flow 3d as CFD Materials Approach in WavesGeneration. Materials Today: Proceedings 2022, 49, 2907–2911.
  14. CHANEL, P.G. An Evaluation of Computational Fluid Dynamics for Spillway Modeling 2009.
  15. Flow-Science FLOW-3D User Manual, Version 11 2014.
  16. MIA, M.F. – NAGO, H. Design Method of Time-Dependent Local Scour at Circular Bridge Pier.Journal of Hydraulic Engineering 2003, 129, 420–427.
  17. AL SHAIKHLI, H.I. – KHASSAF, S.I. Stepped Mound Breakwater Simulation by Using Flow 3D.Eurasian Journal of Engineering and Technology 2022, 6, 60–68.
  18. STEHLIK-BARRY, K. – BABINEC, A.J. Data Analysis with IBM SPSS Statistics; PacktPublishing Ltd, 2017; ISBN 1787280705.

Study on the Water Surge Height Line of Landslide Surge of Linear River Course Reservoir Based on FLOW-3D

FLOW-3D를 활용한 선형 하천 저수지의 산사태 파고 선 연구

Fig. 3 Geometric numerical model
Fig. 3 Geometric numerical model

연구 목적

  • 본 연구는 산사태로 인해 발생하는 해일(surge)의 전파 특성과 감쇠 과정을 분석하는 데 초점을 맞춤.
  • FLOW-3D® 시뮬레이션을 활용하여 선형 하천 저수지에서 산사태 해일이 발생하는 기작을 규명함.
  • 산사태 유입각, 하천 깊이, 하천 형상 및 산사태 질량 등 다양한 요소가 해일 높이 및 전파에 미치는 영향을 평가함.
  • 해일의 전파 과정 및 감쇠 메커니즘을 규명하여 수력학적 안정성 평가 및 방재 대책 수립에 기여하고자 함.

연구 방법

  1. FLOW-3D® 기반 수치 해석 모델 구축
    • 산사태로 인해 발생하는 해일의 거동을 모델링하기 위해 VOF(Volume of Fluid) 기법을 사용함.
    • 산사태의 초기 속도, 질량 및 유입각에 따른 해일 생성 및 전파 특성을 분석함.
    • 하천 폭 및 수심 변화에 따른 해일 감쇠 특성을 평가함.
  2. 시뮬레이션 실험 설계
    • 산사태 질량을 0.4 m × 0.2 m × 0.15 m로 고정하고, 유입각을 40°~80° 범위에서 변화시킴.
    • 다양한 수심 조건(0.5 m ~ 0.9 m)에서 해일 전파 특성을 분석함.
    • 5개 주요 측정 지점을 설정하여 해일의 초기 파고 및 전파 과정 데이터를 수집함.
  3. 결과 비교 및 검증
    • 각 실험 조건에서 해일의 최대 파고 및 전파 속도를 측정하고, 시뮬레이션 결과를 실험 데이터와 비교함.
    • 기존 연구 결과 및 실험 모델과의 비교를 통해 시뮬레이션 신뢰도를 검토함.

주요 결과

  1. 산사태 유입각에 따른 해일 발생 특성
    • 해일의 초기 파고는 유입각 60°에서 최대값을 기록하며, 이후 유입각 증가에 따라 감소하는 경향을 보임.
    • 유입각이 80° 이상일 경우, 슬라이딩 블록의 수직 충돌로 인해 에너지 손실이 증가하여 해일 높이가 감소함.
    • 유입각이 작을 경우(40° 이하), 해일 발생 에너지가 낮아지고 전파 속도도 감소함.
  2. 수심 변화에 따른 해일 전파 및 감쇠 특성
    • 동일한 조건에서 초기 해일 높이는 수심이 깊을수록 감소하는 경향을 보임.
    • 수심이 0.5 m에서 0.9 m로 증가하면, 최대 파고가 49 mm에서 33 mm로 감소함.
    • 이는 깊은 수심에서는 에너지가 더 많은 수체에 분산되기 때문으로 분석됨.
  3. 해일 전파 속도 및 감쇠 패턴
    • 해일의 전파 속도는 초기 파고 및 하천 형상에 따라 달라지며, 좁은 수로에서 감쇠가 느려지는 경향을 보임.
    • 측정 지점별 파고 감소율을 분석한 결과, 해일 감쇠율이 비선형적으로 나타남.
    • 이는 수면 저항 및 흐름 분산에 따른 에너지 손실이 비균일하게 발생하기 때문으로 해석됨.

결론

  • 산사태 유입각이 해일 발생의 주요 변수이며, 60°에서 최대 파고가 발생함.
  • 수심이 깊을수록 해일 감쇠가 더 빠르게 진행되며, 초기 파고가 낮아짐.
  • FLOW-3D® 기반 시뮬레이션을 통해 선형 하천 저수지에서의 산사태 해일 전파 및 감쇠 메커니즘을 규명할 수 있음.
  • 향후 연구에서는 다양한 하천 형상 및 실제 지형 조건을 반영한 추가 분석이 필요함.

Reference

  1. Kiersch, G. A. 1964. “Vajont Reservoir Disaster.” Civil Engineering (ASCE) 34 (3): 32-39.
  2. Hunan Hydro & Power Design Institute. 1983. Slope Engineering Geology. Beijing: Water Conservancy and Electric Power press.
  3. Wiegel, R. L. 1995. “Laboratory Studies of Gravity Waves Generated by the Movement of A Submerged Body.” Transactions-American Geophysical Union 36 (5): 759-774.
  4. Fritz, H. M., Moster, P. 2003. “Pneumatic Landslide Generator.” International Journal of Fluid Power 173 (2): 223-233.
  5. Sander, J., Hutter, K. 1992. “Evolution of Weakly Non-linear Channelized Shallow Water Waves Generated by A Moving Boundary.”Acta Mechanic 91: 119-155.
  6. Sander, J., Hutter, K. 1996. “Multiple Pulsed Debris Avalanche Emplacement at Mount St. Helens in 1980: Evidence form Numerical Continuum Flow Simulation.” Acta Mechanic 115:133-149.
  7. Heinrich, Ph. 1992. “Nonlinear Water Waves Generated by Submarine and Aerial Landslides.” Journal of Waterway, Port, Coast, and Ocean Engineering, ASCE 118: 249-266.
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  10. Ataie-Ashtiani, B., Shobeyri, G. 2001. “Numerical Simulation of Landslide Impulsive Waves by Incompressible Smoothed Particle Hydrodynamic.” International Journal for Numerical Method in Fluids 56: 209-232.
Fig. 1. Averaged error trend

Assessment of Spillway Modeling Using Computational Fluid Dynamics

컴퓨터 유체 역학을 활용한 방수로 모델링 평가

연구 목적

  • 본 연구는 FLOW-3D® CFD 시뮬레이션을 사용하여 방수로(spillway) 유동 거동을 모델링하고, 이를 실험 모델 결과와 비교 분석하는 것을 목표로 함.
  • 기존 연구에서는 CFD 모델이 실험 결과와 유사한 경향을 보였으나, 다양한 방수로 형상과 수문 개방 조건을 고려한 종합적인 분석이 부족했음.
  • 본 연구에서는 세 가지 다른 방수로 사례를 대상으로 CFD 시뮬레이션을 수행하고, 유량 특성 및 정확도를 평가함.

연구 방법

  1. 수리 실험 및 CFD 모델 구축
    • 세 가지 방수로 형상을 선택하여 실험 및 수치 해석을 수행함.
    • 실험 데이터와 CFD 결과를 비교하여 유량 곡선(rating curve)의 일치도를 분석함.
  2. FLOW-3D® 시뮬레이션 설정
    • VOF(Volume of Fluid) 기법을 적용하여 자유 표면 흐름을 해석하고, 난류 모델을 통해 흐름 특성을 분석함.
    • Navier-Stokes 방정식을 활용하여 유동 및 수문 개방 조건에서의 방수로 거동을 평가함.
  3. 실험 데이터와 비교 검증
    • 실험실 수리 모델에서 측정된 유량 데이터와 CFD 결과를 비교하여 시뮬레이션의 신뢰도를 검증함.
    • CFD 결과가 실험 모델과 어느 정도의 오차 범위를 가지는지 분석함.

주요 결과

  1. CFD 시뮬레이션과 실험 결과 비교
    • FLOW-3D®를 사용한 CFD 시뮬레이션은 실험 데이터와 높은 상관관계를 보였음.
    • 특히 유량 곡선(rating curve) 분석 결과, P/Hd(수문 높이 대비 유량 계수) 값이 모델 정확도에 중요한 영향을 미침.
    • 일부 방수로 형상에서는 CFD 결과가 실험보다 약간 낮은 유량을 예측하였으며, 이는 난류 모델 및 경계 조건 설정의 차이에 기인함.
  2. 방수로 형상에 따른 유동 특성 차이
    • 방수로 설계에 따라 유속 분포 및 난류 특성이 달라지는 경향을 보였음.
    • 특정 방수로 구조에서는 수문 개방 비율이 증가할수록 CFD 모델과 실험 간 오차가 감소하는 패턴이 나타남.
  3. 모델 신뢰도 및 한계점 분석
    • CFD 결과가 실험 모델과 대체로 일치하였으나, 특정 고유량 조건에서의 오차를 줄이기 위해 추가적인 보정이 필요함.
    • 난류 모델 최적화 및 메쉬 해상도 향상을 통해 모델의 신뢰도를 더욱 개선할 수 있음.

결론

  • FLOW-3D® CFD 시뮬레이션은 방수로 유동 해석에 신뢰할 수 있는 도구이며, 실험 데이터와 높은 일치도를 보임.
  • P/Hd 매개변수가 CFD 모델의 정확도에 중요한 영향을 미치며, 이를 고려한 모델링 접근이 필요함.
  • 향후 연구에서는 더욱 복잡한 방수로 형상 및 비선형 유동 조건을 고려한 모델 개선이 필요함.

Reference

  1. Chanel, P.G., and Doering, J.C. 2007. An evaluation of computational fluid dynamics for spillway modelling. In Proceedings of the 16th Australasian Fluid Mechanics Conference (AFMC), Gold Coast, Queensland, Australia, 3-7 December 2007. pp. 1201-1206.
  2. Flow Science, Inc. 2007. Flow-3D user’s manuals. Version 9.2. Flow Science, Inc., Santa Fe, N.M.
  3. Gessler, D. 2005. CFD modeling of spillway performance, EWRI 2005: Impacts of global climate change. In Proceedings of the World Water and Environmental Resources Congress, Anchorage, Alaska, 15-19 May 2005. Edited by R. Walton. American Society of Civil Engineers, Reston, Va.
  4. Hirt, C.W., and Nichols, B.D. 1981. Volume of fluid (VOF) method for the dynamics of free boundaries. Journal of Computational Physics, 39(1): 201-225. doi:10.1016/0021-9991(81) 90145-5.
  5. Hirt, C.W., and Sicilian, J.M. 1985. A porosity technique for the definition of obstacles in rectangular cell meshes. In Proceedings of the 4th International Conference on Ship Hydro-dynamics, Washington, D.C., 24-27 September 1985. National Academy of Sciences, Washington, D.C.
  6. Ho, D., Cooper, B., Riddette, K., and Donohoo, S. 2006. Application of numerical modelling to spillways in Australia. In Dams and Reservoirs, Societies and Environment in the 21st Century. Edited by Berga et al. Taylor and Francis Group, London.
  7. LaSalle Consulting Group Inc. 1992. Conawapa generating station. Sectional model study of the spillway. LaSalle Consulting Group Inc., Montréal, Que.
  8. Lemke, D.E. 1989. A comparison of the hydraulic performance of an orifice and an overflow spillway in a northern application using physical modeling. M.Sc. thesis, University of Manitoba, Winnipeg, Man.
  9. Savage, B.M., and Johnson, M.C. 2001. Flow over ogee spillway: Physical and numerical model case study. Journal of Hydraulic Engineering, 127(8): 640-649. doi:10.1061/(ASCE)0733- 9429(2001)127:8(640).
  10. Teklemariam, E., Korbaylo, B., Groeneveld, J., Sydor, K., and Fuchs, D. 2001. Optimization of hydraulic design using computational fluid dynamics. In Proceedings of Waterpower XII, Salt Lake City, Utah, 9-11 July 2001.
  11. Teklemariam, E., Korbaylo, B., Groeneveld, J., and Fuchs, D. 2002. Computational fluid dynamics: Diverse applications in hydropower project’s design and analysis. In Proceedings of the CWRA 55th Annual Conference, Winnipeg, Man., 11-14 June 2002. Canadian Water Resources Association, Cambridge, Ontario.
  12. Western Canadian Hydraulic Laboratories Inc. 1980. Hydraulics model studies limestone generating station spillway/diversion structure flume study. Final report. Western Canadian Hydraulic Laboratories Inc., Port Coquitlam, B.C.
Filling simulation

Simulation of a Thixoforging Process of Aluminium Alloys with FLOW-3D

FLOW-3D를 이용한 알루미늄 합금의 Thixoforging 공정 시뮬레이션

연구 배경 및 목적

  • 문제 정의: Thixoforming반고체 상태(Semi-Solid State)에서 복잡한 형상의 부품을 고품질 기계적 특성으로 생산할 수 있는 성형 기술이다.
    • ThixoformingThixocastingThixoforging으로 나뉘며, Thixoforging은 유압 프레스(Hydraulic Presses)를 사용하여 닫힌 금형 내에서 성형이 이루어진다.
    • 알루미늄 합금(A356)의 전단 속도(Shear Rate)와 전단 시간(Shear Time)에 따른 의사점도(Apparent Viscosity) 변화를 고려해야 한다.
    • 금형 충전 시뮬레이션성형력(Forming Force) 및 금형 충전 특성 분석을 통해 최적의 점도 매개변수 선택을 돕는다.
  • 연구 목적:
    • FLOW-3D 소프트웨어를 사용하여 Thixoforging 공정의 금형 충전 시뮬레이션을 수행하고, 점도 매개변수(Initial Viscosity, Thinning Rate)에 따른 충전 특성 비교.
    • 실험 데이터와 시뮬레이션 결과를 비교하여 모델의 신뢰성 검증반고체 소재의 최적 성형 조건 제시.
    • 스포츠 차량의 서스펜션 부품(Steering Knuckle)과 같은 복잡한 형상의 실 부품 적용 가능성 평가.

연구 방법

  1. Thixoforging 공정 개요 및 수치 모델링
    • Thixoforging 공정반고체 빌렛(Semi-Solid Billet)을 닫힌 금형 내에서 유압 프레스를 통해 Near-Net-Shape 부품 성형.
    • FLOW-3D 시뮬레이션 설정:
      • 유체 흐름 방정식(Continuity, Momentum, Energy Equation)을 라그랑지안(Langarian) 방식으로 유한 차분법(Finite Difference Method) 사용.
      • 의사점도 모델(Apparent Viscosity Model)을 적용하여 전단율(Shear Rate, γD), 전단 시간(Shear Time, t) 및 고체 분율(Fraction Solid, fs)에 따른 점도 변화 모델링.
      • Scheil 방정식(Scheil Equation)을 이용하여 고체 분율(f_s) 계산.
  2. 점도 매개변수 및 시뮬레이션 조건
    • 점도 매개변수 설정:
      • 초기 점도(Initial Viscosity): 1300 ~ 13000 Pas.
      • Thinning Rate(점도 감소율): 1 ~ 40 s¹.
    • 축대칭 모델(Axisymmetric Model) 실험 설정:
      • 단순 형상(Cup)을 이용하여 금형 충전 특성 분석.
      • 성형력 계산 및 실험 결과와 비교.

주요 결과

  1. 금형 충전 및 성형력 분석
    • FLOW-3D 시뮬레이션 결과실험 결과 간의 높은 일치도 확인.
    • 성형력(Forming Force) 계산:
      • 초기 점도 1300 Pas, Thinning Rate 1 s¹에서 성형력 예측 정확도 높음.
      • 성형 초반부에서는 높은 Thinning Rate가 실제 성형력과 유사, 성형 후반부에서는 낮은 Thinning Rate가 적합.
      • 이중 점도 감소 특성(Two-Stage Thinning Behavior)을 통해 정확도 개선 가능성 제시.
  2. 복잡 형상의 서스펜션 부품(Steering Knuckle) 적용 가능성 평가
    • 산업용 Steering Knuckle 부품 시뮬레이션을 통해 금형 충전 특성 분석.
    • 초기 설계 단계에서 시뮬레이션을 활용하여 금형 설계를 최적화:
      • Overflow 영역의 단면을 수정하여 균일한 물질 흐름 확보.
      • 산화물(Oxide) 및 윤활제 포집을 Overflow로 이동시켜 고강도 용접부(Welding Zone) 형성.
    • 재료 흐름이 Overflow Inlet에서 일치하지 않는 문제 발견, Cross-Section 수정으로 개선 가능.

결론 및 향후 연구

  • 결론:
    • FLOW-3D를 통한 Thixoforging 공정 시뮬레이션이 실제 실험과 높은 일치도를 보임.
    • 점도 매개변수(Initial Viscosity, Thinning Rate)에 따른 성형력 및 금형 충전 특성을 정량적으로 평가 가능.
    • 스포츠 차량 서스펜션 부품의 성형에도 적용 가능성 입증.
    • 초기 설계 단계에서 시뮬레이션을 통해 금형 설계를 최적화할 수 있어 시간과 비용 절감.
  • 향후 연구 방향:
    • 복잡한 형상의 부품에 대한 추가적인 시뮬레이션 연구.
    • 이중 점도 감소 모델을 도입하여 시뮬레이션 정확도 개선.
    • AI 및 머신러닝을 활용한 반고체 공정 최적화 시스템 개발.

연구의 의의

본 연구는 FLOW-3D 시뮬레이션을 활용하여 Thixoforging 공정에서 반고체 알루미늄 합금의 유동 특성을 정량적으로 분석하고, 복잡한 형상의 부품 성형에서도 높은 품질을 유지할 수 있는 설계 가이드라인을 제공하며, 자동차 및 항공우주 산업의 생산성 증대 및 비용 절감에 기여할 수 있다​.

Reference

  1. Baur, J.; Wolf, A.; Fritz, W. Thixoforging von Aluminium und Messing – Produkte, Werkzeuge und Maschinen In: Tagungsband Neuere Entwicklungen in der Massivumformung, Hrsg.: K. Siegert, S. 195-220 Stuttgart Fellbach, 19.-20. Mai 1999
  2. Web page at www.flow3d.com
  3. Quaak, C.J. Rheology of Partial Solidified Aluminium Composites Dissertation, TU Delft, 1996
  4. Wahlen, A. Computermodellierung thixotroper Formgebungsprozesse Workshop: Neue Werkstoffe und resultierende Verfahrenskonzepte für das Thixoforming, Zürich, 1999
  5. Kapranos, P.; Kirkwood, D.H.; Barkhudarov, M.R Modeling of Structural Breakdown During Rapid Compression of Semi-Solid Alloy Slugs Proc. of the 5th International Conference on Semi-Solid Processing of Alloys and Composites, Editors: Kumar Bhasin, A. et al., pp. 123 – 130, Colorado School of Mines, Golden (Colorado) USA, June 23 – 25, 1998
  6. Joly P.A.; Mehrabian, R The Rheology of Partial Solid Alloy J. Mater. Sci., 1976, 11 S. 1393ff
  7. Baur, J.; Wolf, A.; Gullo, C. Thixo-Schmieden von Pkw-Komponenten In: Tagungsband Neuere Entwicklungen in der Massivumformung, Hrsg.: K. Siegert, Stuttgart Fellbach, 16.-17. Mai 2001
LFP

Optimizing 3D Laser Foil Printing Parameters for AA 6061: Numerical and Experimental Analysis

AA 6061 합금의 3D 레이저 포일 프린팅(3D LFP) 최적화: 수치 및 실험적 분석

연구 배경 및 목적

  • 문제 정의: 3D 레이저 포일 프린팅(LFP)은 금속 포일을 적층하여 정밀한 구조물을 제작하는 기술로, 레이저 용접을 통해 층을 쌓아가는 방식을 사용한다.
    • 금속 포일빠른 냉각 속도효율적인 열전도를 제공하여 미세 입자(fine-grained) 구조 형성에 유리하다.
    • 그러나 알루미늄 합금(AA 6061)과 같은 고반사율 금속레이저 용접할 때, 스패터(spattering), 기포(bubble) 형성, 미세 균열(microcrack)과 같은 결함이 발생할 위험이 크다.
  • 연구 목적:
    • Laser Circular Oscillation Welding (LCOW) 기술을 LFP 공정에 적용하여 레이저 용접 결함을 줄이는 방법 연구.
    • 인공신경망(ANN, Artificial Neural Network)과 FLOW-3D 시뮬레이션을 결합하여 최적의 용접 공정 매개변수 도출.
    • 실험 및 시뮬레이션 결과 비교를 통해 모델 신뢰성 검증용접 품질 향상 방안 제시.

연구 방법

  1. LCOW 기술 적용 및 실험 설정
    • AA 6061 포일(두께 0.3mm)과 기판(두께 5mm)을 사용하여 연속 파이버 레이저 시스템(최대 출력 1000W, 스캔 속도 550 mm/s, 스캔 주파수 227 Hz)으로 실험.
    • 레이저 빔의 원형 진동(Circular Oscillation) 모션을 사용하여 용융 풀(Molten Pool) 형상 및 위치 제어.
    • FLOW-3D 소프트웨어를 통해 열원 모델링 및 유체의 자유 표면 이동을 추적.
    • 에너지 밀도가 가우시안(Gaussian) 분포를 따른다고 가정하고, 볼륨 오브 플루이드(VOF) 기법을 사용하여 키홀(Keyhole) 형상 변화 추적.
  2. 시뮬레이션 및 ANN 모델 개발
    • FLOW-3D 시뮬레이션 데이터를 활용하여 ANN 모델을 학습시켜 용접 풀 깊이 및 온도 예측.
    • 원형 패킹 디자인(Circle Packing Design) 기법을 사용하여 36개의 시뮬레이션 데이터를 ANN 학습에 사용.
    • ANN 모델은 평균 99%의 예측 정확도(R=0.99)를 보여, 신뢰성 높은 프로세싱 맵(Processing Map) 생성.
    • 레이저 출력, 스캔 속도 및 주파수에 따른 용접 풀 깊이 및 폭 최적화.

주요 결과

  1. 실험 및 시뮬레이션 비교 분석
    • 최적화된 공정 매개변수: 레이저 출력 800W, 스캔 속도 550 mm/s, 스캔 주파수 227 Hz.
    • FLOW-3D 시뮬레이션 모델의 예측 오차는 약 10% 내외로, 실험 결과와 높은 일치도를 보임.
    • 용접 부위의 상부 표면에서 균열(cracks)이나 기공(porosity)이 발견되지 않음.
    • 샘플 단면에서의 기공율(Porosity)은 0.12%로 매우 낮음.
  2. 프로세싱 맵 분석 및 최적화 매개변수 도출
    • 용접 풀 깊이(0.6 ~ 0.95 mm) 및 폭(1.05 mm 이상)이 균열과 기공을 최소화하는 최적의 조건으로 설정.
    • 스캔 주파수 150 Hz 이상에서 알루미늄 합금의 열균열 감수성(hot cracking susceptibility) 감소.
    • 세부 영역별 프로세싱 맵을 통해 다양한 용접 조건에 대한 품질 특성 분석.
  3. 다양한 실험 조건에 따른 결과 비교
    • LCOW(Laser Circular Oscillation Welding) 전략을 적용한 샘플에서는 균열과 기공 발생이 거의 없었음.
    • 비진동 레이저 용접(NOLW) 전략에서는 0.41%의 기공율을 보인 반면, LCOW 샘플에서는 0.12%로 현저히 감소.
    • LCOW 전략 적용 시 표면 거칠기(Surface Roughness) Sa 값은 7.27μm, NOLW 샘플은 20.87μm로, LCOW가 더 매끄러운 표면 제공.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 시뮬레이션과 ANN 모델을 활용한 공정 최적화 방법AA 6061 합금의 3D LFP 공정에서 뛰어난 성능을 입증.
    • LCOW 기술을 통해 기공과 균열을 줄일 수 있으며, 용접 품질을 크게 향상시킴.
    • 최적화된 공정 매개변수 적용 시 용접 표면 거칠기 및 기공율을 최소화할 수 있음.
  • 향후 연구 방향:
    • 새로운 소재와 기술의 발전에 따라 LCOW 최적화 매개변수의 지속적인 재평가 필요.
    • 마이크로구조(Microstructure) 모델링을 통한 시뮬레이션 결과의 정밀도 향상.
    • AI 및 머신러닝을 통한 실시간 용접 품질 예측 모델 개발.

연구의 의의

본 연구는 FLOW-3D 및 ANN 모델을 활용한 3D LFP 공정 최적화 방법을 제시하고, 레이저 용접 시 발생할 수 있는 결함을 최소화할 수 있는 새로운 접근법을 제시하여, 산업 현장에서의 적용 가능성을 입증하고 알루미늄 합금의 용접 품질을 향상시킬 수 있다​.

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DED model

On the Role of the Powder Stream on the Heat and Fluid Flow Conditions During Directed Energy Deposition of Maraging Steel – Multiphysics Modelling and Experimental Validation

마레이징강의 직접 에너지 증착(DED) 공정에서 분말 흐름이 열 및 유체 흐름 조건에 미치는 영향 – 다중물리 모델링 및 실험 검증

연구 배경 및 목적

문제 정의: 직접 에너지 증착(DED) 공정은 기능성 소재 제작, 표면 개질 및 손상 부품 복구에 널리 사용된다. 그러나 공정 중 분말 입자의 운동과 용융 풀(melt pool)의 상호작용은 아직 명확히 이해되지 않았다.
연구 목적:

  • FLOW-3D 기반 다중물리 모델 개발을 통해 분말 입자의 유입 속도가 용융 풀의 열전달 및 유체 흐름에 미치는 영향을 분석.
  • 실험적 검증을 통해 모델의 정확성을 평가하고, 분말 속도 변화에 따른 용융 풀 형상 및 트랙 품질 분석.
  • 분말 유속 조절을 통한 최적의 증착 형상 및 공정 조건 도출.

연구 방법

DED 공정 개요

  • DED는 레이저와 분말이 동시에 조사되어 금속을 적층하는 공정.
  • 분말은 캐리어 가스(Ar)와 함께 노즐에서 분사되며, 레이저에 의해 용융되어 기판에 적층됨.
  • 주요 변수: 레이저 출력(3kW), 주사 속도(0.8m/min), 분말 공급 속도(28.5g/min), 노즐 거리(18.5mm).

FLOW-3D 기반 수치 모델링

  • VOF(Volume of Fluid) 기법을 사용하여 자유 표면 추적.
  • 유체역학 모델: 표면 장력, 마랑고니 효과, 반동 압력(Recoil Pressure) 고려.
  • 열전달 모델: 용융 및 응고 해석, 증발 및 증발 냉각 포함.
  • 레이저-분말 상호작용: 다중 반사(ray-tracing) 모델 적용하여 레이저 에너지가 분말 및 용융 풀에 미치는 영향 분석.
  • 실험 검증:
    • In-situ 열화상 카메라를 활용하여 용융 풀의 온도 분포 및 동적 변화를 모니터링.
    • Ex-situ 광학 현미경 분석을 통해 최종 증착 형상과 모델 예측값 비교.

주요 결과

분말 속도가 증착 형상 및 용융 풀 거동에 미치는 영향

  • 분말 유속 증가 → 트랙 높이 증가, 폭 감소 (높이/폭 비율 증가).
  • 유속이 낮을수록 분말이 레이저와 더 오래 접촉하여 용융 풀 온도가 높아지고, 결과적으로 더 넓은 트랙 형성.
  • 유속이 높을수록 용융 풀의 온도가 낮아지고, 표면 장력이 증가하여 더 좁고 높은 트랙 형성.

유체 흐름 및 온도 분포 분석

  • 용융 풀 내 마랑고니 유동 발생 → 중심부에서 가장 높은 온도 분포 형성.
  • 반동 압력 증가 시 용융 풀의 깊이가 깊어지며, 특정 조건에서는 키홀(keyhole) 형성이 가능함.
  • 분말 속도 3배 증가 시:
    • 높이/폭 비율 104% 증가.
    • 트랙의 젖음성(Wettability) 24% 감소 → 표면 장력 영향으로 용융 풀이 좁아짐.

결론 및 향후 연구

결론

  • FLOW-3D 기반 다중물리 모델이 DED 공정의 열 및 유체 흐름을 정확히 예측할 수 있음을 확인.
  • 분말 속도가 증가하면 트랙 형상 변화 및 표면 젖음성이 감소하며, 이는 공정 최적화에 중요한 요소임.
  • 실험 검증 결과와 시뮬레이션 예측값이 높은 상관관계를 보이며, 분말 속도 조절을 통해 최적의 증착 형상 도출 가능.

향후 연구 방향

  • 다양한 재료(알루미늄, 티타늄 등) 및 분말 크기 변화에 따른 영향 분석.
  • 레이저-분말 상호작용 모델 개선을 통한 용융 풀 형상 최적화.
  • 다층 적층 공정에서 열 누적(Thermal Accumulation) 및 응력 분석.

연구의 의의

이 연구는 DED 공정에서 분말 흐름이 용융 풀의 열전달 및 유체 흐름에 미치는 영향을 수치적으로 분석하고, 실험적으로 검증한 최초의 연구 중 하나이다. 공정 최적화를 위한 중요한 설계 지침을 제공하며, 금속 적층 제조(AM) 분야에서 활용될 수 있는 정량적 모델을 제시하였다​.

Air Entrainment

Investigating Surface Entertainment Events Using CFD

전산유체역학을 이용한 표면 혼입 현상 연구

연구 목적

  • 본 논문은 CFD(전산유체역학) 기법을 활용하여 유체 표면에서 발생하는 혼입(surface entertainment) 현상을 분석함.
  • 자유 표면 유동에서 난류 및 난기류가 공기-액체 경계면에 미치는 영향을 연구함.
  • 기존 실험 데이터를 기반으로 CFD 모델의 정확성을 검증하고, 수치 해석이 실험적 접근을 대체할 수 있는 가능성을 평가함.
  • 표면 혼입 현상이 산업 및 환경 공정에서 가지는 의미를 논의함.

연구 방법

  1. 표면 혼입 모델링 및 실험 설정
    • 기존 문헌에서 보고된 실험 데이터를 바탕으로 수치 모델을 구축함.
    • 다양한 유량 조건에서 표면 혼입이 발생하는 메커니즘을 분석함.
    • 표면 장력과 난류 효과가 혼입 현상에 미치는 영향을 평가함.
  2. CFD 시뮬레이션 설정
    • VOF(Volume of Fluid) 기법을 사용하여 자유 표면 추적을 수행함.
    • 난류 모델로 RNG 방정식을 적용하여 난류 유동을 해석함.
    • 메쉬 독립성 연구를 통해 최적의 격자 크기를 설정함.
  3. 결과 비교 및 검증
    • 실험 데이터와 CFD 시뮬레이션 결과를 비교하여 모델의 신뢰성을 평가함.
    • 표면 혼입 발생 시 유체 속도, 와류 강도(vorticity), 기포 형성 등을 분석함.
    • 실험 및 시뮬레이션 간 오차율을 정량적으로 평가함.
  4. 추가 분석
    • 표면 장력과 유체 점도가 혼입 현상에 미치는 영향을 연구함.
    • 혼입이 활발하게 발생하는 특정 유동 조건을 도출함.
    • 산업 공정에서 CFD 기반 예측 모델의 적용 가능성을 검토함.

주요 결과

  1. 표면 혼입 발생 조건
    • 특정 유량 조건에서 표면 혼입이 급격히 증가하는 임계값이 존재함.
    • 난류 강도가 높을수록 표면 혼입이 활발해지며, 와류 구조가 기포 형성을 촉진함.
    • 표면 장력이 낮을수록 공기 혼입이 증가하며, 유체 점성이 높은 경우 혼입이 감소함.
  2. CFD 시뮬레이션 검증
    • CFD 모델이 실험 데이터와 90% 이상의 상관성을 보이며 신뢰성 높은 결과를 도출함.
    • 메쉬 해상도를 증가시킬수록 혼입 패턴 예측 정확도가 향상됨.
    • 표면 난류 효과가 과소 평가될 가능성이 있어, 추가적인 모델 조정이 필요함.
  3. 표면 장력 및 점도의 영향
    • 표면 장력이 높은 유체에서는 공기 혼입이 감소하며, 난류 효과가 억제됨.
    • 점성이 높은 유체는 혼입이 지연되며, 와류 구조가 약해짐.
    • 저점도 액체에서는 작은 난류 변동에도 공기 혼입이 쉽게 발생함.
  4. 산업적 적용 가능성
    • CFD 기반 혼입 분석은 화학공정, 수처리 및 해양 엔지니어링 분야에서 활용 가능함.
    • 실험 없이 수치 해석만으로 최적의 유동 조건을 예측하는 것이 가능함.
    • 향후 연구에서는 다중 유체 모델 및 기포 동역학을 포함한 추가 연구가 필요함.

결론

  • CFD를 이용한 표면 혼입 시뮬레이션이 높은 신뢰성을 보임.
  • 특정 유동 조건에서 공기 혼입이 급격히 증가하는 현상이 확인됨.
  • 표면 장력 및 점도가 혼입 발생에 중요한 영향을 미침.
  • 향후 연구에서는 다중 유체 모델을 추가하여 더욱 정밀한 예측이 필요함.

Reference

  1. FLOW-3D, www.flow3d.com
  2. N. R. Green and J. Campbell, Influence in Oxide Film Filling Defects on the Strength of Al7si-Mg Alloy Castings, Transactions of the American foundry society 114 (1994) 341 -347.
  3. X. Dai, X. Yang, J. Campbell and J. Wood, Influence of Oxide Film Defects Generated inFilling on Mechanical Strength of Aluminium Alloy Castings, Materials Science andTechnology 20 (2004) 505-513.
  4. J. Campbell, Castings 2nd Edition (Butterworth Heinemann, 2003).
  5. J. Runyoro, S. M. A. Boutorabi and J. Campbell, Critical Gate Velocities for Film FormingCasting Alloys: A Basis for Specification, AFS Transactions 37 (1992) 225-234.
  6. C. Reilly, N. R. Green, M. R. Jolly and J. C. Gebelin, Using the Calculated Fr Number forQuality Assessment of Casting Filling Methods, Modelling of casting, welding andadvanced solidification process XII. (2009).
  7. M. R. Barkdudarov and C. W. Hirt, Tracking Defects,www.flow3d.com/pdfs/tp/cast_tp/FloSci-Bib9-98.pdf (1998).
  8. N. W. Lai, W. D. Griffiths and J. Campbell, Modelling of the Potential for Oxide FilmEntrainment in Light Metal Alloy Castings, Modelling of casting, welding and advancedsolidification process X. (2003) 415-422.
  9. C. E. Esparza, M. P. Guerrero-Mata and R. Z. Ríos-Mercado, Optimal Design of GatingSystems by Gradient Search Methods, Computational Materials Science 36 (2006) 457 -467.
  10. J. Campbell, Review of Computer Simulation Versus Casting Reality, Modelling of Casting,Welding and Advanced Solidification Processes VII (1995) 907-935.
  11. M. R. Jolly, S. W. Wen, A. Lapish, N. D. Butler, M. Wickins and J. Campbell,Investigation of Running Systems for Grey Cast Iron Camshafts, Modelling of casting,Welding and advanced solidification processes VIII (1998) 67-75.
  12. X. Yang, X. Huang, X. Dia, J. Campbell and J. Tatler, Numerical Modelling ofEntrainment of Oxide Film Defects in Filling Aluminium Alloy Castings, Internationaljournal of Cast Metals Research 17 (2004) 321-331.
Coupling

Experimental and Numerical Analysis of Flow Behavior and Particle Distribution in A356/SiCp Composite Casting

A356/SiCp 복합재 주조에서 유동 거동 및 입자 분포에 대한 실험적 및 수치적 분석

연구 목적

  • 본 연구는 A356/SiCp 복합재 주조 과정에서 유동 거동 및 입자 분포를 실험적·수치적으로 분석하는 것을 목표로 함.
  • 실시간 X선 방사 촬영(Real-time X-ray radiography)을 이용하여 주형 충진 과정을 관찰하고, 실험 데이터를 CFD 시뮬레이션과 비교함.
  • Euler 및 Lagrangian 방법을 적용하여 유체 흐름 및 입자 분포를 모델링하고, 예측 결과와 실험 결과를 검증함.
  • 복합재 주조 과정에서 발생하는 입자 분리(particle segregation) 현상을 최소화하는 최적 조건을 도출함.

연구 방법

  1. 실험 설정 및 데이터 수집
    • 실시간 X선 방사 촬영(RT-XRR)을 활용하여 주조 과정 동안 유체 유동 및 입자 이동을 추적함.
    • A356/SiCp 복합재의 입자 크기 분포 및 미세 구조를 광학 현미경 및 주사전자현미경(SEM)으로 분석함.
    • 실험 결과와 CFD 시뮬레이션을 비교하여 유동 거동 및 입자 분포를 평가함.
  2. FLOW-3D® CFD 시뮬레이션 설정
    • VOF(Volume of Fluid) 방법을 적용하여 자유 표면 흐름을 해석하고, 입자 거동을 추적함.
    • 유동 해석(Euler 모델) 및 입자 추적(Lagrangian 모델)을 결합하여 복합재 충진 과정에서의 입자 분포를 예측함.
    • 난류 모델 적용: k-ε 및 Large Eddy Simulation(LES) 모델을 비교하여 난류가 입자 분포에 미치는 영향을 분석함.
  3. 결과 비교 및 검증
    • 입자 분포 및 유동 패턴을 실험 데이터와 비교하여 CFD 시뮬레이션의 신뢰성을 평가함.
    • 충진 전후 입자 농도를 측정하여 입자 분포 변화를 정량적으로 분석함.
    • 예측 결과와 실험 데이터 간의 오차율을 분석하여 모델의 정확도를 검증함.

주요 결과

  1. 입자 유동 및 충진 과정에서의 거동 분석
    • 입자 유동은 주조 과정의 각 단계에서 서로 다른 흐름 패턴을 보임.
    • 중력 영향이 큰 영역에서는 소용돌이(Eddy Flow)가 형성되며, 이는 입자 농도 증가의 원인이 됨.
    • 유동 방향 변화에 따라 후류(Back Flow) 형성이 관찰되며, 이는 일부 입자의 이동을 제한함.
  2. 실험과 CFD 시뮬레이션 비교 검증
    • 실제 실험에서 관찰된 입자 농도와 시뮬레이션 예측 결과가 높은 상관성을 보임.
    • 그러나 일부 중력 영향이 큰 영역(R7, R8)에서 시뮬레이션이 입자 분포를 과소평가하는 경향이 있음.
    • 이는 후류(Back Flow)에 의한 입자 이동 제한 효과가 모델에서 과도하게 반영되었기 때문으로 분석됨.
  3. 입자 분포 최적화 및 개선 가능성
    • 입자 분포는 유동 패턴, 난류 강도 및 충진 속도에 의해 결정됨.
    • 충진 속도를 조절하여 후류 형성을 최소화하면 입자 분포의 균일성을 향상시킬 수 있음.
    • 입자가 중앙부에 집중되는 경향이 있으며, 표면부에서는 상대적으로 적은 입자가 분포함.
  4. 최적 주조 조건 도출
    • 충진 속도 및 유체 유동 조건을 조정하여 입자 분리를 최소화할 수 있음.
    • 유체 흐름을 최적화하면 주조물 내 입자 농도를 균일하게 유지할 수 있음.
    • 후류(back flow) 및 소용돌이 현상(eddy flow)을 조절하면 입자 분포의 균일성을 더욱 개선 가능.

결론

  • A356/SiCp 복합재 주조에서 유동 거동 및 입자 분포를 CFD 시뮬레이션과 실험을 통해 성공적으로 분석함.
  • FLOW-3D® 시뮬레이션 결과와 실험 데이터 간 높은 상관성을 확인하였으며, 일부 영역에서의 과소평가는 모델 개선이 필요함.
  • 입자 분포 최적화를 위해 후류 및 난류 영향을 고려한 충진 속도 조절이 필요함.
  • 향후 연구에서는 다양한 입자 크기 및 형상에 따른 유동 거동을 추가적으로 평가해야 함.

Reference

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  2. D.B. Miracle, Metal matrix composites-from science to technologicalsignificance, Compos. Sci. Technol. 65 (2005) 2526–2540.
  3. B. Mondal, S. Kundu, A.K. Lohar, B.C. Pai, Net-shape manufacturing of intricatecomponents of A356/SiCp composite through rapid-prototyping-integratedinvestment casting, Mater. Sci. Eng. A 498 (2008) 37–41.
  4. S. Pattnaik, P.K. Jha, D.B. Karunakar, A review of rapid prototyping integratedinvestment casting processes, Proc. Inst. Mech. Eng. L: J. Mater. 228 (2014)249–277.
  5. B. Previtali, D. Pocci, C. Taccardo, Application of traditional investment castingprocess to aluminium matrix composites, Composites A 39 (2008) 1606–1617.
  6. P.N. Bindumadhavan, T.K. Chia, M. Chandrasekaran, H.K. Wah, L.N. Lam, O.Prabhakar, Effect of particle-porosity clusters on tribological behavior of castaluminum alloy A356–SiCp metal matrix composites, Mater. Sci. Eng. A 171(2001) 268–273.
  7. V.A. Romanova, R.R. Balokhonov, S. Schmauder, The influence of thereinforcing particle shape and interface strength on the fracture behavior ofa metal matrix composite, Acta Mater. 57 (2009) 97–107.
  8. D.J. Lloyd, Particle reinforced aluminum and magnesium matrix composites,Int. Mater. Rev. 39 (1994) 1–23.
  9. J. Hashim, L. Looney, M.S.J. Hashmi, Particle distribution in cast metal matrixcomposites – Part II, J. Mater. Process. Technol. 123 (2002) 258–263.
  10. S.B. Prabu, L. Karunamoorthy, S. Kathiresan, B. Mohan, Influence of stirringspeed and stirring time on distribution of particles in cast metal matrixcomposite, J. Mater. Process. Technol. 171 (2006) 268–273.
  11. S. Naher, D. Brabazon, L. Looney, Computational and experimental analysis ofparticulate distribution during Al–SiC MMC fabrication, Composites: Part A 38(2007) 719–729.
  12. Z. Zhang, X.G. Chen, A. Charette, Particle distribution and interfacial reactionsof Al–7%Si–10%B4C die casting composite, J. Mater. Sci. 42 (2007) 7354–7362.
  13. C.E. Brennen, Fundamentals of Multiphase Flows, Cambridge University Press,London, 2005.
  14. T.J. Heindel, J.N. Gray, T.C. Jensen, An X-ray system for visualizing fluid flows,Flow Meas. Instrum. 19 (2008) 67–78.
  15. A. Seeger, K. Affeld, L. Goubergrits, U. Kertzscher, E. Wellnhofer, X-ray-basedassessment of the three-dimensional velocity of the liquid phase in a bobblecolumn, Exp. Fluids 31 (2001) 193–201.
  16. B. Sirrell, M. Holliday, J. Campbell, Benchmark testing the flow andsolidification modeling of Al castings, JOM-US 48 (1996) 20–23.
  17. D.Z. Li, J. Campbell, Y.Y. Li, Filling system for investment cast Ni-base turbineblades, J. Mater. Process. Technol. 148 (2004) 310–316.
  18. S. Kashiwai, I. Ohnaka, A. Kimastsuka, T. Kaneyoshi, T. Ohmichi, J. Zhu,Numerical simulation and X-ray direct observation of mould filling duringvacuum suction casting, Int. J. Cast. Met. Res. 18 (2005) 144–148.
  19. H.D. Zhao, I. Ohnaka, J.D. Zhu, Modeling of mold filling of Al gravity casting andvalidation with X-ray in-situ observation, Appl. Math. Model. 32 (2008) 185–194.
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Way

Three-dimensional numerical simulation of flow in trapezoidal cutthroat flumes based on FLOW-3D

FLOW-3D를 이용한 사다리꼴 컷스로트 플룸(Trapezoidal Cutthroat Flume) 내 유동의 3차원 수치 시뮬레이션

연구 배경 및 목적

  • 문제 정의: 물 부족 문제가 심화됨에 따라 농업용 관개 시스템에서의 효율적인 물 배분이 필수적이다.
    • 플룸(Flume)은 개방 수로(Open Channel)에서 유량을 측정하는 장치로, 기존의 직사각형 컷스로트 플룸(Rectangular Cutthroat Flume)은 큰 수두 손실(Head Loss)과 시공의 어려움을 가지고 있다.
    • 사다리꼴 채널(Trapezoidal Channel)에 적합한 유량 측정 구조물의 부재로 인해, 정확한 유량 측정이 어려운 문제가 존재한다.
  • 연구 목적:
    • FLOW-3D 소프트웨어를 사용하여 사다리꼴 컷스로트 플룸의 3차원 수치 시뮬레이션을 통해 유동 특성(속도 분포, Froude 수, 수두 손실) 분석.
    • RNG k-ε 난류 모델TruVOF 기법을 활용하여 다양한 유량 조건에서의 수치 모델 검증 및 성능 평가.
    • 실험 데이터를 바탕으로 시뮬레이션 결과 검증 및 회귀 분석을 통한 방류식 개발.

연구 방법

  1. 물리 모델 및 실험 설정
    • 사다리꼴 컷스로트 플룸 설계:
      • 길이 1.80m, 높이 0.5m, 사다리꼴 목부(Throat)의 바닥 폭 0.18m, 측벽 기울기 75°.
      • 수렴부(Converging Section), 목부(Throat Section), 발산부(Diverging Section)의 14개 측정 단면을 통해 수리학적 매개변수 측정.
    • 실험 시스템 구성:
      • 저수조, 펌핑 스테이션, 전자기 유량계, 조절 밸브, 안정화 연못, 공급 파이프, 테일게이트, 90° V-notch 위어(Weir)로 구성.
      • 낮은 수두 손실과 높은 측정 정확도를 목표로 설계.
  2. 수치 시뮬레이션 및 모델링
    • FLOW-3D의 RNG k-ε 난류 모델TruVOF 기법을 사용하여 유동 시뮬레이션.
    • 연속 방정식(Continuity Equation) 및 Navier-Stokes 방정식을 통해 비압축성 뉴턴 유체 흐름 모델링.
    • 격자 설정:
      • 격자 크기 0.02m × 0.02m × 0.02m, 총 78만 3천 개의 격자 사용.
      • FAVOR(Fractional Area Volume Obstacle Representation) 방법을 활용하여 복잡한 형상에서도 높은 정확도 보장.
    • 경계 조건 설정:
      • 입출구 경계: 유량 조건에 따른 자동 유체 높이 조절.
      • 벽면(Wall Boundary): 비투과성(Impermeable) 경계 조건.
      • 상단(Top Boundary): 대칭 경계(Symmetry Boundary).

주요 결과

  1. 모델 검증 및 속도 분포 분석
    • FLOW-3D 시뮬레이션 결과실험 데이터 간의 평균 속도 비교에서 상대 오차 10% 미만.
    • 수렴부에서는 Froude 수가 0.5 미만, 목부에서 임계 흐름(Critical Flow)이 나타남.
    • 발산부에서는 Froude 수가 감소, 수두 손실이 기존 직사각형 플룸 대비 약 9% 감소.
  2. 수두 손실(Head Loss) 비교
    • 사다리꼴 컷스로트 플룸의 수두 손실은 최대 8.955%로, 직사각형 플룸의 11.097%보다 낮음.
    • 유량 증가에 따른 수두 손실 변화 분석에서 0.045 m³/s 이상의 유량에서는 수두 손실 증가율이 감소.
  3. 방류 계산식(Discharge Calculation Formula) 도출
    • 자유 흐름(Free Flow)침수 흐름(Submerged Flow) 조건에서의 회귀 분석을 통해 방류 계산식 개발.
    • 상류 깊이와 방류량 간의 상관계수 0.992, 5% 이내의 오차율을 보이며 농업용 관개 시스템의 정확도 요건 충족.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 시뮬레이션을 통해 사다리꼴 컷스로트 플룸이 직사각형 플룸 대비 높은 측정 정확도와 낮은 수두 손실을 제공.
    • 단순한 구조, 저비용, 다양한 수자원 조건에서의 적용 가능성을 입증.
    • 특히 고침전물 환경에서도 우수한 성능을 보임.
  • 향후 연구 방향:
    • 다양한 사다리꼴 채널 기울기 및 유량 조건에서의 성능 평가.
    • AI 및 머신러닝을 활용한 실시간 유량 예측 모델 개발.
    • 장기적인 현장 실험을 통한 모델의 신뢰성 강화.

연구의 의의

이 연구는 FLOW-3D를 활용하여 사다리꼴 컷스로트 플룸의 유동 특성을 정량적으로 분석하고, 정확한 유량 측정 및 수자원 관리 효율성을 높이는 설계 기준을 제시하며, 농업용 관개 시스템의 물 절약 및 생산성 향상에 기여할 수 있다​.

Reference

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Velocity Magnitude

Study of Velocity, Flow Depth and Froude Number of HDPE Diagonal Modular Pavement Using FLOW-3D

FLOW-3D를 이용한 HDPE 대각선 모듈러 포장(HDP Diagonal Modular Pavement)의 속도, 유동 깊이 및 Froude 수 연구

연구 배경 및 목적

  • 문제 정의: 기존의 아스팔트 포장 도로물의 자연스러운 흐름을 방해하고 홍수 위험을 증가시키는 환경적 문제를 초래한다.
    • 모듈러 포장 시스템(Modular Pavement System)은 투수성 재료와 중첩된 빈 공간 구조를 통해 강우 유출을 줄이고 지하수 재충전을 촉진할 수 있다.
    • 그러나 물리적 실험 방법은 비용이 많이 들고 시간 소모적이기 때문에, 수치 시뮬레이션을 통한 효율적 설계 방법이 필요하다.
  • 연구 목적:
    • FLOW-3D 소프트웨어를 활용하여 대각선 HDPE 모듈러 포장 시스템의 수리적 특성(속도, 유동 깊이, Froude 수)을 분석.
    • 말레이시아 실제 강우 데이터를 사용하여 다양한 강우 강도(5 mm/h 및 85 mm/h)에 따른 포장의 물 흡수 능력 평가.
    • 예비 설계 방법으로서의 FLOW-3D 사용 가능성 검증.

연구 방법

  1. 포장 모델 설계 및 시뮬레이션 설정
    • AutoCAD를 이용해 모듈러 포장 모델링을 수행하고, FLOW-3D 소프트웨어에서 수치 시뮬레이션을 진행.
    • 포장 모델 구성:
      • 모듈러 포장층, 자갈층, 모래층의 3가지 레이어로 구성.
      • HDPE 모듈러 포장80 mm 직경, 5 mm 두께의 얇은 대각선 기둥 구조.
      • Jabatan Kerja Raya 표준에 따라 설계.
    • 수치 모델 설정:
      • FLOW-3D의 VOF(Volume of Fluid) 기법을 사용하여 유체 흐름 및 유동 깊이 예측.
      • Navier-Stokes 방정식을 사용하여 3차원 불압축성 유동(Incompressible Flow) 시뮬레이션.
      • 모듈러 포장 모델의 경계 조건대칭(Symmetry), 연속(Continuative), 체적 유량(Volume Flow Rate), 벽(Wall) 경계로 설정.
  2. 시뮬레이션 시나리오 및 변수 설정
    • 강우 강도 시나리오:
      • 낮은 강우(5 mm/h)높은 강우(85 mm/h) 조건을 설정하여 모듈러 포장의 유동 특성 분석.
    • 측정 변수:
      • 속도(속도의 x, y, z 성분), 유동 깊이(Flow Depth), Froude 수(Fr)를 측정.
      • Froude 유속과 관성력의 비율을 나타내며, 유동 상태(서브크리티컬 또는 슈퍼크리티컬) 평가에 사용.

주요 결과

  1. 속도(X-, Y-, Z-방향) 분석
    • 시뮬레이션 결과:
      • x, y 속도z 속도보다 크게 나타남.
      • 200초 초기 단계에서 x 속도는 122.40 ~ 125.28 cm/h, 6000초 후에는 68.04 ~ 78.12 cm/h로 감소.
      • z 속도는 40.68 ~ 44.28 cm/h(200초)에서 22.32 ~ 30.6 cm/h(6000초)로 다소 적은 변화를 보임.
    • 속도 감소 원인 분석:
      • 낮은 토양 투수성으로 인해 강우 강도가 유속에 미치는 영향 미미.
      • 모듈러 포장 구조 내 작은 기공(Pore Space)과 모세관 현상(Capillarity) 제한으로 유속 감소.
  2. 유동 깊이(Flow Depth) 변화 분석
    • 모든 강우 강도 조건(5 mm/h, 85 mm/h)에서 유동 깊이는 425.65 mm로 일정하게 유지.
    • 포장 내 물의 유입 및 유출이 균형을 이루어 정상 상태(Steady State) 도달.
    • 포장 구조의 투수성 덕분에 강우 강도가 증가해도 표면 유출(Surface Runoff)이 발생하지 않음.
  3. Froude 수(Fr) 평가
    • 모든 강우 조건에서 Froude 수는 0으로 유지, 서브크리티컬 흐름(Subcritical Flow, Fr < 1) 상태.
    • 모듈러 포장이 물 저장 및 투수 역할을 수행하여 흐름 에너지를 낮추고 난류(Turbulence) 감소 효과.
    • 높은 Froude 수낮은 전단력 방출(Shear Force Discharge) 및 높은 침전물 운반 용량을 의미하지만, 본 연구에서는 낮은 Fr 값으로 침전물 운반 감소 효과 확인.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 소프트웨어를 활용하여 HDPE 모듈러 포장의 수리적 특성을 정확히 분석 가능.
    • 모듈러 포장이 강우 유출을 줄이고 지하수 충전에 효과적임을 입증.
    • 말레이시아 실제 강우 데이터를 활용하여 현지 조건에서도 적합성을 보임.
    • FLOW-3D는 모듈러 포장 설계 시 예비 평가 도구로 활용 가능.
  • 향후 연구 방향:
    • 다양한 경사(Slope) 조건에서의 모듈러 포장 성능 분석 필요.
    • 최적 강우 강도 및 침투 효율성 평가를 위한 시뮬레이션 확장.
    • AI 및 머신러닝을 활용한 실시간 수리적 성능 예측 모델 개발.

연구의 의의

이 연구는 FLOW-3D를 활용하여 HDPE 대각선 모듈러 포장의 수리적 성능을 정량적으로 평가하고, 비용 효율적인 강우 관리 및 침수 예방을 위한 설계 가이드라인을 제공하며, 도시 홍수 위험을 줄이고 지속 가능한 물 관리 정책 수립에 기여할 수 있다​.

Reference

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  2. Shafique, M., Kim, R., & Kwon, K. H. 2018 Rainfall Runoff Mitigation by Retrofitted PermeablePavement in an Urban Area Sustainability (Switzerland) 10 (4)
  3. Chen et al. 2020 Effect of Rainfall, Runoff and Infiltration Processes on the Stabily of FootslopesWater 12 (1229) 1-19.
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  6. Sharma, S., Sharma, P. K., & Upadhyay, N. 2020 Properties of Bituminous Bindermodified withPolyethylene Journal of Physics: Conference Series 1531 (1).
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  9. Abdurrasheed et al. 2019 Modelling of Flow Parameters through Subsurface Drainage Modulesfor Application in BIOECODS Water (Switzerland) 11 (9) 1–15.
  10. Zhao et al (2019) Effects of Rainfall Intensity and Vegetation Cover on Erosion Characteristicsof a Soil Containing Rock Fragments Slope Advances in Civil Engineering 2019.
  11. Song et al. (2014) Study of The Fluid Flow Characteristics in a Porous Medium For CO2Geological Storage using MRI Magnetic Resonance Imaging 32 (5) 574–584.
  12. Payus et al. (2020) Impact of Extreme Drought Climate on Water Security in North Bornea: CaseStudy of Sabah Water 12 (1135) 1-19.
  13. Cherkauer, D. S. (2021). The effect of urbanization on kinetic energy distributions in smallwatersheds.
  14. Zhang et al (2015) Approximate Simulation of Strom Water Runoff over Pervious PavementInternational Journal of Pavement Engineering 18 (3) 247-259
  15. Liu et al. (2019) Laboratory Analysis on the Surface Runoff Pollution Reduction Performance ofPermeable Pavements Science of the Total Environment 691 1–8.
  16. Khan et al. (2016) Effect of Slope, Rainfall Intensity and Mulch on Erosion and Infiltrationunder Simulated Rain on Purple Soil of South-Western Sichuan Province, China Water(Switzerland) 8 (11) 1–18.
  17. Lee et al (2013) Modelling the Hydrologic Process of a Permeable Pavement System Journal ofHydrologic Engineering 20 (5) 04014070
  18. Wolff, A. (2012) Simulation of Pavement Surface Runoff using the Depth-Averaged ShallowWater Equations. 93(März), 149.
  19. Lei et al. (2020) Study on Runoff and Infiltration for Expansive Soil Slopes in Simulated RainfallWater 12 (1) 222.
  20. Inn et al. (2020) Features of the Flow Velocity and Pressure Gradient of an Undular Bore on aHorizontal Bed Physics of fluids 32 (4) 043603.
Dam

Numerical Simulation of Dam Failure Process Based on FLOW-3D

FLOW-3D를 이용한 댐 붕괴 과정의 수치 시뮬레이션

연구 배경 및 목적

  • 문제 정의: 댐 붕괴(Dam Failure)는 하류 지역의 인명 및 재산 안전에 심각한 위협을 가할 수 있다.
    • 댐 붕괴 시 발생하는 홍수예측이 어렵고 복잡한 수리학적 현상을 동반하며, 긴급 구조 및 대응 계획 마련이 필수적이다.
    • 특히 Tangjiashan 산사태 댐(Tangjiashan Landslide Dam)과 같은 장애호수(Barrier Lake)의 붕괴는 갑작스러운 월류 및 사면 불안정(Slope Instability)을 초래할 수 있다.
  • 연구 목적:
    • FLOW-3D 소프트웨어를 활용하여 Tangjiashan 산사태 댐의 붕괴 과정3차원 수치 모델링을 통해 시뮬레이션.
    • 초기 붕괴 수위(Initial Breach Water Level)의 민감도 분석을 통해 붕괴 유량 및 최종 붕괴 폭(Breach Width)에 미치는 영향 평가.
    • 비상 계획 수립 및 재난 대응을 위한 기술적 참조 자료 제공.

연구 방법

  1. 댐 모델링 및 시뮬레이션 설정
    • 모델 구축:
      • Autodesk Civil3D 소프트웨어를 사용하여 위성 원격 감지 데이터를 바탕으로 Tangjiashan 댐의 3D 모델 생성.
      • 댐의 실제 지형 데이터를 1:1 비율로 반영하여 복잡한 월류 및 붕괴 과정을 시뮬레이션.
    • FLOW-3D를 이용한 시뮬레이션:
      • 3차원 수치 모델을 통해 월류(Ovetopping) 및 붕괴 과정 재현.
      • 계산 효율성을 높이기 위해:
        • 모델 크기: 1100m × 700m × 150m.
        • 붕괴 영역(Breach Area)에는 세밀한 격자(2.5m × 2.5m × 2.5m) 사용.
        • 총 유효 격자 수: 약 390만 개.
    • 경계 조건(Boundary Condition) 설정:
      • 상류(Upstream): 압력 경계(Pressure Boundary).
      • 하류(Downstream): 자유 유출(Outflow) 경계.
      • 측면(Sides): 대칭 경계(Symmetrical Boundary).
      • 바닥(Bottom): 벽(Wall) 경계.
      • 상단(Top): 대기압과 동일한 압력 경계(Atmospheric Pressure).
  2. 민감도 분석(Sensitivity Analysis)
    • 초기 붕괴 수위 변화 시나리오:
      • 742m, 745m, 748m의 세 가지 초기 수위 조건을 설정.
      • 각각의 초기 수위에 따른 최대 붕괴 유량(Peak Breach Flow) 및 붕괴 폭 변화 분석.
    • 침식 및 퇴적 모델링:
      • 댐 재료의 물리적 특성(예: 건조 벌크 밀도 2200 kg/m³, 임계 Froude 수 0.05)을 반영.
      • 모델 입력 파라미터는 기존 연구 및 현장 측정 데이터를 활용.

주요 결과

  1. 시뮬레이션 결과 분석
    • 최대 붕괴 유량(Peak Breach Flow):
      • 742m 초기 수위에서 6937 m³/s 도달.
      • 745m 초기 수위에서는 7597 m³/s, 9.5% 증가.
      • 748m 초기 수위에서는 8542 m³/s, 23.1% 증가.
    • 최종 붕괴 폭(Breach Width):
      • 초기 수위 증가에 따라 150m → 220.8m47.2% 증가.
    • 유량 도달 시간(Time to Peak Flow):
      • 초기 수위 증가 시 도달 시간이 단축:
        • 742m 수위에서는 5.83시간, 748m에서는 3.55시간(39.1% 감소).
    • 모델 검증(Validation):
      • 시뮬레이션 결과와 현장 측정 데이터 비교:
        • 최대 붕괴 유량상대 오차 7.05%.
        • 최종 붕괴 폭의 상대 오차 4.16%.
        • 유량 도달 시간은 실제보다 약 40분 빠름.
  2. 민감도 분석 결과
    • 초기 붕괴 수위는 붕괴 과정에 매우 민감:
      • 수위가 높아질수록 붕괴 유량 및 하류 방출 유량이 급격히 증가.
      • 정확한 초기 수위 측정의 중요성 강조.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 소프트웨어를 통한 Tangjiashan 댐 붕괴 시뮬레이션이 실제 현상과 높은 일치도를 보임.
    • 초기 붕괴 수위는 붕괴 유량, 최종 붕괴 폭 및 붕괴 과정 전반에 큰 영향을 미침.
    • 긴급 구조 및 대응 계획 수립 시 초기 수위 데이터를 정확히 반영할 필요.
    • 본 연구 결과는 향후 장애호수 붕괴 대응 및 재난 관리 정책 수립에 중요한 기술적 참조 자료 제공.
  • 향후 연구 방향:
    • 수치 시뮬레이션의 정확도 향상을 위해 물의 밀도 변화(퇴적물 침식에 따른 영향) 고려.
    • 다양한 초기 조건(예: 강우 패턴, 하천 유량 변화)에 따른 시나리오 분석.
    • AI 및 머신러닝을 활용한 실시간 댐 붕괴 예측 모델 개발.

연구의 의의

이 연구는 FLOW-3D를 활용하여 Tangjiashan 산사태 댐의 붕괴 과정을 정량적으로 평가하고, 재난 대응 및 비상 계획 수립을 위한 실질적인 데이터와 설계 기준을 제공하며, 장애호수 붕괴 시 인명 및 재산 피해를 최소화하는 데 기여할 수 있다​.

Reference

  1. Zuwen Yan , Yingqi Wei, Hong Cai. Formation mechanism and stability analysis of barrier dam [J].Chinese Journal of geological hazards and prevention, 2009,20(04) : 55-59.
  2. Costa J E,Schuster R L. The formation and failure of natural dams [J]. Geological Society of AmericaBulletin,1988,100 (7):1054 – 1068.
  3. Schuster R L, Costa J E,Rl S. A perspective on landslide Dams. Lands1ide Dams: processes, risk andmitigation [J]. Geotechnical Special Publication,1986,(3):1 – 20.
  4. Jianguo Zhang,Cheng Wang,Xuejun Xu . Numerical simulation of Tangjiashan Lake Flow [J] . People’sYangtze River, 2009,40(22) : 60-62.
  5. Yonghui Zhu, Beilin Fan, Jinyou Lu, Xibing Zhang, Wenjun Yang, Geng Qu. Analysis of TangjiashanLake dam-break flood and simulation of discharge scour [J]. People’s Yangtze River, 2008,39(22):79-82.DOI: 10.16232/J. CNKI. 1001-4179.2008.22.023.
  6. Tianlong Zhao, Shengshui Chen, Junjie Wang, qiming zhong,Changjing Fu. Centrifuge model test onovertopping failure of barrier dam [J] . Geotechnical engineering, 2016,38(11) : 1965-1972.
  7. Liu N,Chen Z Y,Zhang J X,et al. Draining the Tangjiashan barrier lake [J]. Journal of HydraulicEngineering,2010,136 (11 ):914-923.
  8. Shufei Li, Weizhong Hu. Possible Tangjiashan Lake of water level [J] . People’s Yangtze River,2008,39(22) : 73-75.
Casting

Effect of Casting Parameters on Microstructure and Casting Quality of Si-Al Alloy for Vacuum Sputtering

진공 스퍼터링용 Si-Al 합금의 미세 구조 및 주조 품질에 미치는 주조 매개변수의 영향

연구 목적

  • 본 연구는 FLOW-3D® 시뮬레이션을 활용하여 Si-30wt.% Al 합금의 주조 품질을 분석함.
  • 실험 결과와 시뮬레이션을 비교하여 주조 결함(수축 기공 및 조성 편석) 발생 원인을 규명함.
  • 금형 두께, 주조 온도, 주형 온도 등의 주조 매개변수가 주조물의 미세 구조 및 품질에 미치는 영향을 연구함.
  • Si-Al 합금의 비전도성 진공 금속화(Non-Conductive Vacuum Metallization, NCVM) 특성을 평가하여 최적 조성을 도출함.

연구 방법

  1. 실험 및 시뮬레이션 설정
    • Si-Al 합금(20, 25, 30, 35wt.% Al)을 진공 유도로에서 용해한 후 얇은 금형에 주조함.
    • FLOW-3D® 시뮬레이션을 수행하여 주조 유동 및 응고 과정에서의 결함 발생 패턴을 분석함.
    • 금형 두께, 주조 온도, 주형 온도 변화가 미세 구조 및 수축 기공 형성에 미치는 영향을 평가함.
  2. 미세 구조 및 필름 특성 분석
    • 주조 후, 광학 현미경(OM) 및 주사전자현미경(SEM)을 사용하여 Si-Al 합금의 미세 조직을 관찰함.
    • 반사율 측정(n&k 분석기 1280)을 통해 Si-Al 박막의 반사율 특성을 평가함.
    • Si-30wt.%Al 박막을 유리 기판에 스퍼터링하여 전도성 및 비전도성 특성을 비교 분석함.
  3. 결과 비교 및 검증
    • 실험 결과와 FLOW-3D® 시뮬레이션 비교를 통해 주조 결함 및 응고 거동을 분석함.
    • 응고 속도를 조절하여 수축 기공 및 조성 편석을 최소화하는 최적 조건을 도출함.

주요 결과

  1. Si-Al 박막의 반사율 및 전도성 변화
    • Al 함량이 증가할수록 박막의 반사율이 증가하나, 전기 전도성이 향상됨.
    • 비전도성 특성을 유지하면서 반사율을 극대화하려면 Al 함량을 30wt.%로 유지하는 것이 최적.
  2. 주조 결함 분석
    • Si-Al 합금은 응고 시 심각한 조성 편석과 다량의 수축 기공(shrinkage pores)을 형성.
    • 두꺼운 금형을 사용할 경우 수축 기공이 증가하지만, 얇은 금형을 사용하면 기공 형성이 감소함.
    • 주조 온도를 1270°C, 금형 온도를 50°C로 설정하면 Al 편석이 억제되고 수축 기공이 4% 이하로 감소.
    • 반대로 주조 온도 1300°C 이상, 금형 온도 200°C 이상에서는 심각한 수축 기공과 Al 편석이 발생.
  3. FLOW-3D® 시뮬레이션 검증
    • 시뮬레이션 결과, 얇은 금형을 사용할 경우 주조물 표면에 “hot spot”이 형성되며 국부적인 과열로 인해 표면 결함 발생.
    • 용탕이 라이저(riser)에서 금형 내부로 흐를 때, 고온 영역에서 표면 기포(casting pits)가 집중적으로 형성됨.
    • 시뮬레이션 결과와 실험 데이터 간 평균 오차율이 5~8% 수준으로 확인됨.
  4. 최적 주조 조건 및 개선 방안
    • U자형 주조 결함(U-shaped defect)은 주조 흐름이 갑자기 증가할 때 발생하며, 주조 흐름을 안정화하기 위해 턴디시(tundish) 사용 필요.
    • 용탕이 금형 내부로 직접 유입되도록 개선하면 “hot spot” 발생 억제 가능.
    • 최적화된 주조 조건: 주조 온도 1270°C, 금형 온도 50°C, 얇은 금형 사용.

결론

  • Si-30wt.% Al 합금은 NCVM 박막의 최적 조성을 제공하며, 반사율과 비전도성을 동시에 만족시킴.
  • 주조 결함(수축 기공, 조성 편석)은 금형 두께 및 주조 조건을 최적화하여 크게 줄일 수 있음.
  • FLOW-3D® 시뮬레이션을 활용한 주조 결함 예측이 높은 신뢰도를 보이며, 실험 데이터와 유사한 결과를 제공함.
  • 향후 연구에서는 주조 공정 최적화를 위한 추가적인 냉각 제어 및 형상 설계가 필요.

Reference

  1. J.C. Pan: Industial Materials Magazine, 253(2008) p. 189.
  2. J.C. Pan: Industial Materials Magazine, 255(2008) p. 193.
  3. S. P. Nikanorov: Material Science and Engineering A, 390(2005) p. 63.
  4. G. J. Davies: Solidification and Casting, Applied Science Publisher, London, 1984.
  5. M. C. Flemings: Solidification Processing, McgrawHill, New York, 1978.
  6. W. G. Winegard: An Introduction to The Solidification of Metals, London, 1964.
  7. B. Chalmers: Principles of Solidification, Robert E. Krieger Publishing Company, London, 1964.
  8. D. A. Porter: Phase Transformations in Metals and Alloys, Stanley Thornes, UK, 1981.
HPDC

Design of Gating System for Radiator Die Castings Based on FLOW-3D Software

FLOW-3D 소프트웨어를 기반으로 한 라디에이터 다이캐스팅 주입 시스템 설계

연구 목적

  • 본 연구는 FLOW-3D®를 사용하여 라디에이터 다이캐스팅 공정의 게이팅 시스템(Gating System) 설계 최적화를 수행함.
  • 두 가지 다른 게이트 구조를 비교 분석하여 금속 충진(filling) 및 결함 형성을 평가함.
  • 기포(Porosity), 산화물(Oxide Inclusion), 불완전 충진(Incomplete Filling) 등의 결함을 예측하고 최적의 설계안을 도출함.
  • 최적화된 게이팅 시스템이 충진 균일성 및 표면 결함 감소에 미치는 영향을 분석함.

연구 방법

  1. 다이캐스팅 모델링 및 실험 설정
    • 라디에이터 고압 다이캐스팅(HPDC)을 위한 두 가지 게이트 구조를 설계함.
    • FLOW-3D® 시뮬레이션을 활용하여 금속 충진 과정 및 결함 발생 영역을 예측함.
    • 실험적으로 주입 온도(680°C), 금형 예열 온도(220°C), 주입 속도(60m/s) 조건을 설정함.
  2. FLOW-3D® 시뮬레이션 설정
    • VOF(Volume of Fluid) 모델을 적용하여 충진 거동을 해석함.
    • 난류 모델 및 자유 표면 추적 기법을 활용하여 공기 혼입 및 금속 유동 패턴을 평가함.
    • 네 가지 게이팅 시스템 변형 모델을 추가적으로 분석하여 최적 설계를 도출함.
  3. 결과 비교 및 검증
    • 각 게이팅 구조에서 금속 충진 균일성, 표면 결함 분포, 산화물 혼입 여부를 평가함.
    • 시뮬레이션을 통해 예측된 결함 위치를 실제 주조 실험과 비교하여 검증함.
    • 최적의 게이트 및 오버플로우 트로프(Overflow Trough) 설계를 도출함.

주요 결과

  1. 충진 균일성 및 유동 패턴 분석
    • 최적의 게이팅 시스템에서는 금속이 고르게 충진되며 표면 결함이 최소화됨.
    • 일부 설계에서는 유속이 너무 빠르게 형성되며 산화물 혼입 및 불완전 충진 발생.
    • 오버플로우 트로프를 적절히 배치하면 유동 균형이 개선되며 기공 발생이 감소함.
  2. 결함 예측 및 최적화 가능성
    • 기포 및 산화물 결함은 특정 영역에서 집중적으로 발생하며, 게이팅 디자인 변경으로 30% 이상 감소 가능.
    • 충진 속도가 너무 빠르면 난류 효과가 증가하여 불완전 충진 및 산화물 혼입이 심화됨.
    • 유동 방향을 제어하기 위한 게이트 크기 및 배치 최적화 필요.
  3. CFD 시뮬레이션 검증 결과
    • FLOW-3D® 기반 시뮬레이션은 실험 데이터와 85% 이상의 상관관계를 보임.
    • 시뮬레이션을 활용하여 충진 패턴 및 결함 예측이 가능하며, 최적 설계 도출에 효과적.
    • 추가 연구를 통해 다양한 재료 및 환경 조건에서도 적용 가능성 확인 필요.

결론

  • FLOW-3D® 기반 CFD 시뮬레이션을 활용하여 다이캐스팅 게이팅 시스템 최적화 가능.
  • 최적의 게이팅 설계로 기포 및 산화물 결함을 30% 이상 감소 가능.
  • 충진 속도 및 유동 균형을 고려한 설계가 표면 결함 억제에 중요.
  • 향후 연구에서는 다양한 다이캐스팅 소재 및 복합 설계 적용을 추가적으로 분석할 필요.

Reference

  1. Peng, Y.,Wang,S.C., Zheng,K.H. (2013)Research progress of high performance magnesium alloycasting technology .J. Casting Technology , 34: 203 -204.
  2. Chen,X.H., Geng,Y.X., Liu,J. (2013)Research progress of functional materials of magnesium andmagnesium alloys.J. Journal of Materials Science and Engineering, 31: 148-152.
  3. An,S.J.(2015)Mg-Al-Mn alloy by super vacuum die casting.J. Scripta Material, 67: 879-882.
  4. Qi,W.J.,Song,D.F.,Cai,C.(2014)Research on vacuum technology for vacuum die casting ofmagnesium alloy radiators.J. Casting, 63: 328-329.
  5. Chen,S.T., Qi,W.J., Song,D.F.(2013)Optimization of pouring system for magnesium alloy radiatordie casting.J. Special casting and non-ferrous alloys, 33:1134-1136.
  6. Song,D.F., Qi,W.J., Wang,H.Y., et al. (2015)Study on die-casting process of magnesium alloy heatsink for LED.J.Casting, 64: 403-404.
  7. Li,X.B., Cao,W.T., Bai,J.Y.(2010)Study on the heat dissipation performance of AZ91D.J. Journalof Henan University of Technology, 29:685-688.
Melt Pool

Investigations of Weld Profiling and Intermetallic Formation in Laser Welding of Steel-to-Aluminium: A Multi-Physics CFD Approach Using Beam Shaping

강-알루미늄 레이저 용접에서 용접 형상 및 금속간 화합물 형성 연구: 빔 형상을 활용한 다중 물리 CFD 접근

연구 목적

  • 본 논문은 FLOW-3D® 기반 CFD 시뮬레이션을 활용하여 강-알루미늄 레이저 용접 과정에서의 용접 형상 및 금속간 화합물(IMC) 형성을 분석함.
  • 빔 형상(Laser Beam Shaping) 기법이 키홀(Keyhole) 안정성, 기공 형성, 용접 품질 및 IMC 형성에 미치는 영향을 연구함.
  • 링-코어 빔(Ring-Core Beam) 비율 조정을 통해 용접 품질을 개선할 수 있는 가능성을 평가함.
  • 실험 결과와 CFD 시뮬레이션 결과를 비교하여 용접 공정 최적화 방향을 제안함.

연구 방법

  1. 레이저 용접 모델링 및 실험 설정
    • 강(IF steel) – 알루미늄(1050 Al) 이종 금속 용접을 수행함.
    • 고출력 연속파 레이저(16kW) 및 다양한 빔 형상 조합(코어-링 빔 비율 조정)을 적용함.
    • 용접 형상, 기공 생성, IMC 형성 정도를 평가하여 실험 데이터를 확보함.
  2. FLOW-3D® 시뮬레이션 설정
    • 다중 물리 CFD 모델을 사용하여 용융지 유동, 열 전달, 상변화(Phase Change) 및 기공 형성을 해석함.
    • 레이저 빔 흡수 모델 및 증발 유도 반동 압력(Recoil Pressure) 효과를 포함함.
    • 다양한 링-코어 빔 비율(100% 코어, 100% 링, 혼합 모드 등)을 적용하여 용접 특성을 비교 분석함.
  3. 결과 비교 및 검증
    • 용접 형상(비드 폭, 깊이), 키홀 안정성, IMC 두께를 실험과 CFD 결과를 비교하여 검증함.
    • 고해상도 현미경(HR Microscopy) 및 기계적 시험을 수행하여 용접부의 물리적 특성을 분석함.
    • CFD 모델과 실험 데이터를 기반으로 최적의 용접 빔 형상 및 공정 조건을 도출함.

주요 결과

  1. 키홀 안정성 및 기공 형성 영향
    • 순수 코어 빔(Core-Only Beam) 사용 시 키홀이 불안정하며 기공(Porosity)이 증가하는 경향을 보임.
    • 순수 링 빔(Ring-Only Beam) 적용 시 키홀 안정성이 향상되며, 기공 형성이 최대 50% 감소함.
    • 혼합 모드(Core-Ring Combination)에서는 코어 빔의 깊이 효과와 링 빔의 안정성이 조합되어 최적의 용접 품질을 보임.
  2. IMC 두께 및 용접 강도 비교
    • 순수 코어 빔 사용 시 IMC 두께가 증가(최대 8µm)하여 취성이 증가함.
    • 순수 링 빔 적용 시 IMC 두께가 감소(최대 50%)하며, 용접부 강도가 16% 증가함.
    • 링 빔을 활용하면 냉각 속도 조절을 통해 과도한 IMC 형성을 억제할 수 있음.
  3. CFD 시뮬레이션 검증 및 최적화 가능성
    • CFD 모델을 통해 용융지 유동 및 키홀 형상 예측이 실험과 85% 이상의 상관관계를 보임.
    • 레이저 빔 형상의 조정이 용접 품질에 미치는 영향을 정량적으로 분석 가능.
    • 향후 연구에서는 다양한 레이저 파장 및 펄스 변조 기법을 적용한 추가적인 검증이 필요함.

결론

  • FLOW-3D® 기반 CFD 시뮬레이션은 강-알루미늄 레이저 용접의 용접 형상 및 IMC 형성을 정밀하게 예측 가능.
  • 링 빔을 활용한 용접이 키홀 안정성 향상 및 IMC 감소에 효과적임.
  • 실험과 시뮬레이션 결과가 높은 신뢰도를 보이며, 용접 공정 최적화 가능성을 확인함.
  • 향후 연구에서는 다양한 레이저 빔 형상 및 추가적인 용접 환경 변수를 고려해야 함.

Reference

  1. Sergey Kuryntsev, “A Review : Laser Welding of Dissimilar Materials,”Materials (Basel)., vol. 15, no. 122, 2022, doi:https://doi.org/10.3390/ma15010122.
  2. A. Gullino, P. Matteis, and F. D. Aiuto, “Review of aluminum-to-steelwelding technologies for car-body applications,” Metals (Basel)., vol. 9,no. 3, pp. 1–28, 2019, doi: 10.3390/met9030315.
  3. S. Jabar, A. Baghbani Barenji, P. Franciosa, H. R. Kotadia, and D.Ceglarek, “Effects of the adjustable ring-mode laser on intermetallicformation and mechanical properties of steel to aluminium laser weldedlap joints,” Mater. Des., vol. 227, 2023, doi:10.1016/j.matdes.2023.111774.
  4. S. Jabar et al., “Effect of a ring-shaped laser beam on the weldability ofaluminum-to-hilumin for battery tab connectors,” J. Laser Appl., vol. 35,no. 04, 2023, doi: 10.2351/7.0001156.
  5. H. R. Kotadia, P. Franciosa, S. Jabar, and D. Ceglarek, “Remote laserwelding of Zn coated IF steel and 1050 aluminium alloy: processing,microstructure and mechanical properties,” J. Mater. Res. Technol., vol.19, pp. 449–465, 2022, doi: 10.1016/j.jmrt.2022.05.041.
  6. J. Yang et al., “Laser techniques for dissimilar joining of aluminum alloysto steels: A critical review,” J. Mater. Process. Technol., vol. 301, no.November 2021, p. 117443, 2022, doi: 10.1016/j.jmatprotec.2021.117443.
  7. M. Mohammadpour, N. Yazdian, G. Yang, H. P. Wang, B. Carlson, andR. Kovacevic, “Effect of dual laser beam on dissimilar welding-brazing ofaluminum to galvanized steel,” Opt. Laser Technol., vol. 98, pp. 214–228,2018, doi: 10.1016/j.optlastec.2017.07.035.
  8. S. Yan, Z. Hong, T. Watanabe, and T. Jingguo, “CW/PW dual-beam YAGlaser welding of steel/aluminum alloy sheets,” Opt. Lasers Eng., vol. 48,no. 7–8, pp. 732–736, 2010, doi: 10.1016/j.optlaseng.2010.03.015.
  9. H. Xia, W. Tao, L. Li, C. Tan, K. Zhang, and N. Ma, “Effect of laser beammodels on laser welding–brazing Al to steel,” Opt. Laser Technol., vol.122, no. September 2019, p. 105845, 2020, doi:10.1016/j.optlastec.2019.105845.
  10. R. Yuan, S. Deng, H. Cui, Y. Chen, and F. Lu, “Interface characterizationand mechanical properties of dual beam laser welding-brazing Al/steeldissimilar metals,” J. Manuf. Process., vol. 40, no. January, pp. 37–45,2019, doi: 10.1016/j.jmapro.2019.03.005.
  11. G. Chianese, Q. Hayat, S. Jabar, P. Franciosa, D. Ceglarek, and S.Patalano, “A multi-physics CFD study to investigate the impact of laserbeam shaping on metal mixing and molten pool dynamics during laserwelding of copper to steel for battery terminal-to-casing connections,” J.Mater. Process. Technol., vol. 322, no. April, p. 118202, 2023, doi:10.1016/j.jmatprotec.2023.118202.
  12. Y. Hao, N. Chen, H. P. Wang, B. E. Carlson, and F. Lu, “Effect of zincvapor forces on spattering in partial penetration laser welding of zinccoated steels,” J. Mater. Process. Technol., vol. 298, no. July, p. 117282,2021, doi: 10.1016/j.jmatprotec.2021.117282.
  13. W. Huang, W. Cai, T. J. Rinker, J. Bracey, and W. Tan, “Effects of laseroscillation on metal mixing, microstructure, and mechanical property ofAluminum–Copper welds,” Int. J. Mach. Tools Manuf., vol. 188, no.September 2022, p. 104020, 2023, doi:10.1016/j.ijmachtools.2023.104020.
Cladding

Influence of Fluid Convection on Weld Pool Formation in Laser Cladding

레이저 클래딩(Laser Cladding)에서 유체 대류(Fluid Convection)가 용융풀(Weld Pool) 형성에 미치는 영향

연구 배경 및 목적

  • 문제 정의: 레이저 클래딩(Laser Cladding)은 금속 표면에 보호 코팅을 입히거나 마모된 부품을 복구하는 데 사용되는 정밀 금속 적층 기술이다.
    • Inconel® 718 초합금을 사용한 제트 엔진 터빈 블레이드 팁 재생 및 부품 보호에 적용된다.
    • 그러나 복잡한 물리적 현상정확하게 예측할 수 있는 모델의 부족으로 인해 경제적인 응용 개발에 어려움이 존재한다.
  • 연구 목적:
    • FLOW-3D 소프트웨어를 활용하여 Inconel® 718 레이저 클래딩용융풀 형성, 유체 대류, 응고(Solidification) 현상 분석.
    • 마랑고니(Marangoni) 대류에 의한 온도 프로파일 변화유동 패턴을 평가.
    • 모델 예측 결과를 실험 데이터와 비교하여 시뮬레이션의 신뢰성 검증.

연구 방법

  1. 수치 모델링 및 시뮬레이션 설정
    • FLOW-3D 소프트웨어VOF(Volume of Fluid) 기법을 사용하여 유체 흐름 및 용융풀 형상 예측.
    • 질량, 에너지 및 운동량 보존 방정식을 기반으로 용융풀 및 기판 모델링.
    • 열전달, 질량 및 운동량 추가를 통한 정확한 공정 모델링 구현.
    • 마랑고니 대류(Marangoni Convection) 모델링:
      • 표면 장력 변화용융풀 내 유체 흐름에 미치는 영향 분석.
      • 표면 활성 원소(Surface-Active Elements)인 황(S)의 농도에 따른 표면 장력 기울기 변화 반영.
  2. 실험 설정 및 시뮬레이션 조건
    • 재료 및 장비:
      • IN718 초합금 분말(100–325 메쉬)을 사용.
      • 350~550 W의 균일한 강도(Fiber Laser)를 사용하여 아르곤 분위기에서 실험 수행.
      • 빔 스폿 직경 1.0 mm, 빔 이동 속도 1.016 cm/s.
    • Boundary Condition:
      • 입출구 및 벽면 경계 조건:
        • 입구(Inlet): 유량 일정 조건.
        • 출구(Outlet): 자유 유출 조건.
        • 벽면(Wall): 비투과성 경계 조건.
      • 레이저 에너지 흡수율 계산:
        • Hagen-Rubens 관계식을 이용하여 온도 변화에 따른 흡수율(A(T)) 평가.

주요 결과

  1. 용융풀 형상 및 유동 패턴
    • 예측된 용융풀 형상실험 데이터 간 높은 일치도 확인.
    • 350, 450, 550 W 레이저 출력 조건에서의 용융풀 폭, 높이, 침투 깊이 비교.
    • 레이저 출력 증가 시:
      • 용접 폭 및 침투 깊이 증가.
      • 클래딩 높이는 상대적으로 일정하게 유지.
  2. 마랑고니 대류 및 온도 분포 분석
    • 마랑고니 흐름에 의해 용융풀 후방(Back)에서 가장 깊은 침투 영역 형성.
    • 표면 장력 기울기 전환 지점(Ti)에서 상대적으로 평탄한 온도 프로파일 형성.
    • 온도 구배(G) 및 응고 속도(R)를 통해 응고 모드(Columnar Dendritic Solidification) 예측.
    • 표면 장력 변화유체 흐름을 저온에서 고온 영역으로 유도하여 혼합 및 침투 증가를 촉진.
  3. 시뮬레이션 신뢰성 및 유효성 검증
    • 시뮬레이션 예측 결과실험 측정치의 일치도 평가.
    • 예측된 용융풀 형상, 폭, 깊이실험 데이터와 평균 5% 이내의 오차율을 보임.
    • FLOW-3D 모델이 복잡한 용융풀 대류 현상 및 응고 메커니즘을 정확히 설명할 수 있음을 증명.

결론 및 향후 연구

  • 결론:
    • FLOW-3D를 사용한 레이저 클래딩 공정 시뮬레이션용융풀 형성 및 응고 조건을 정확하게 예측할 수 있음.
    • 마랑고니 대류에 의해 용융풀 내 온도 분포 및 유동 패턴이 결정되며, 이는 응고 모드와 기계적 특성에 중요한 영향을 미침.
    • 시뮬레이션 결과를 통해 용접 풀의 중심선 온도 구배(G) 및 응고 속도(R)를 이용해 응고 형태(기둥형 수지상 조직) 예측 가능.
  • 향후 연구 방향:
    • 다층(Multi-Layer) 클래딩 공정으로 연구 확장.
    • 실험적 검증을 통한 시뮬레이션 예측 유동 패턴 및 침투 형상 확인.
    • AI 및 머신러닝을 활용한 레이저 클래딩 공정 최적화 모델 개발.

연구의 의의

이 연구는 FLOW-3D를 활용하여 레이저 클래딩 공정의 복잡한 물리적 현상을 정량적으로 평가하고, 부품 보호 및 재생 공정의 생산성 향상 및 비용 절감에 기여할 수 있는 실질적인 데이터를 제공한다​.

Reference

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  2. Weisheit, A., Gasser, A., Backes, G.,Jambor, T., Pirch, N., and Wissenbach, K.2013. Laser-Assisted Fabrication of Materials — Direct Laser Cladding, Current Statusand Future Scope of Application. pp.221–240, New York, N.Y.: Springer.
  3. Hoadley, A. F. A., and Rappaz, M.1992. A thermal model of laser cladding bypowder injection. MetallurgicalTransactions B 23(5): 631–642.
  4. Picasso, M., and Rappaz, M. 1994.Laser-powder-material interactions in thelaser cladding process. Journal De PhysiqueIV 4(C4): 27–33.
  5. Toyserkani, E., Khajepour, A., andCorbin, S. 2004. 3-D finite element modeling of laser cladding by powder injection:Effects of laser pulse shaping on theprocess. Optics and Lasers in Engineering41(6): 849–867.
  6. Choi, J., Han, L., and Hua, Y. 2005.Modeling and experiments of lasercladding with droplet injection. Journal of Heat Transfer 127(9): 978–986.
  7. Wen, S., and Shin, Y. C. 2010. Modeling of transport phenomena during thecoaxial laser direct deposition process.Journal of Applied Physics 108(4): 044908.
  8. Sahoo, P., DebRoy, T., and McNallan,M. J. 1988. Surface tension of binarymetal-surface active solute systems underconditions relevant to welding metallurgy.Metallurgical Transactions B 19B(3):483–491.
  9. Lee, P. D., Quested, P. N., andMcLean, M. 1998. Modelling of Marangonieffects in electron beam melting. Philosophical Transactions of the Royal Society of London 356(1739): 1027–1043.
  10. Su, Y., and Mills, K. C. 2005. Amodel to calculate surface tension of commercial alloys. Journal of Materials Science40(9-10): 2185–2190.
  11. Zhao, C. X., Kwakernaak, C., Pan, Y.,Richardson, I. M., Saldi, Z., Kenjeres, S.,and Kleijn, C. R. 2010. The effect ofoxygen on transitional Marangoni flow inlaser spot welding. Acta Materialia 58(19):6345–6357.
  12. Cho, M. H., Lim, Y. C., and Farson,D. F. 2006. Simulation of weld pool dynamics in the stationary pulsed gas metal arcwelding process and final weld shape.Welding Journal 85(12): 271-s to 283-s.
  13. Cho, J. H., Farson, D. F., Milewski, J.O., and Hollis, K. J. 2009. Weld pool flowsduring initial stages of keyhole formationin laser welding. Journal of Physics D:Applied Physics 42(17): 175502.
  14. Mills, K. C. 2002. Recommendedvalues of thermophysical properties for selected commercial alloys. pp. 181–190,Cambridge, England: Woodhead.
  15. Pottlacher, G., Hosaeus, H.,Kaschnitz, E., and Seifter, A. 2002. Thermophysical properties of solid and liquidInconel 718 alloy. Scandinavian Journal ofMetallurgy 31(3): 161–168.
  16. Lewandowski, M. S., and Overfelt,R. A. 1999. High temperature deformationbehavior of solid and semi-solid alloy 718.Acta Materialia 47(18): 4695–4710.
  17. Gedda, H., Powell, J., Wahlstrom,G., Li, W. B., Engstrom, H., and Magnusson, C. 2002. Energy redistribution duringCO2 laser cladding. Journal of Laser Applications 14(2): 78–82.
  18. Xie, J., Kart, A., Rothenflue, J. A.,and Latham, W. P. 1997. Temperature-dependent absorptivity and cutting capability of CO2, Nd:YAG and chemical oxygeniodine lasers. Journal of Laser Applications9(2): 77–85.
  19. Shelton, J. A., and Shin, Y. C. 2010.Comparative evaluation of laser-assistedmicro-milling for AISI 316, AISI 422, TI6Al-4V and Inconel 718 in a side-cuttingconfiguration. Journal of Micromechanicsand Microengineering 20(7): 075012.
  20. Kim, K. R., and Farson, D. F. 2001.CO2 laser-plume interaction in materialsprocessing. Journal of Applied Physics 89(1):681–688.
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  22. Kou, S. 2012. Fluid flow and solidification in welding: Three decades of fundamental research at the University of Wisconsin. Welding Journal 91(11): 287-sto 302-s.
  23. Zacharia, T., David, S. A., Vitek, J.M., and DebRoy, T. 1989. Weld pool development during GTA and laser beam welding of type 304 stainless steel — Part I:Theoretical analysis. Welding Journal68(12): 499-s to 509-s.
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mornig glory test

Numerical Modelling of Flow in Morning Glory Spillways Using FLOW-3D

FLOW-3D를 이용한 모닝 글로리(Morning Glory) 월류수문에서의 유동 수치 모델링

연구 배경 및 목적

  • 문제 정의: 모닝 글로리(Morning Glory) Spillway는 댐의 수위 조절 및 홍수 방지를 위해 사용되는 원형 월류수문이다.
    • 기존 설계에서는 부유물(Suspended Load)의 영향을 간과하는 경우가 많았으며, 이는 설계 가정에 큰 변화를 초래할 수 있다.
    • 부유물 함유 흐름물의 밀도를 변화시켜 수문 성능에 영향을 미칠 수 있다.
  • 연구 목적:
    • FLOW-3D 소프트웨어를 사용하여 모닝 글로리 수문에서의 부유물 농도 변화가 유량(Flow Discharge)에 미치는 영향을 평가.
    • 3000, 6000, 9000, 12000 ppm의 부유물 농도를 적용하여 수문 상부에서 다양한 수위 조건에서의 유량 변화를 분석.
    • 수치 모델 결과를 물리적 모델 실험 데이터와 비교하여 FLOW-3D의 예측 성능을 검증.

연구 방법

  1. 수치 모델링 및 시뮬레이션 설정
    • FLOW-3D 소프트웨어VOF(Volume of Fluid) 기법FAVOR(Fractional Area-Volume Obstacle Representation) 기법을 사용하여 유동 및 고체 경계 시뮬레이션.
    • k-ε 및 RNG 난류 모델을 사용하여 난류 효과를 모델링.
    • 모닝 글로리 수문 설계:
      • 해라즈(Haraz) 댐의 모닝 글로리 Spillway를 모델링.
      • Solidworks 소프트웨어를 이용해 3D 모델링을 수행하고, FLOW-3D에 가져와 수치 시뮬레이션을 설정.
    • 부유물 농도 설정:
      • 3000, 6000, 9000, 12000 ppm의 부유물을 흐름에 추가하여 유량 변화 분석.
      • 부유물 농도가 증가함에 따라 점도 및 유체의 물리적 특성이 변화함을 고려.
  2. 경계 조건 설정
    • 입출구 및 벽면 경계 조건:
      • 입구(Inlet): 유량 조건을 일정하게 유지.
      • 출구(Outlet): 자유 유출 조건을 적용.
      • 벽면(Wall): 비투과성(Impermeable) 경계 조건 설정.
    • 공기-물 경계:
      • 자유 수면(Free Surface) 조건을 적용하여 공기와의 접촉을 고려.

주요 결과

  1. 부유물 농도 증가에 따른 유량 변화
    • 순수 물(부유물 없음) 상태에서의 평균 유량: 600 m³/s.
    • 부유물 농도에 따른 유량 감소 효과:
      • 3000 ppm: 평균 유량 605 m³/s, 유량 감소 3.8%.
      • 6000 ppm: 평균 유량 575 m³/s, 유량 감소 87.12%.
      • 9000 ppm: 평균 유량 575 m³/s, 유량 감소 7.18%.
      • 12000 ppm: 평균 유량 483 m³/s, 유량 감소 26%.
    • 부유물 농도가 증가할수록 수문을 통과하는 유량이 감소하며, 이는 부유물이 물의 점도 증가밀도 변화에 따른 흐름 저항 증가에 기인.
  2. 유동 패턴 및 수문 성능 변화
    • FLOW-3D 시뮬레이션에서 부유물 농도가 증가할수록 유동의 안정성이 감소.
    • 특히 터널 및 월류수문 목(Throat) 부분에서의 유량 변화가 뚜렷하게 나타남.
    • 수문 상부에서의 월류 유속 감소혼합 층의 두께 증가가 관찰됨.
  3. FLOW-3D 모델의 신뢰성 평가
    • FLOW-3D 시뮬레이션 결과와 실험 결과 간 높은 일치도 확인.
    • 모델 검증 결과, 예측된 유량 변화가 물리적 실험과 평균 5% 이내의 오차율을 보임.
    • 이는 FLOW-3D가 복잡한 부유물 흐름을 정확하게 모델링할 수 있음을 의미.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 소프트웨어는 모닝 글로리 월류수문의 부유물 농도 변화에 따른 유량 감소를 정확히 예측할 수 있음.
    • 부유물 농도가 높을수록 유량 감소율이 증가하며, 특히 12000 ppm에서는 평균 26%의 유량 감소가 나타남.
    • 이는 댐 설계 및 운영 시 부유물 농도를 고려해야 함을 시사하며, 월류수문의 성능을 보장하기 위한 설계 기준 마련 필요.
  • 향후 연구 방향:
    • 다양한 부유물 크기 및 형태에 따른 유량 변화 추가 연구 필요.
    • 다양한 수문 형상 및 경사 조건에서 FLOW-3D 모델 검증.
    • AI 및 머신러닝을 활용한 부유물 농도 변화에 따른 유량 예측 모델 개발.

연구의 의의

이 연구는 FLOW-3D를 활용하여 모닝 글로리 월류수문의 부유물 농도 변화가 유량에 미치는 영향을 정량적으로 평가하고, 댐 안전성 및 수문 설계 최적화에 기여할 수 있는 실질적인 데이터를 제공한다​.

Reference

  1. Kavan, Jan, Jakub Ondruch, Daniel Nývlt, Filip Hrbáček, Jonathan L. Carrivick, and Kamil Láska. “Seasonal hydrological andsuspended sediment transport dynamics in proglacial streams, James Ross Island, Antarctica.” Geografiska Annaler: Series A,Physical Geography 99, no. 1 (2017): 38-55.
  2. Ervine, D. A., and A. A. Ahmed. “A Scaling relationship for a two-dimensional vertical dropshaft.” In Proc. Intl. Conf. onHydraulic Modelling of Civil Engineering Structures, pp. 195-214. 1982.
  3. Zhao, Can-Hua, David Z. Zhu, Shuang-Ke Sun, and Zhi-Ping Liu. “Experimental study of flow in a vortex drop shaft.” Journalof Hydraulic Engineering 132, no. 1 (2006): 61-68.
  4. Emamgheis, Reza Jamali, and Ebrahim Nohani. “Review of the efficiency of shaft spillway discharge influenced by sharptriangular vortex breaker blades with rectangular body.” Advances in Environmental Biology (2014): 285-290.
  5. Shemshi, Roya, and Abdorreza Kabiri-Samani. “Swirling flow at vertical shaft spillways with circular piano-key inlets.” Journalof Hydraulic Research 55, no. 2 (2017): 248-258.
  6. Coleman, H. Wayne, C. Y. Wei, and James E. Lindell. “Hydraulic design of spillways.” Hydraulic design handbook (2004): 17-41.
  7. Xianqi, Zhang. “Hydraulic characteristics of rotational flow shaft spillway for high dams.” International Journal of Heat andTechnology 33, no. 1 (2015): 167-174.
  8. Petaccia, G., and A. Fenocchi. “Experimental assessment of the stage–discharge relationship of the Heyn siphons of Bric Zerbinodam.” Flow Measurement and Instrumentation 41 (2015): 36-40.
  9. Houichi L, Ibrahim G, Achour B. Experiments for the discharge capacity of the siphon spillway having the Creager Ofitserovprofile. Int J Fluid Mech Res 2006; 33(5):395–406. http://dx.doi.org/10.1615/InterJFluidMechRes.v33.i5.10.
  10. Houichi L, Ibrahim G, Achour B. Experimental comparative study of siphon spillway and overflow spillway. Cour Savoir 2009;9:95–100.
  11. Gramatky, Ferdinand Gunner, and Kenneth Hall Robinson. “Siphon spillway.” PhD diss., California Institute of Technology,1929.
  12. Nohani, Ebrahim. “An experimental study on the effect of vortex breakers thickness on discharge efficiency for the shaftspillways.” Science International 27, no. 3 (2015).
  13. Hirt, C. W., and B. Nichols. “Flow-3D User’s Manual.” Flow Science Inc (1988).
  14. Lenzi, Mario A., and Lorenzo Marchi. “Suspended sediment load during floods in a small stream of the Dolomites (northeasternItaly).” Catena 39, no. 4 (2000): 267-282.
  15. Fokema, M. D., S. M. Kresta, and P. E. Wood. “Importance of using the correct impeller boundary conditions for CFDsimulations of stirred tanks.” The Canadian Journal of Chemical Engineering 72, no. 2 (1994): 177-183

Wave

Using FLOW-3D as a CFD Materials Approach in Waves Generation

FLOW-3D를 이용한 파랑 생성의 CFD 재료 접근법

연구 목적

  • 본 연구는 FLOW-3D®를 이용하여 파랑 생성 및 파랑 붕괴 현상을 수치적으로 분석함.
  • 실험적인 접근법과 비교하여 CFD 기반 시뮬레이션의 정확도 및 적용 가능성을 평가함.
  • 포리어 급수(Fourier series) 및 CFD 모델을 적용하여 다양한 파랑 조건을 해석함.
  • 해양 구조물 및 파력 발전 설계를 위한 정확한 파랑 모델링 가능성을 탐색함.

연구 방법

  1. 파랑 수치 모델링 및 설정
    • FLOW-3D®의 자유 표면 모델(Free-Surface Model)을 활용하여 파랑 형성을 시뮬레이션함.
    • 포리어 급수(Fourier Series) 방법을 적용하여 수치적으로 파랑의 기본 형태를 정의함.
    • 난류 모델 적용: Reynolds-Averaged Navier-Stokes(RANS) 모델을 사용하여 난류 효과를 고려함.
  2. FLOW-3D® 시뮬레이션 설정
    • 초기 및 경계 조건을 설정하여 파랑의 전파 및 붕괴 과정을 분석함.
    • 다양한 파고 및 주기를 적용하여 파랑의 다양한 특성(높이, 주기, 속도 등)을 평가함.
    • 실험 데이터와 비교하여 모델의 신뢰성을 검증함.
  3. 결과 비교 및 검증
    • 시뮬레이션 결과를 실험적 연구 및 기존 문헌 데이터와 비교 분석함.
    • 파랑 생성 및 붕괴 과정에서 발생하는 동역학적 변화를 평가함.
    • 해양 구조물 및 파력 발전과의 적용 가능성을 논의함.

주요 결과

  1. 파랑 생성 및 붕괴 특성 분석
    • FLOW-3D® 시뮬레이션을 통해 다양한 높이와 주기의 파랑을 생성할 수 있음.
    • 높은 주파수의 파랑에서는 강한 붕괴(breaking) 현상이 발생하며, 저주파 파랑은 안정적인 진행성을 유지함.
    • 파랑 붕괴 시 에너지 소산 및 흐름 변화가 명확하게 나타남.
  2. 수치 모델의 신뢰성 평가
    • 실험 결과와 비교했을 때 시뮬레이션의 평균 오차율이 5~10% 수준으로 확인됨.
    • 높은 파고(high wave height)에서는 실험값보다 약간 낮은 수치를 예측하는 경향이 있음.
    • 추가적인 모델 보정 및 난류 효과 개선이 필요함.
  3. 해양 공학 및 에너지 적용 가능성
    • FLOW-3D®를 활용하면 파력 발전 시스템의 설계 최적화 가능.
    • 해양 구조물(방파제, 해상 플랫폼 등) 설계 시 파랑 하중 분석에 유용하게 적용 가능.
    • 향후 연구에서는 다양한 환경 조건에서 추가적인 시뮬레이션 검증 필요.

결론

  • FLOW-3D®를 활용한 CFD 시뮬레이션은 파랑 생성 및 붕괴 분석에 효과적임.
  • 실험 데이터와 비교했을 때 높은 신뢰성을 보이며, 일부 난류 모델 개선이 필요함.
  • 해양 공학 및 파력 발전 설계에 적용할 수 있는 가능성을 확인함.
  • 향후 연구에서는 다양한 파랑 조건 및 실제 환경 적용성을 추가로 검토해야 함.

Reference

  1. Abd Alall, Mostafa. ‘‘Numerical Investigation of hydrodynamic Performance ofDouble Submerged Breakwaters”, International Journal of Scientific &Engineering Research 11(3), (2020). ISSN 2229-5518
  2. Ahmed, Hany and Abo-Taha, M. ‘‘Numerical Investigation of Regular WavesInteraction with Submerged Breakwater”, International Journal of Scientific &Engineering Research 10(11), (2019). ISSN 2229-5518.
  3. S.T. Grilli, M.A. Losada, F. Martin, Characteristics of solitary wave breakinginduced by breakwaters, J. Waterway, Port, Coastal, Ocean Eng. 120 (1) (1994)74–92.
  4. F. Hajivalie, A. Yeganeh-Bakhtiary, Numerical study of breakwater steepnesseffect on the hydrodynamics of standing waves and steady streaming, J.Coastal Res. (2009) 658–662.
  5. F. Hajivalie, A. Yeganeh-Bakhtiary, J.D. Bricker, Numerical study of theeffect of submerged vertical breakwater dimension on wave hydrodynamicsand vortex generation, Coastal Eng. J. 57 (3) (2015) 1550009-1–1550009-21.
  6. Hayakawa, Norio, Tokuzo Hosoyamada, Shigeru Yoshida, and GozoTsujimoto. ‘‘Numerical simulation of wave fields around the submergedbreakwater with SOLA-SURF method.” In Coastal Engieering 1998, pp. 843-852. (1999).
  7. D.-S. Hur, C.-H. Kim, D.-S. Kim, J.-S. Yoon, Simulation of the nonlinear dynamicinteractions between waves, a submerged breakwater and the seabed, OceanEng. 35 (5-6) (2008) 511–522.
  8. D.-S. Hur, K.-H. Lee, D.-S. Choi, Effect of the slope gradient of submergedbreakwaters on wave energy dissipation, Eng. Appl. Comput. Fluid Mechanics 5(1) (2011) 83–98.
  9. K. Kawasaki, Numerical simulation of breaking and post-breaking wavedeformation process around a submerged breakwater, Coastal Eng. J. 41 (3-4) (1999) 201–223.
  10. B. Liang, G. Wu, F. Liu, H. Fan, H. Li, Numerical study of wave transmission overdouble submerged breakwaters using non-hydrostatic wave model,Oceanologia 57 (4) (2015) 308–317.
  11. H.A.H. Petit, P. Tönjes, M.R.A. Van Gent, P. Van Den Bosch, Numericalsimulation and validation of plunging breakers using a 2D Navier-Stokesmodel, Coastal Eng. 1994 (1995) 511–524.
  12. A. Sasikumar, A. Kamath, O. Musch, A. Erling Lothe, H. Bihs, Numerical studyon the effect of a submerged breakwater seaward of an existing breakwater forclimate change adaptation, ASME 2018 37th International Conference onOcean, Offshore and Arctic Engineering, American Society of MechanicalEngineers Digital Collection, 2018.
  13. Takahiro Uemura, A numerical simulation of the shape of submergedbreakwater to minimize mean water level rise and wave transmission,TVVR13/5004 (2013).
Schematic-representation-of-the-structure-of-a-rapid-shell-system-2

Advancing Current Materials and Methods Used in the Investment Casting of Cobalt Prosthesis

코발트 보형물 정밀 주조에서 사용되는 최신 소재 및 방법의 발전

연구 목적

  • 본 논문은 MedCast 프로젝트의 일환으로 정밀 주조(investment casting)에서 사용되는 재료 및 공정 방법을 개선하는 연구를 진행함.
  • 특히, 고속 쉘 건조(Rapid Shell Drying) 기술과 주조 공정 시뮬레이션(Casting Modelling)에 중점을 둠.
  • 쉘 건조 시간 단축산화물 필름 혼입(Oxide Film Entrainment, OFEM) 및 미세 기공 결함 감소를 목표로 함.
  • FLOW-3D® 시뮬레이션을 활용하여 주조 결함 분석 및 최적화 전략을 도출함.

연구 방법

  1. 고속 쉘 건조 기술(Rapid Shell Technology) 평가
    • 기존 세라믹 쉘 시스템과 비교하여 고속 쉘 건조 기술이 주조 품질에 미치는 영향을 평가함.
    • 쉘의 미세 구조(microstructure) 변화, 기공 형성, 기계적 강도 감소(20%) 등을 분석함.
    • 추가적인 쉘 코팅을 통해 강도를 보완하면서도 건조 시간 단축(1/3 감소) 가능성을 탐색함.
  2. FLOW-3D® 기반 주조 공정 시뮬레이션
    • 산화물 필름 혼입(Oxide Film Entrainment Model, OFEM) 모델을 적용하여 산화물 형성 및 최종 위치 예측.
    • 입자 추적 기법을 활용하여 주형 사전 가열 시 생성된 재의 거동을 모델링함.
    • 산화물과 미세 입자(ash particles)의 이동 경로를 예측하고, 결함이 발생하는 주요 영역을 파악함.
  3. 실험 데이터 검증
    • 실제 주조 실험(in-process foundry trials)을 수행하여 시뮬레이션 결과를 검증함.
    • 기공 발생 패턴과 OFEM 예측값을 비교하여 시뮬레이션의 정확성을 평가함.
    • 실험 데이터를 기반으로 주조 결함 저감 전략을 도출함.
  4. 추가 분석
    • 쉘 건조 속도, 산화물 형성 과정, 용탕 충진 패턴 등을 종합적으로 고려하여 최적화 방안을 연구함.
    • 주조 결함을 최소화할 수 있는 쉘 코팅 두께 및 건조 환경 조정 전략을 평가함.

주요 결과

  1. 쉘 건조 속도 및 기계적 특성 변화
    • 고속 쉘 건조(Rapid Shell Drying) 공정을 적용한 결과, 건조 시간이 1/3로 단축됨.
    • 그러나 기존 쉘 대비 기계적 강도가 20% 감소하는 경향이 확인됨.
    • 추가적인 코팅을 적용하면 강도 저하를 보완하면서도 건조 시간 단축 가능.
  2. 산화물 필름 및 미세 입자 추적 결과
    • FLOW-3D® OFEM 모델을 활용한 시뮬레이션에서, 산화물 필름 혼입이 특정 위치에 집중됨을 확인함.
    • 주형 사전 가열 과정에서 발생한 재(ash) 입자가 주형 내부에 부착됨 → 이는 최종 주조물 표면의 미세 기공 결함(pinhole defects) 발생 원인이 됨.
    • 실험 데이터와 비교했을 때, 입자 추적 시뮬레이션 결과가 높은 상관성을 보임.
  3. 주조 결함 분석 및 개선 가능성
    • 실험 결과, 주조물 상단(top row)에서 기공 결함이 가장 많음.
    • 이는 용탕 충진 시 난류(turbulent flow)와 산화물 혼입이 주요 원인으로 분석됨.
    • 용탕 충진 경로 및 주형 내부 표면 처리 방식을 개선하면 기공 결함을 30% 이상 줄일 수 있음.
  4. 실험과 시뮬레이션 비교 검증
    • FLOW-3D® 기반 시뮬레이션 결과와 실제 실험 데이터 간 80~90%의 상관 관계를 확인함.
    • 다만, 실험에서는 예상보다 더 많은 미세 기공이 발생함 → 이는 주형 내부 잔류 왁스(wax residue) 연소 영향 때문으로 추정됨.
    • 주형 사전 세척 및 표면 처리 개선이 필요함.

결론

  • 고속 쉘 건조 기술은 기존 방식 대비 건조 시간 단축 효과가 크지만, 기계적 강도 저하 문제 해결 필요.
  • FLOW-3D® OFEM 시뮬레이션을 활용하여 산화물 및 미세 기공 결함 원인을 효과적으로 분석 가능.
  • 실험 결과와 시뮬레이션이 높은 일치도를 보이며, 주조 결함 개선을 위한 설계 최적화 가능성 확인.
  • 향후 연구에서는 주형 표면 처리 및 용탕 충진 최적화를 추가적으로 고려해야 함.

Reference

  1. Rapid Shell Build for investment Casting: Wax to De-Wax in Minutes. Jones, S.Deaerborn, MI: 53rd ICI Conference, 2005.
  2. Improved Investment Casting Process. Jones, S. University of Birmingham: PatentNo. PCT/GB2005/000408, 7th February 2005.
  3. Swelling Behaviours of Polyacrylate Superabsorbent in the Mixtures of Water andHydrophilic Solvents. J Chen, J Shen. Guandong, China: Journal of Applied PolymerScience Vol. 75, Issue 11, Pages 1331-1338 , March 2000.
  4. Improved Investmnet Casting Process. Jones, S. Birmingham: European Patent05708244.8, February 2005.
  5. The Influence of Autoclave Steam on Polymer and Organic Fibre Modified CeramicShells. C Yuan, S Jones, S Blackburn. Birmingham: Journal of European CeramicSociety, Pages 1081-1087, 2005.
  6. Methods of testing refractory materials. Properties measured under an applied stress.Determination of Modulus of Rupture at ambient temperature. BSI. 1984.
  7. Evaluation of the Mechanical Properties of Investment Casting Shells. R Hyde, SLeyland, P Withey, S Jones. Bath, UK: 22nd BICTA Conference Proceedings, 1995.
  8. Methods of Testing Refractory Materials, Part 10: Investment casting shell mouldsystems. BSI. 1994.
  9. The Impact of Ceramic Shell Strength on Hot Tearing during Investment Casting. SNorouzi, H Farhangi. Paris : American Institute of Physics, Vol. 1315, Pages 662-667,2010.
  10. International, ASTM. Standard Specification for Total Knee Prosthesis. s.l.: ASTM.F2083 – 11.
  11. FLOW3D. [Online] www.flow3d.com.
  12. MR Barkhudarov, CW Hirt. Casting Simulation: Mold Filling and Solidification -Benchmark Calculations using Flow-3D; Technical Report. Sante Fe: Flow Science,1993.
  13. Krack, R. Using Solidification Simulations for Optimising Die Cooling Systems.Sante Fe: Flow Science, 2008.
  14. Optimisation of gating System Design for Die Casting of Thin MagnesiumAlloy-Based Multi-Cavity LCD Housings. BD Lee, UH Baek and JW Han. 1, s.l.:Journal of Materials Engineering and Performance, Vol. 16. 1059-9495.
  15. Factors Affecting the Nucleation Kinetics of Microporosity Formation in AluminumAlloy A356. L Yao, S Cockcroft, C Reilly, J Zhu. 3, s.l.: Metallurgical and MaterialsTransactions, 2011, Vol. 43.
  16. Development of Quantitive Quality Assessment Criteria Using Process Modelling(Thesis). Reilly, C. PhD Thesis, University of Birmingham: s.n., 2010.
  17. Numerical Modelling of Entrainment of Oxide Film Defects in Filling AluminiumAlloy Castings. X Yang, X Huang, X Dai, J Campbell. 321, s.l.: International Journalof Cast Metal Research , 2004, Vol. 17.
  18. Investigating Surface Entrainment Events Using CFD for the Assessment ofCasting Filling Methods. C Reilly, MR Jolly, NR Green. s.l.: TMS, 2008.
  19. Inclusion Transport Phenomena in Casting Furnaces. S Instone, A Buchholz, GGruen. s.l.: TMS, 2008.
  20. Lide, DR. CRC Handbook of Chemistry and Physics. s.l.: CRC Press, 2006. ISBN0-8493-0487-3.
Welding

Effect of Laser Oscillation and Beam Incident Angle on Porosity in Double-Sided Filler Welding of 2219 Aluminum Alloy T Joint

레이저 진동 및 빔 입사각이 2219 알루미늄 합금 T 조인트의 양면 충진 용접 시 기공(Porosity)에 미치는 영향

연구 배경 및 목적

  • 문제 정의: 2219 알루미늄 합금은 항공우주 분야에서 연료탱크 제조에 널리 사용되며, 고강도 및 우수한 용접성을 제공한다. 그러나 레이저 빔 용접(LBW, Laser Beam Welding)키홀(Keyhole) 불안정성불순물로 인해 기공(Porosity) 결함이 발생한다.
  • 연구 목적:
    • FLOW-3D 시뮬레이션을 이용하여 빔 진동(Laser Oscillation) 및 빔 입사각(Beam Incident Angle)이 기공 형성 메커니즘에 미치는 영향을 분석.
    • 2219 Al-Cu 합금 T 조인트의 양면 레이저 빔 충진 용접(DLBW)과 진동 레이저 빔 충진 용접(DLBOW)을 비교.
    • 빔 입사각(20°~40°)과 빔 진동기공 억제기계적 특성에 미치는 영향을 실험 및 시뮬레이션을 통해 평가.

연구 방법

  1. 실험 설정 및 시뮬레이션 조건
    • 재료 및 장비:
      • 2219-T8 알루미늄 합금을 피부재(Skin), 2219-T6 알루미늄 합금을 스트링거(Stringer)로 사용.
      • Dual Fiber Laser System을 활용하여 양면에서 동시에 용접 수행.
      • 3D X-ray CT 스캔을 통해 용접부 내 기공의 3차원 위치 및 형태 분석.
      • IPG YLS-6000 및 YLS-10000 레이저 시스템 사용.
      • FLOW-3D v12 소프트웨어의 Flow WELD 모듈을 이용하여 키홀 동작 및 기공 형성 시뮬레이션 수행.
  2. 시뮬레이션 모델링
    • Cartesian 좌표계에서 모델을 구축하고, Gaussian Heat Source를 적용.
    • VOF(Volume of Fluid) 기법을 사용하여 가스-액체-고체 접합 모델링.
    • 표면 장력, 반동 압력, 열 부력 등의 구동력(driving forces)을 고려하여 실험 결과와의 일치도를 높임.
  3. 레이저 용접 변수
    • 빔 입사각: 20°, 30°, 40°.
    • 레이저 출력: 3500 W (DLBW), 3900 W (DLBOW).
    • 용접 속도: 20 mm/s.
    • 와이어 공급 속도: 5 m/min.
    • 진동 주파수: 300 Hz.
    • 진동 진폭: 1.0 mm.

주요 결과

  1. 기공 형성 메커니즘
    • FLOW-3D 시뮬레이션 결과:
      • DLBW(Dual Laser Beam Welding)에서는 키홀 불안정성으로 인해 큰 기포(Bubble) 형성기공 결함 증가.
      • DLBOW(Dual Laser Beam Oscillation Welding)에서는 빔 진동이 키홀을 안정화시켜 기공 억제 효과가 나타남.
      • 20° 입사각에서 기공률이 0.26%로 가장 낮았으며, 기계적 특성도 가장 우수함.
      • 기공 크기DLBW에서 2.15 mm, DLBOW에서 0.85 mm로, 진동 레이저기공 크기를 60% 이상 감소시킴.
  2. 기계적 특성 개선
    • 20° 입사각 DLBOW에서 후프 인장 강도(Hoop Tensile Strength)는 403 MPa, T-Pull 인장 강도302 MPa로 측정됨.
    • 이는 기초 금속(Base Metal) 강도 대비 각각 89.5%, 71.6% 수준을 기록.
    • 빔 입사각 증가인장 강도 감소:
      • DLBW: 후프 강도 352 MPa → 313 MPa, T-Pull 강도 302 MPa → 214 MPa.
      • DLBOW: 후프 강도 403 MPa → 364 MPa, T-Pull 강도 301 MPa → 284 MPa.
  3. 미세구조(Microstructure) 분석
    • DLBOW에서는 미세 결정립(Equiaxed Grain Zone, EQZ)이 작아지고, 부분 용융대(Partially Melted Zone, PMZ) 폭 감소.
    • DLBW에서는 ‘V’ 형태의 용접 단면이 관찰되었으며, DLBOW에서는 ‘W’ 형태로 변화.

결론 및 향후 연구

  • 결론:
    • 레이저 빔 진동 및 작은 입사각2219 알루미늄 합금 T 조인트의 기공 억제에 효과적.
    • 20° 입사각 DLBOW에서 기공률 0.26%로 기계적 특성 개선기공 결함 감소.
    • FLOW-3D 시뮬레이션키홀 불안정성기공 형성 메커니즘을 정량적으로 설명할 수 있음.
  • 향후 연구 방향:
    • 다양한 용접 속도 및 레이저 출력 조건에서 기공 억제 메커니즘 추가 분석.
    • AI 및 머신러닝을 활용한 기공 예측 모델 개발.
    • 산업 응용을 위한 최적화 설계 연구.

연구의 의의

이 연구는 레이저 빔 진동 및 입사각 조절을 통한 기공 억제 메커니즘을 규명하고, 2219 알루미늄 합금 T 조인트의 용접 품질을 향상시킬 수 있는 실질적인 설계 지침을 제공하며, 항공우주 산업의 경량화 및 생산성 증대에 기여할 수 있다​.

Reference

  1. S. Malarvizhi, K. Raghukandan, N. Viswanathan, Fatigue behaviour of post weldheat treated electron beam welded AA2219 aluminium alloy joints, Materials & Design29(8) (2008) 1562-1567.
  2. Q. Li, A.-p. Wu, Y.-j. Li, G.-q. Wang, B.-j. Qi, D.-y. Yan, L.-y. Xiong, Segregationin fusion weld of 2219 aluminum alloy and its influence on mechanical properties ofweld, Transactions of Nonferrous Metals Society of China (English Edition) 27(2)(2017) 258-271.
  3. H. Wang, Y. Yi, S. Huang, Investigation of quench sensitivity of high strength 2219aluminum alloy by TTP and TTT diagrams, Journal of Alloys and Compounds 690(2017) 446-452.
  4. J. Schumacher, I. Zerner, G. Neye, K. Thormann, Laser beam welding of aircraftfuselage panels, ICALEO, 2002.
  5. B. Han, W. Tao, Y. Chen, New technique of skin embedded wire double-sided laserbeam welding, Optics and Laser Technology 91 (2017) 185-192.
  6. J. Enz, S. Riekehr, V. Ventzke, N. Kashaev, N. Huber, Process optimization for thelaser beam welding of high-strength aluminum–Lithiumalloys, Schweißen undSchneiden 64(8) (2012) 482–485.
  7. A. Matsunawa, N. Seto, J.-D. Kim, M. Mizutani, S. Katayama, Dynamics of keyholeand molten pool in high power CO2 laser welding, High-Power Lasers inManufacturing, November 1, 1999 – November 5, 1999, Society of Photo-OpticalInstrumentation Engineers, Osaka, Jpn, 2000, pp. 34-45.
  8. N. Seto, S. Katayama, A. Matsunawa, Porosity formation mechanism andsuppression procedure in laser welding of aluminum alloys, Welding International 15(3)(2001) 191-202.
  9. V. Ventzke, S. Riekehr, M. Horstmann, P. Haack, N. Kashaev, One-sided Nd: YAGlaser beam welding for the manufacture of T-joints made of aluminium alloys foraircraft construction, Welding and Cutting 13(4) (2014) 245-249.
  10. W.A. Sudnik, V.A. Erofeev, Computational simulation of laser fillet and tailored blank welding, International Conference on Lasers, Applications, and Technologies2005 – High-Power Lasers and Applicatons, May 11, 2005 – May 15, 2005, SPIE, St.Petersburg, Russia, 2006, pp. Russian Ministry of Education and Science, Russia;Russian Foundation for Basic Research, Russia; Russian Union of Physicists, Russia;SPIE Russia Chapter.
  11. A.C. Oliveira, R.H.M. Siqueira, R. Riva, M.S.F. Lima, One-sided laser beamwelding of autogenous T-joints for 6013-T4 aluminium alloy, Materials & Design(1980-2015) 65 (2015) 726-736.
  12. N.S. Shanmugam, G. Buvanashekaran, K. Sankaranarayanasamy, S. RameshKumar, A transient finite element simulation of the temperature and bead profiles of Tjoint laser welds, Materials & Design 31(9) (2010) 4528-4542.
  13. M. Miyagi, Y. Kawahito, H. Kawakami, T. Shoubu, Dynamics of solid-liquidinterface and porosity formation determined through x-ray phase-contrast in laserwelding of pure Al, Journal of Materials Processing Technology 250 (2017) 9-15.
  14. C. Zhang, M. Gao, D. Wang, J. Yin, X. Zeng, Relationship between poolcharacteristic and weld porosity in laser arc hybrid welding of AA6082 aluminum alloy,Journal of Materials Processing Technology 240 (2017) 217-222.
  15. J. Xu, Y. Rong, Y. Huang, P. Wang, C. Wang, Keyhole-induced porosity formationduring laser welding, Journal of Materials Processing Technology 252 (2018) 720-727.
  16. Y. Hao, L. Li, Y. Sun, C. Shao, F. Lu, Dynamic behavior of keyhole and moltenpool under different oscillation paths for galvanized steel laser welding, InternationalJournal of Heat and Mass Transfer 192 (2022) 122947.
  17. T. Liu, Z. Mu, R. Hu, S. Pang, Sinusoidal oscillating laser welding of 7075aluminum alloy: Hydrodynamics, porosity formation and optimization, InternationalJournal of Heat and Mass Transfer 140 (2019) 346-358.
  18. W. Tao, Z. Yang, C. Shi, D. Dong, Simulating effects of welding speed on meltflow and porosity formation during double-sided laser beam welding of AA6056-T4/AA6156-T6 aluminum alloy T-joint, Journal of Alloys and Compounds 699 (2017)638-647.
  19. Z. Yang, X. Zhao, W. Tao, C. Jin, Effects of keyhole status on melt flow and flowinduced porosity formation during double-sided laser welding of AA6056/AA6156aluminium alloy T-joint, Optics & Laser Technology 109 (2019) 39-48.
  20. G. Xu, L. Li, H. Wang, P. Li, Q. Guo, Q. Hu, B. Du, Simulation and experimentalstudies of keyhole induced porosity in laser-MIG hybrid fillet welding of aluminumalloy in the horizontal position, Optics and Laser Technology 119 (2019).
  21. S. Pang, W. Chen, J. Zhou, D. Liao, Self-consistent modeling of keyhole and weldpool dynamics in tandem dual beam laser welding of aluminum alloy, Journal ofMaterials Processing Technology 217 (2015) 131-143.
  22. F. Teichmann, S. Müller, K. Dilger, On the occurrence of weld bead porosityduring laser vacuum welding of high pressure aluminium die castings, Procedia CIRP74 (2018) 438-441.
  23. E. Punzel, F. Hugger, T. Dinkelbach, A. Bürger, Influence of power distributionon weld seam quality and geometry in laser beam welding of aluminum alloys, ProcediaCIRP 94 (2020) 601-604.
  24. F. Fetzer, M. Sommer, R. Weber, J.-P. Weberpals, T. Graf, Reduction of pores bymeans of laser beam oscillation during remote welding of AlMgSi, Optics and Lasersin Engineering 108 (2018) 68-77.
  25. Z. Wang, J.P. Oliveira, Z. Zeng, X. Bu, B. Peng, X. Shao, Laser beam oscillatingwelding of 5A06 aluminum alloys: Microstructure, porosity and mechanical properties,Optics & Laser Technology 111 (2019) 58-65.
  26. L. Wang, Y. Liu, C. Yang, M. Gao, Study of porosity suppression in oscillatinglaser-MIG hybrid welding of AA6082 aluminum alloy, Journal of Materials ProcessingTechnology 292 (2021) 117053.
  27. L. Chen, G. Mi, X. Zhang, C. Wang, Effects of sinusoidal oscillating laser beamon weld formation, melt flow and grain structure during aluminum alloys lap welding,Journal of Materials Processing Technology 298 (2021) 117314.
  28. S. Chen, Y. Wu, Y. Li, M. Chen, Q. Zheng, X. Zhan, Study on 2219 Al-Cu alloyT-joint used dual laser beam bilateral synchronous welding: Parameters optimizationbased on the simulation of temperature field and residual stress, Optics & LaserTechnology 132 (2020) 106481.
  29. Z. Wan, Q. Wang, Y. Zhao, T. Zhao, J. Shan, D. Meng, J. Song, A. Wu, G. Wang,Improvement in tensile properties of 2219-T8 aluminum alloy TIG welding joint byPMZ local properties and stress distribution, Materials Science and Engineering: A 839(2022) 142863.
  30. C. Huang, S. Kou, Partially melted zone in aluminum welds: Solute segregationand mechanical behavior, Welding Journal (Miami, Fla) 80(1) (2001) 9-17.
FLOW Vector

Analysis of Flow in the Pool of Fishway Using FLOW-3D Model

FLOW-3D 모형을 이용한 어도(Fishway) Pool 내 흐름 해석

연구 배경 및 목적

  • 문제 정의: 어도(Fishway)는 댐이나 하천에 설치되어 어류가 상류로 이동할 수 있도록 돕는 수리구조물이다. 하지만 기존 어도의 설계는 어류의 생태적 특성과 물리적 환경을 충분히 반영하지 못해 기능이 미흡한 경우가 많았다.
  • 연구 목적:
    • FLOW-3D CFD 모델을 활용하여 어도 내 Pool(휴식 공간)의 유동 특성을 분석.
    • 어류의 소상(Migration) 환경을 최적화하기 위해 월류 수심(Overflow Depth)과 유속 분포를 평가.
    • 군남홍수조절지를 대상으로 어도의 설계 조건을 검증하고 최적화 방안을 제시.

연구 방법

  1. 수치 모델링 및 시뮬레이션 설정
    • FLOW-3D 소프트웨어를 활용하여 3차원 CFD 해석 수행.
    • VOF(Volume of Fluid) 기법을 사용하여 자유 수면을 정확히 모델링.
    • RNG k-ε 난류 모델을 적용하여 난류 흐름을 해석.
    • 격자 설정:
      • 계산 영역은 4m × 4m 크기, 격자는 200 × 120 × 30 (총 720,000개) 사용.
      • 격자 간격은 x 방향 0.18m, y 방향 0.14m ~ 0.88m, z 방향 0.07m.
  2. 어도 설계 및 실험 조건
    • 대상지: 군남홍수조절지 내 Pool식 어도.
    • 수치 모델 검증:
      • 기존 잠실수중보 어도의 최적 월류 수심인 10 cm를 적용.
      • 초기 조건:
        • 풀 내 물의 흐름이 정지된 상태에서 격벽 상단부의 월류를 시작으로 계산.
        • 물의 물리적 성질:
          • 온도 20℃, 밀도 1,000 kg/m³, 동점성계수 1.005 × 10⁻⁶ m²/s, 중력가속도 9.81 m/s², 조도계수 0.05.
  3. 분석 항목
    • 유속 및 유동 패턴:
      • Pool 내 유입어도 노치(Notch)와 잠공(Orifice) 부분에서의 최대 유속 분석.
      • 순환류 발생 여부유속의 범위 평가.
    • 월류 수심 변화에 따른 영향:
      • 월류 수심 10 cm를 기준으로, 유입 유속 증가 시 어류의 소상 환경 변화를 분석.

주요 결과

  1. 유속 및 순환류 분석
    • 월류 수심이 10 cm인 경우:
      • Pool 내 최대 유속 0.4 m/s 이하 유지.
      • 국부적 집중 유속에 의해 순환류 발생.
      • 유속의 최대 범위 0.15 m/s를 넘지 않음.
      • 이는 어류의 중간 휴식처로서 적절한 환경을 제공.
  2. 월류 수심 증가 시 어류 소상 환경 변화
    • 월류 수심이 10 cm를 초과할 경우:
      • 풀 내 유입 유속 증가로 어류의 소상 환경이 불량해질 것으로 예상.
      • 특히 어류의 돌진 속도를 초과하는 유속 발생이동 어려움이 발생할 수 있음.
  3. FLOW-3D 모델의 신뢰성 평가
    • 정상 상태 도달 시간운동에너지가 일정하게 유지되는 시점으로 간주하여 효율적인 해석을 수행.
    • 모델 결과와 기존 연구 비교:
      • 기존 잠실수중보 어도의 최적 수심 결과와 일치.
      • 어류 이동을 위한 안전하고 안정적인 유속 분포를 확보.

결론 및 향후 연구

  • 결론:
    • FLOW-3D를 활용한 어도 내 유동 해석이 실질적인 어류 소상 환경 평가에 유용함을 입증.
    • 월류 수심 10 cm를 유지할 때 어류의 휴식처로 최적의 환경을 제공할 수 있음.
    • 월류 수심이 증가할 경우 유입 유속이 증가하여 어류 이동에 부정적인 영향을 미칠 수 있음.
    • 격벽부의 월류 수심을 10 cm로 유지하여 어류의 소상 환경을 최적화할 필요가 있음.
  • 향후 연구 방향:
    • 다양한 어류의 종류 및 크기에 따른 최적 유속 및 수심 조건 추가 검토.
    • 다양한 난류 모델(예: LES, k-ω 모델) 적용 및 비교.
    • AI 및 머신러닝을 활용한 어도 내 유동 예측 모델 개발.
    • 계절 및 유량 변화에 따른 어도 설계 최적화 연구.

연구의 의의

이 연구는 FLOW-3D를 활용하여 어도 내 유동 특성을 정량적으로 평가하고, 어류 소상 환경을 최적화할 수 있는 설계 지침을 제시하며, 자연 생태계 보전 및 수산자원 보호에 기여할 수 있다​.

Reference

  1. 김혜성, 윤용진, 이동훈, 이은태(2007).어도 및 유인수로의 공간적 배치와 흐름 한국수자원학회 학술 발표회논문집 ,한국수자원학회 , pp. 602-606.
  2. 이진원, 강창수, 이삼희(2000). 혼합형 어도 개발 및 FLUENT 수치모형에 의한 적정성 검토 한국수
    자원학회 학술발표회논문집 한국수자원학회 , pp. 667-672.
  3. 한국수자원학회 (2005). 댐설계기준, 한국수자원학회 .
FLOW-3D MESH

Characterizing Flow Losses Occurring in Air Vents and Ejector Pins in High-Pressure Die Castings

고압 다이캐스팅에서 공기 배출구 및 이젝터 핀에서 발생하는 유동 손실 특성화

연구 목적

  • 본 논문은 **FLOW-3D®**를 사용하여 **고압 다이캐스팅(HPDC)**에서 공기 배출구 및 이젝터 핀에서 발생하는 유동 손실을 수치적으로 분석함.
  • 주조 과정에서 발생하는 **기공(porosity), 공기 함유량, 유동 손실 계수(loss coefficient)**를 측정하고 모델링함.
  • 실험 데이터를 바탕으로 CFD 모델을 보정하여 실제 다이캐스팅 공정의 유동 손실을 예측함.
  • 공기 배출 및 유동 손실을 효과적으로 제어할 수 있는 주조 설계 최적화 방안을 제안함.

연구 방법

  1. 공기 유동 및 손실 모델링
    • 공기 유동 손실은 배출구, 이젝터 핀, 잔류 누출 경로에서 발생하는 것으로 가정됨.
    • FLOW-3D®의 단열 기포 모델(Adiabatic Bubble Model)을 활용하여 유동 손실을 분석함.
    • Darcy 마찰계수 및 Moody 다이어그램을 활용한 기존 이론 모델과 비교 검증함.
  2. FLOW-3D® 시뮬레이션 설정
    • 유체 유동을 분석하기 위해 압력 강하(pressure drop) 및 공기 배출 경로를 모델링함.
    • 공기 유동을 비압축성 가스로 모델링한 경우단열 기포 모델을 적용한 경우를 비교 분석함.
    • 실험 데이터와 비교하여 시뮬레이션 결과의 정확성을 평가함.
  3. 실험 데이터 기반 검증
    • 실험은 Littler DieCast에서 수행되었으며, 금속이 없는 상태에서 공기 유동 실험을 진행함.
    • 다음의 5가지 조건에서 실험을 수행함.
      1. 모든 배출구 개방 (All Open)
      2. 배큠 밸브 닫힘 (Vacuum Closed)
      3. 분할선 닫힘 (Parting Line Closed)
      4. 이젝터 핀 및 분할선 닫힘 (Ejector and Parting Line Closed)
      5. 모든 배출구 닫힘 (All Closed)
    • 압력 변화 곡선을 측정하여 유동 손실을 정량화함.
  4. 추가 분석
    • 배출구 크기, 이젝터 핀 배치, 누출 경로 변화에 따른 유동 손실 변화를 분석함.
    • FLOW-3D® 시뮬레이션 결과와 실험 데이터를 비교하여 손실 계수를 보정함.
    • 고압 다이캐스팅에서 공기 배출 효율을 높일 수 있는 설계 변경안을 평가함.

주요 결과

  1. 유동 손실 및 압력 강하 분석
    • 실험 결과, 배큠 밸브가 주요 배출 경로이며, 밸브가 닫힐 경우 내부 압력이 증가함.
    • 이젝터 핀이 열려 있을 경우에도 압력 강하가 크지 않음 (압력 차 2psi 이하).
    • 분할선 배출은 압력에 거의 영향을 미치지 않으며, 배출 설계 시 주요 고려 대상이 아님.
  2. FLOW-3D® 시뮬레이션 검증
    • “All Closed” 실험과 CFD 결과 비교 시, 압력 차이가 5% 이내로 유사하게 예측됨.
    • 단열 기포 모델(Adiabatic Bubble Model)을 적용한 경우, 실험과 가장 일치하는 압력 곡선을 보임.
    • 잔류 누출(Residual Leak)이 존재할 경우, 모델과 실험 간 차이가 발생하며, 이는 금형 설계 시 고려해야 함.
  3. 배출 경로 최적화 가능성
    • 배큠 밸브가 없는 경우에도, 연장된 러너 시스템이 자연 배출구 역할을 수행할 수 있음.
    • 잔류 누출 경로(shot sleeve, parting line 등)가 전체 유동 손실에 미치는 영향이 큼.
    • 이젝터 핀 및 잔류 배출구를 최적화하면 배큠 밸브 없이도 효과적인 공기 배출 가능.
  4. 설계 개선 및 향후 연구 방향
    • FLOW-3D®를 활용하여 밸브 형상 및 배출 경로 최적화 가능.
    • 잔류 누출을 고려한 CFD 모델을 추가적으로 보정할 필요가 있음.
    • 실제 금속 충진 실험과 결합하여 기공 형성 및 공기 배출 성능을 종합적으로 분석해야 함.

결론

  • FLOW-3D® 시뮬레이션은 고압 다이캐스팅의 공기 유동 손실 분석에 효과적임.
  • 배큠 밸브가 없어도 연장된 러너 시스템을 활용하여 공기 배출 가능함.
  • 단열 기포 모델을 적용한 CFD 결과가 실험과 가장 높은 일치도를 보임.
  • 향후 연구에서는 금속 충진 과정까지 포함한 종합적인 유동 해석이 필요함.

Reference

  1. White, F.M., Fluid Mechanics, 4th ed., p 256, John Fellows Publishing Co., New York, NY (1940)
  2. Flow of Fluids Through Valves, Fittings, and Pipe, Crane Technical Paper No. 410, Joliet, IL: Crane Co., 1988.
  3. C.W. Hirt and B.D. Nichols, “Volume-of-Fluid (VOF) Method for the Dynamics of. Free Boundaries,” J.
    Comp. Phys., 39, 1981, pp. 201-225.
  4. FLOW-3D® v 9.4 Manual
  5. Mold Filling Simulation of High Pressure Die Casting for Predicting Gas Porosity, Modeling of asting, Welding, and Advanced Solidification Processes X, TMS (The Mineral, Metals, & Materials Society), 2003, pp. 335
  6. Modeling of Air Venting in Pressure Die Casting Process, Nouri-Borujerdi, A., Goldak, J.A., AD, Journal of Manufacturing and Science and Engineering, ASME, 2004
Welding

CFD Simulations for Laser Welding of Aluminum Alloys Using FLOW-3D

FLOW-3D를 이용한 알루미늄 합금 레이저 용접의 CFD 시뮬레이션

연구 목적

  • 본 논문은 FLOW-3D를 활용하여 알루미늄 합금의 레이저 용접(Laser Welding) 공정을 수치적으로 분석함.
  • 용접 공정에서 발생하는 기공(porosity) 형성 및 용융지(melt pool) 동역학을 해석하여 품질 향상 방안을 제시함.
  • 레이저 빔 경사각 및 용접 속도가 기공 형성 및 용접 품질에 미치는 영향을 평가함.
  • 실험 데이터를 CFD 모델링과 비교하여 시뮬레이션의 신뢰성을 검증함.

연구 방법

  1. 실험 및 모델링 설정
    • AA5182 알루미늄 합금 판재(1mm + 2mm)를 사용하여 원격 레이저 용접을 수행함.
    • 6kW 연속파 광섬유 레이저(IPG)를 사용하고, Galvo 미러로 빔을 조준함.
    • 레이저 경사각을 -15°에서 45°까지 변화시키며 용접 실험을 진행함.
    • 고속 CCD 카메라를 사용하여 용융지 형성과 기공 발생을 기록함.
  2. FLOW-3D 시뮬레이션 설정
    • VOF(Volume of Fluid) 방법을 적용하여 자유 표면 유동을 추적함.
    • 레이저-재료 상호작용, 상변화, 유체 유동, 응고 과정을 포함한 CFD 모델 구축.
    • Fresnel 흡수 모델을 사용하여 빔 각도에 따른 에너지 흡수를 반영함.
    • 메쉬 독립성 연구를 수행하여 최적의 격자 해상도를 결정함.
  3. 결과 비교 및 검증
    • 실험과 시뮬레이션을 비교하여 기공 형성 메커니즘을 분석함.
    • 용접 속도 증가가 기공 형성에 미치는 영향을 실험적으로 검증함.
    • 기공 억제 전략을 도출하여 용접 품질 향상을 위한 설계 지침을 제안함.
  4. 추가 분석
    • 용접 속도 및 레이저 경사각 변화가 용융지 내 난류 구조 및 기공 형성에 미치는 영향을 분석함.
    • 고출력 레이저 용접 시 키홀(Keyhole) 안정성을 평가함.
    • 향후 연구 방향으로 다중 재료 용접 및 다이캐스팅 부품 용접에 대한 추가 연구를 제안함.

주요 결과

  1. 기공 형성 및 용접 품질 분석
    • 고출력(6kW) 및 높은 용접 속도(12m/min)에서 키홀이 안정적으로 유지됨.
    • 키홀 벽면이 붕괴할 때 기공이 형성되며, 용접 속도가 높을수록 기공 억제 효과가 증가함.
    • 레이저 빔 경사각이 45°일 때 후면 용융지에 난류가 줄어들며, 기공 형성이 감소함.
  2. 용융지 유동 패턴 및 난류 영향
    • 레이저 빔이 수직(0°)일 때, 후면 용융지가 불안정하여 기공이 쉽게 발생함.
    • 30° 이상의 경사각에서는 용융지 유동이 균형을 이루며 기공 형성이 감소함.
    • 마랑고니 대류(Marangoni convection)와 재충돌(Recoil pressure) 영향이 용융지 유동에 주요한 역할을 함.
  3. 시뮬레이션 검증 및 오차 분석
    • 실험 결과와 시뮬레이션 비교 시 기공 면적 비율 차이 평균 오차 5~8% 수준으로 확인됨.
    • 실험에서는 키홀 붕괴로 인해 발생한 기공 크기가 시뮬레이션보다 다소 크게 측정됨.
    • 레이저 초점 위치 오차가 실험과 시뮬레이션 결과 차이의 원인 중 하나로 분석됨.
  4. 용접 공정 최적화 방안
    • 고출력(6kW) + 높은 용접 속도(12m/min) + 경사각 45° 조합이 기공 최소화에 효과적임.
    • 키홀이 안정적인 상태에서 후면 용융지 난류 감소 시 기공 형성이 억제됨.
    • 향후 연구에서 레이저 빔 모양 및 펄스 변조 기법을 적용하여 추가 실험이 필요함.

결론

  • FLOW-3D 시뮬레이션은 레이저 용접 공정의 기공 형성 예측에 효과적임.
  • 높은 용접 속도와 레이저 경사각 증가가 기공 억제에 유리함.
  • 실험과 시뮬레이션 간 높은 상관관계를 보이며, 일부 차이는 초점 위치 및 난류 모델 영향으로 판단됨.
  • 향후 연구에서는 다이캐스팅 부품 및 다중 재료 용접 적용성 연구가 필요함.

Reference

  1. L.J. Zhang, J.X. Zhang, A. Gumenyuk, M. Rethmeier, S.J. Na, Numerical simulation of full penetration laser welding of thick steel plate with high power high brightness laser, Journal of Materials Processing Technology, Volume 214, Issue 8, 2014.
  2. Flow Science, Inc., 2017. FLOW 3D User Manual V11.2.
  3. Runqi Lin, Hui-ping Wang, Fenggui Lu, Joshua Solomon, Blair E. Carlson, Numerical study of keyhole dynamics and keyhole-induced porosity formation in remote laser welding of Al alloys, International Journal of Heat and Mass Transfer, Volume 108, Part A, 2017.
Numerical-modelling

A Study of the Conditions of Energy Dissipation in Stepped Spillways with Λ-shaped step Using FLOW-3D

FLOW-3D를 이용한 Λ자형 계단식 여수로의 에너지 소산 조건 연구

연구 목적

  • 본 논문은 FLOW-3D를 활용하여 Λ자형 계단식 여수로(stepped spillway)의 에너지 소산 효과를 분석함.
  • 기존 계단식 여수로와 Λ자형 계단식 여수로의 유동 특성을 비교하여 에너지 소산 성능을 평가함.
  • 다양한 유량 조건에서 난류 구조 및 수력 특성을 해석하여 최적의 설계 조건을 탐색함.
  • 수치 해석을 통해 실험적 연구의 한계를 보완하고, 여수로 설계 최적화 가능성을 검토함.

연구 방법

  1. 여수로 모델링 및 실험 설정
    • Λ자형 계단식 여수로와 기존 계단식 여수로를 비교하기 위해 3D 모델을 구축함.
    • 다양한 유량 조건에서 수면 형상, 속도 분포, 공기 혼입 효과 등을 평가함.
    • 실험 데이터를 통해 시뮬레이션 결과를 검증하고, 모델의 신뢰성을 평가함.
  2. FLOW-3D 시뮬레이션 설정
    • VOF(Volume of Fluid) 기법을 적용하여 자유수면 흐름을 해석함.
    • 난류 모델로 RNG k−εk-\varepsilonk−ε 방정식을 사용하여 유동 특성을 분석함.
    • 메쉬 독립성 검토를 통해 최적의 해상도를 설정하고 계산 정확도를 높임.
  3. 결과 비교 및 검증
    • 실험 데이터를 바탕으로 에너지 소산율 및 유동 패턴을 비교 분석함.
    • Λ자형 계단식 여수로와 기존 계단식 여수로 간의 차이를 정량적으로 평가함.
    • 시뮬레이션 결과와 실험 데이터 간의 평균 오차율을 계산하여 모델의 정확성을 검증함.
  4. 추가 분석
    • 유량 변화가 여수로 내 유동 특성 및 에너지 소산에 미치는 영향을 연구함.
    • 공기 혼입 현상이 여수로 성능에 미치는 영향을 평가함.
    • 향후 연구 방향으로 추가적인 실험적 검증 및 최적 설계 기법을 제안함.

주요 결과

  1. 에너지 소산 성능 비교
    • Λ자형 계단식 여수로는 기존 계단식 여수로보다 평균 12~18% 높은 에너지 소산율을 보임.
    • 높은 유량 조건에서도 안정적인 유동을 유지하며, 월류(overflow) 및 난류 강도가 감소함.
    • 기존 계단식 여수로에 비해 낙하한 물이 계단 표면에서 분산되면서 충격 에너지가 감소함.
  2. 유동 패턴 및 난류 구조
    • Λ자형 계단식 여수로에서는 물이 계단 측면으로 확산되면서 유동이 균등하게 분포됨.
    • 기존 계단식 여수로에서는 수직 방향 난류가 강하게 발생하며, 불균형한 흐름이 형성됨.
    • 계단 형상이 난류 구조 및 에너지 소산 효율에 중요한 영향을 미침.
  3. 공기 혼입 효과
    • Λ자형 계단식 여수로에서는 공기 혼입이 균일하게 발생하여 압력 변화가 완화됨.
    • 기존 계단식 여수로보다 기포 형성이 균일하며, 수압 변동이 줄어들어 구조적 안정성이 향상됨.
    • 공기 함유량이 증가하면 에너지 소산 효과가 더욱 높아지는 경향을 보임.
  4. 시뮬레이션과 실험 비교
    • 실험 데이터와 시뮬레이션 결과 간 평균 오차율은 4~7% 수준으로 나타남.
    • 특정 유량 조건에서 시뮬레이션 결과가 실험값보다 다소 낮게 예측되는 경향이 있음.
    • 메쉬 해상도 및 난류 모델 보정을 통해 예측 정확도를 향상시킬 수 있음.

결론

  • Λ자형 계단식 여수로는 기존 계단식 여수로보다 높은 에너지 소산 효과를 보임.
  • 공기 혼입이 균일하게 발생하여 수압 변동이 줄어들고 구조적 안정성이 증가함.
  • 실험과 시뮬레이션 결과 간의 높은 상관성을 확인함.
  • 향후 연구에서는 다양한 계단 형상과 추가적인 실험적 검증이 필요함.

Reference

  1. Chanson, Hubert. Hydraulics of stepped chutes and spillways. CRC Press, 2002.
  2. Cassidy, John J. “Irrotational flow over spillways of finite height.” Journal of the Engineering Mechanics Division 91, no. 6(1965): 155-176.
  3. Sorensen, Robert M. “Stepped spillway hydraulic model investigation.” Journal of Hydraulic Engineering 111, no. 12 (1985):1461-1472.
  4. Pegram, Geoffrey GS, Andrew K. Officer, and Samuel R. Mottram. “Hydraulics of skimming flow on modeled stepped spillways.”Journal of hydraulic engineering 125, no. 5 (1999): 500-510.
  5. Tabbara, Mazen, Jean Chatila, and Rita Awwad. “Computational simulation of flow over stepped spillways.” Computers &structures 83, no. 27 (2005): 2215-2224.
  6. Pedram, A and Mansoori, A. “Study on the end sill stepped spillway energy dissipation”, Seventh Iranian Hydraulic Conference,Power and Water University of Technology, Tehran, Iran, (2008) (In Persian).
  7. Naderi Rad, A et al. “Energy dissipation in various types of stepped spillways including simple, sills, and sloped ones usingFLUENT numerical model”, journal of civil and environmental engineering 39, no 1 (2009) (In Persian).
  8. Stephenson, D. “Energy dissipation down stepped spillways.” International water power & dam construction 43, no. 9 (1991):27-30.
  9. Soori, S and Mansoori, A. “compared energy dissipation in Nappe flow and Skimming flow regime using FLOW-3D”,International Conference on Civil, Architecture and Urban Development, Islamic Azad University, Tabriz, Iran, (2013) (In Persian).
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  11. Pfister, Michael, and Willi H. Hager. “Self-entrainment of air on stepped spillways.” International Journal of Multiphase Flow37, no. 2 (2011): 99-107.
  12. Hamedi, Amirmasoud, Mohammad Hajigholizadeh, and Abbas Mansoori. “Flow Simulation and Energy Loss Estimation in theNappe Flow Regime of Stepped Spillways with Inclined Steps and End Sill: A Numerical Approach.” Civil Engineering Journal 2,no. 9 (2016): 426-437.
  13. Sedaghatnejad, S. “Investigation of energy dissipation in the end sill stepped spillways”, Master thesis, Sharif University ofTechnology, (2009)..
impulse wave

3D Simulations of Impulse Waves Originating from Concurrent Landslides Near an Active Fault Using FLOW-3D Software: A Case Study of Çetin Dam Reservoir

FLOW-3D를 이용한 활성 단층 인근 동시 산사태 발생에 따른 충격파 시뮬레이션: 터키 남동부 체틴 댐 저수지 사례 연구

연구 목적

  • 본 논문은 FLOW-3D를 활용하여 체틴 댐 저수지에서 발생할 수 있는 **충격파(impulse wave)**의 특성을 3D 수치 시뮬레이션으로 분석함.
  • 활성 단층 지역에서 발생하는 산사태가 저수지 내에서 충격파를 유발하는 메커니즘을 연구함.
  • 단일 산사태와 동시 다발적 산사태가 발생할 경우의 충격파 영향을 비교 분석함.
  • 충격파의 간섭(interference) 효과가 저수지 내 파랑 특성과 댐 구조물에 미치는 영향을 평가함.

연구 방법

  1. 지질 및 지형 모델링
    • 연구 지역은 터키 남동부 체틴 댐 저수지로, 아라비아판과 타우루스판이 만나는 조산대에 위치함.
    • 댐과 저수지 주변의 주요 단층 구조와 산사태 가능 지역을 고려하여 3D 지형 모델을 생성함.
    • 1/25,000 축척의 디지털 지형 데이터를 사용하여 저수지 및 주변 지형을 모델링함.
  2. FLOW-3D 시뮬레이션 설정
    • VOF(Volume of Fluid) 방법을 사용하여 자유수면과 산사태 물질 간의 상호작용을 해석함.
    • RNG k−εk-\varepsilonk−ε 난류 모델을 적용하여 유체 흐름과 충격파 전파 특성을 평가함.
    • 부분적으로 잠긴 산사태(4900m 거리)와 완전히 노출된 산사태(800m 거리)를 각각 독립적으로 모델링하고, 이후 두 산사태가 동시에 발생하는 경우를 시뮬레이션함.
  3. 결과 비교 및 검증
    • 개별 산사태와 동시 산사태가 발생했을 때의 충격파 높이와 전파 속도를 비교함.
    • 실험 및 문헌 데이터를 활용하여 시뮬레이션 결과의 신뢰성을 검증함.
    • 충격파 간섭 현상이 발생하는 위치와 그 영향 범위를 분석함.
  4. 추가 분석
    • 충격파의 증폭(constructive interference) 또는 감쇠(destructive interference) 여부를 평가함.
    • 저수지 경계 및 댐 구조물과의 충돌이 파형 변화에 미치는 영향을 연구함.
    • 충격파의 전파 거리와 수심에 따른 에너지 소산 효과를 분석함.

주요 결과

  1. 산사태별 충격파 특성
    • 산사태 1(800m 거리, 육상 산사태): 34초 후 댐에 도달, 최대 파고 4.0m 발생.
    • 산사태 2(4900m 거리, 부분 침수 산사태): 205초 후 댐에 도달, 최대 파고 4.2m 발생.
    • 단일 산사태의 경우, 발생 위치에 따라 파고와 도달 시간이 달라짐.
  2. 동시 발생 산사태의 파랑 간섭 효과
    • 두 충격파가 97초 후 상호 충돌하며 최대 5.7m의 파고를 형성함.
    • 댐 인근에서 최종적으로 5.6m의 파고가 형성되었으며, 이는 개별 산사태보다 1.4m 증가한 수치임.
    • 예상과 달리 충격파가 서로 상쇄되지 않고 증폭(interference amplification) 되는 현상이 관찰됨.
  3. 저수지 내 충격파 감쇠 현상
    • 충격파는 저수지 지형과 충돌하면서 일부 감쇠됨.
    • 산사태에서 댐까지의 거리, 산사태 질량, 충격각도에 따라 파랑의 감쇠율이 달라짐.
    • 5km 이상 이동한 충격파는 경로 상 장애물에 의해 에너지가 감소하는 경향을 보임.
  4. 댐 안전성 및 설계 시 고려사항
    • 활성 단층 인근의 저수지는 동시 다발적 산사태로 인한 복합 충격파 위험을 고려해야 함.
    • 기존 단일 충격파 분석만으로는 실제 위험성을 과소평가할 가능성이 있음.
    • 향후 연구에서는 실규모 실험과 추가적인 CFD 모델링을 통해 댐 설계 및 운영 기준을 개선해야 함.

결론

  • FLOW-3D를 이용한 시뮬레이션 결과, 충격파는 개별 산사태보다 동시 산사태에서 더 높은 파고를 형성함.
  • 충격파의 간섭 효과로 인해 댐 인근에서 5.6m의 높은 파고가 발생할 가능성이 있음.
  • 산사태의 발생 위치, 저수지 지형, 파랑 간섭 효과 등을 종합적으로 고려해야 함.
  • 향후 연구에서는 다중 산사태 시뮬레이션을 추가로 수행하여 댐의 안전성을 정량적으로 평가해야 함.

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scouring

Three-Dimensional Numerical Simulation of Local Scour Around Circular Bridge Pier Using FLOW-3D Software

FLOW-3D 소프트웨어를 이용한 원형 교각 주변 국부 세굴의 3차원 수치 시뮬레이션


연구 배경 및 목적

  • 문제 정의: 교각(Bridge Pier) 주변의 국부 세굴(Local Scour)은 하천 바닥의 침식으로 인해 구조물의 안전성을 위협하는 주요 요인 중 하나이다.
  • 연구 목적: FLOW-3D를 활용하여 교각 주변의 국부 세굴 형상을 3D 시뮬레이션하고, 실험 데이터를 비교하여 모델의 신뢰성을 검증하는 것이다.
  • 핵심 기여:
    • FLOW-3D를 활용한 CFD 모델 개발: 유체 흐름과 퇴적물 이동을 고려한 세굴 시뮬레이션.
    • 실험 결과와 비교 검증: Melville 실험 데이터를 바탕으로 모델 검증 및 정확도 평가.
    • 세굴 깊이 예측 및 설계 최적화: 교각 설계 및 유지관리 전략에 적용 가능.

연구 방법

  1. 수치 모델링 및 난류 모델 적용
    • Navier-Stokes 방정식 기반 CFD 해석 수행.
    • VOF(Volume of Fluid) 기법을 활용하여 자유 수면 추적.
    • RNG k-ε 난류 모델을 사용하여 교각 주변 난류 구조를 해석.
  2. 세굴 모델링
    • Meyer-Peter & Müller 공식을 사용하여 침식 및 퇴적 거동 해석.
    • Shields Parameter를 적용하여 세굴 발생 임계값 예측.
    • Melville 실험 모델과 동일한 유속(0.25 m/s) 및 입자 크기(0.385 mm) 설정.
  3. 메쉬 설정 및 경계 조건
    • 격자 독립성 검토: 1~30 mm의 다양한 격자 크기를 적용하여 최적의 메쉬 크기(5 mm) 선정.
    • 경계 조건:
      • 입구: 일정한 유속(0.25 m/s) 설정.
      • 출구: 자유 유출 조건 적용.
      • 하천 바닥: 이동 가능 침전층(Sediment Bed)으로 설정.

주요 결과

  1. 세굴 깊이 비교
    • 실험 값: 4.00 cm
    • Flow-3D 예측값: 3.6 cm (실험 대비 오차 10%)
    • 시뮬레이션 결과와 실험 데이터 간 높은 상관관계 확인.
  2. 유동장 및 세굴 형상 분석
    • 세굴 패턴: 교각 전면부에서 강한 와류(Horseshoe Vortex) 발생 → 침식 심화.
    • 교각 후류(Downstream) 영역: 유속이 급격히 감소하며 침전 형성.
    • RNG k-ε 모델 적용 효과: 세굴 깊이 및 와류 구조를 효과적으로 예측.
  3. 메쉬 크기의 영향
    • 5mm 이하의 세밀한 격자에서 최적의 결과 도출.
    • 30mm 이상의 거친 격자에서는 세굴 깊이가 과소 예측됨.

결론 및 향후 연구

  • FLOW-3D 기반 세굴 시뮬레이션이 실험 결과와 높은 정확도로 일치함을 확인.
  • RNG k-ε 난류 모델이 교각 주변의 난류 구조 및 세굴 깊이 예측에 적합함을 입증.
  • 향후 연구에서는 LES(Large Eddy Simulation) 모델과 비교, 다양한 교각 형상 및 유량 조건에서 추가 검증이 필요.

연구의 의의

이 연구는 FLOW-3D를 활용하여 교각 주변 국부 세굴을 정량적으로 분석하는 방법론을 제시하며, 교량 설계 및 유지보수 전략 수립에 활용될 수 있는 중요한 기초 데이터를 제공한다​.

Reference

  1. Breusers Nicollet and Shen 1977 Local scour around cylindrical piers Journal of Hydraulic Research, IAHR,15 (3): 211-252.
  2. Shepherd R. and Frost J D 1995 Failures in civil engineering: Structural, foundation and geoenvironmental case studies Journal of Hydraulic Engineering, Puolisher ASCE.
  3. Cheremisinoff N P and Cheng S L 1987 Hydraulic mechanics 2 Civil Engineering Practice, Technomic Published Company, Lancaster, Pennsylvania, U.S.A. 780 p.
  4. Melville B W 1975 Local scour at bridge sites University of Auckland, New Zealand, phd. Thesis, Dept. of Civil eng., Rep. No. 117.
  5. Abdul-Nour M 1990 Scouring depth around multiple M.Sc. Thesis , Department of Irrigation and Drainage , University of Baghdad.
  6. Hosny M M 1995 Experimental study of local scour around circular bridge piers in cohesive soils Colorado State University, Fort Collins.
  7. Ansari S A Kothyari U C and Ranga Raju K G 2002 Influence of cohesion on scour around bridge piers Journal of Hydraulic Research, IAHR, pp. 40(6): 717-729.
  8. Khsaf S I 2010 A study of scour around Al-Kufa bridge piers Kufa Engineering Journal.Vol.1No.1,2010, University of Kufa / College Engineering / Civil Department.
  9. Hassan W H Jassem M H and Mohammed S S 2018 A GA-HP Model for the Optimal Design of Sewer Networks Water Resour. Manag., vol. 32, no. 3, pp. 865–879.
  10. Hassan W H 2017 Application of a genetic algorithm for the optimization of a cutoff wall under hydraulic structures J. Appl. Water Eng. Res., vol. 5, no. 1, pp. 22–30, Jan.
  11. Ataie-Ashtiani B 2013 Flow field around single and tandem piers Flow Turbulence and Combustion Journal of Hydraulic Engineering,volume 9429.
  12. Flow -3D manual 2014 Flow-3D user manual version 11, Flow Science Santa Fe, NM.
  13. Richardson J E and Panchang V G 1998 Three-Dimensional Simulation of Scour Inducing Flow at Bridge Piers Journal of Hydraulic Engineering, 124(5), pp. 530–540. doi: 10.1061/(asce)0733- 9429(1998)124:5(530).
  14. Vasquez J and Walsh B 2009 CFD simulation of local scour in complex piers under tidal flow Proceedings of the thirty-third IAHR Congress: Water Engineering for a Sustainable Environment, (604), pp. 913–920.
  15. W H H and Halah k Jalal 2019 Effect of Bridge Pier Shape on Depth of Scour Iop, Conf. Ser.,(under puplication).
  16. Obeid Z H 2016 3D numerical simulation of local scouring and velocity distributions around bridge piers with different shapes A Peer Reviewed International Journal of Asian Academic Research Associates, 20(16), p. 2801. doi: 10.1186/1757-7241-20-67.
  17. Drikakis D 2003 Advances in turbulent flow computations using high-resolution methods Progress in Aerospace Sciences, 39(6–7), pp. 405–424. doi: 10.1016/S03760421(03)00075-7.
  18. Yakhot and Orszag 1986 Renormalization Group Analysis of Turbulence, Basic Theory Journal of Scientific Computing, pp. 3–51. 1, pp. 3–51.
  19. Mastbergen D R and Van Den Berg J H 2003 Breaching in fine sands and the generation of sustained turbidity currents in submarine canyons Sedimentology, 50(4), pp. 625–637. doi: 10.1046/j.1365-3091.2003.00554.x.
  20. Soulsby R L and Whitehouse R J S W 1997 Threshold of sediment motion in Coastal Environments Proc. Combined Australian Coastal Engineering and Port Conference, EA, pp. 149-154.
  21. Meyer-Peter E and Müller R 1948 Formulas for bed-load transport Proceedings of the 2nd Meeting of the International Association for Hydraulic Structures Research, 39– 64.
  22. Wei G Brethour J Grünzner M and Burnham J 2014 Sedimentation Scour Model Flow Science Report 03-14.
Fluid Velocity

Modeling of Local Scour Depth Around Bridge Pier Using FLOW-3D

FLOW-3D를 이용한 교각 주변 국부 세굴 깊이 모델링


연구 배경 및 목적

  • 문제 정의: 교각 주변에서 발생하는 국부 세굴(Local Scour)은 하천 바닥 침식을 유발하여 교량의 구조적 안정성을 위협하는 주요 요인 중 하나이다.
  • 연구 목적:
    • FLOW-3D를 활용한 세굴 모델 개발: CFD(Computational Fluid Dynamics) 기반 수치 모델을 사용하여 교각 주변의 세굴 형상을 예측.
    • 실험 데이터와의 비교: 실험실 실험과 수치 모델의 결과를 비교하여 모델의 신뢰성을 평가.
    • 세굴 깊이 및 유속 패턴 분석: 교각 앞쪽 및 후류에서 형성되는 유동 구조와 세굴의 관계를 분석.

연구 방법

  1. 실험 데이터 수집 및 모델링
    • 실험실 실험:
      • 터키 가지안테프 대학교의 수리 실험실에서 수행.
      • 0.8m × 0.9m 크기의 직사각형 수로에서 직경 10cm의 원형 교각을 배치.
      • 유량 0.048 m³/s, 유속 0.48 m/s, 수심 11cm 설정.
      • 세굴층은 비응집성(non-cohesive) 모래(d₅₀ = 1.45mm)로 구성.
    • FLOW-3D 기반 CFD 모델링:
      • VOF(Volume of Fluid) 기법을 사용하여 자유 수면 모델링.
      • RNG k-ε 난류 모델을 적용하여 난류 흐름 분석.
      • 침식 및 퇴적 모델을 적용하여 하상 변화 예측.
  2. 격자 설정 및 경계 조건
    • 메쉬 독립성 검토: 64,000개 이상의 격자를 사용하여 최적화 수행.
    • 경계 조건:
      • 입구: 일정한 유속(0.48 m/s) 설정.
      • 출구: 자유 유출 조건 적용.
      • 하천 바닥: 이동 가능 침전층(Sediment Bed)으로 설정.

주요 결과

  1. 세굴 깊이 비교
    • 실험 값: 6.9 cm
    • FLOW-3D 예측값: 6.5 cm (실험 대비 오차 10%)
    • 실험과 수치 모델의 결과가 높은 상관관계를 보임.
  2. 유동 및 세굴 패턴 분석
    • 유속 분포:
      • 교각 전면부에서 강한 와류(Horseshoe Vortex) 발생 → 침식 심화.
      • 후류 영역에서는 유속이 감소하며 퇴적 형성.
    • 세굴 형상:
      • 최대 세굴 깊이는 교각 전면부 및 측면에서 발생.
      • FLOW-3D 모델은 세굴 발생 위치 및 심도를 효과적으로 예측.
  3. 시간에 따른 세굴 발전
    • 실험 및 CFD 모델 모두에서 1시간 후 세굴 깊이가 안정화됨.
    • 세굴 속도는 초기 30분 동안 급격히 증가한 후 점진적으로 감소.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 기반 CFD 모델은 교각 주변의 세굴 깊이를 실험 결과와 높은 정확도로 예측할 수 있음.
    • RNG k-ε 난류 모델이 국부 세굴 해석에 적합함을 확인.
    • 세굴 깊이 예측에서 실험 대비 오차는 약 10%로 양호한 결과를 보임.
  • 향후 연구 방향:
    • 더 정교한 난류 모델(예: LES) 적용 및 비교.
    • 다양한 교각 형상 및 유량 조건에서 추가 검증.
    • 인공지능(AI) 및 머신러닝을 활용한 세굴 예측 모델 개발.

연구의 의의

이 연구는 FLOW-3D를 이용한 국부 세굴 예측의 신뢰성을 검증하고, 교량 설계 및 유지보수 전략 수립에 활용될 수 있는 중요한 기초 데이터를 제공한다.

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graph

FLOW-3D 모형의 세굴 매개변수 민감도 분석

연구 배경 및 목적

  • 문제 정의: 하천 및 수공구조물 주변에서 발생하는 국부 세굴(Local Scour)은 하상 침식으로 인해 구조물의 안전성을 위협하는 중요한 요인이다.
  • 연구 목적:
    • FLOW-3D를 활용한 국부 세굴 예측 능력 평가: 수치해석 기반 모델이 실험 결과와 일치하는지 검토.
    • 주요 입력 매개변수의 민감도 분석: 세굴 조절계수, 유사 입경, 안식각 등의 변수에 따른 모델 결과의 변화를 비교 분석.
    • 수치 모델 신뢰성 향상: 실제 실험 데이터를 바탕으로 FLOW-3D 모델의 보정 및 최적화 수행.

연구 방법

  1. FLOW-3D 기반 세굴 모델링
    • VOF(Volume of Fluid) 기법을 적용하여 자유 수면 추적.
    • RNG k-ε 난류 모델을 사용하여 난류 흐름 해석.
    • 침식 및 퇴적 모델 적용:
      • Shields Parameter(한계 무차원 소류력) 활용하여 침식 개시 조건 설정.
      • 유사 조절계수를 조정하여 모델의 반응을 실험 데이터와 비교.
  2. 민감도 분석 대상 매개변수
    • 세굴 조절계수(Scour Erosion Adjustment)
    • 유사 입경(Average Particle Diameter)
    • 안식각(Angle of Repose)
    • 낙차고(Drop Height)
    • 이 중 주요 변수를 중심으로 일정 비율로 값을 변화시키며 모델 반응 분석.
  3. 모의 실험 조건
    • 실험실 실험 데이터 비교:
      • 폭 0.8m, 길이 5m의 수로에 모래층(0.3m) 적용.
      • 다양한 월류 수위 및 보의 높이 조건에서 실험 진행.
    • 격자 독립성 검토:
      • 세굴 영역을 정밀하게 분석하기 위해 총 118,800개의 격자 사용.
    • LES(Large Eddy Simulation) 난류 모델 적용:
      • 보다 정확한 난류 해석을 위해 LES 모델을 추가적으로 사용.

주요 결과

  1. 세굴 깊이에 대한 민감도 분석
    • 세굴 조절계수(Scour Erosion Adjustment): 0.7에서 최적 예측(오차율 5.4%), 0.7보다 크면 과대 예측, 작으면 과소 예측.
    • 유사 입경(Average Particle Diameter): 입경이 감소할수록 세굴 깊이가 증가(민감도 비율 0.76).
    • 안식각(Angle of Repose): 30°에서 가장 신뢰도 높은 결과(오차율 8.5%).
    • 낙차고(Drop Height): 낙차고가 증가할수록 세굴 깊이도 증가(민감도 비율 0.52).
  2. 시간에 따른 세굴 진행 과정
    • 초기 20초 내에서 최종 세굴 깊이의 50%가 발생.
    • 100초 내에서 세굴 깊이의 90% 도달 후 점진적 안정화.
  3. 실험 데이터와의 비교
    • FLOW-3D의 예측값과 실험 데이터 간 평균 오차율은 10% 이내.
    • 특정 매개변수 조정 시 실험값과의 정확도 향상 가능.

결론 및 향후 연구

  • 결론:
    • FLOW-3D 모델이 국부 세굴 예측에서 실험 데이터와 높은 신뢰도를 보임.
    • 유사 입경과 세굴 조절계수가 가장 민감한 변수로 나타났으며, 이를 정확하게 조정하면 모델 성능 개선 가능.
    • 낙차고 및 안식각도 세굴 깊이에 영향을 미치므로 추가 보정 필요.
  • 향후 연구 방향:
    • LES 및 다른 난류 모델과의 비교 연구.
    • 다양한 하천 조건 및 교각 형상 적용하여 보편적 모델 구축.
    • AI 및 머신러닝 기법을 활용한 세굴 예측 모델 개발.

연구의 의의

이 연구는 FLOW-3D를 활용한 국부 세굴 예측의 신뢰성을 검증하고, 수공구조물 설계 및 유지보수 전략 수립에 중요한 기초 데이터를 제공한다.

Reference

  1. 윤세의, 이종태, 손광익, 김준현 (1995). “자유낙하수맥 하류부에서의 세굴에 관한 실험적 연구” 한국수자원학회논문집, 제22권, 제4-B호, pp. 437-446.
  2. D’Agostino (2003). “Scour on Alluvial Bed Downstream of Grade-Control Structures”, Journal of
  3. Hydraulic Research Vol. 46, No. 5, pp. 648-658.
  4. Flow Science, (2003). Flow-3D User’s Manual, Los Alamos, NM, USA.
Schematic-model-representation

Describing the Effect of Local Gas Flow on Keyhole and Melt Flow Dynamics Utilizing High-Speed Synchrotron X-Ray Imaging and Numerical Simulation

고속 싱크로트론 X선 영상 및 수치 시뮬레이션을 이용한 국부 가스 유동이 키홀 및 용융 풀 동역학에 미치는 영향 분석


연구 배경 및 목적

  • 문제 정의: 고합금 강재의 레이저 빔 용접 시 높은 용접 속도에서 스패터(Spatter) 발생이 주요 문제점이며, 이는 용접 품질에 악영향을 미친다.
  • 연구 목적:
    • 국부 가스 공급(Local Gas Supply)이 키홀(Keyhole) 및 용융 풀(Melt Pool) 동역학에 미치는 기계적 영향을 고속 X선 영상과 CFD 시뮬레이션을 통해 분석.
    • FLOW-3D 소프트웨어를 활용하여 국부 가스 흐름에 의한 동압(Dynamic Pressure)이 키홀 형상 및 용융 풀 유동에 미치는 영향을 정량화.
    • 스패터 형성 억제 메커니즘을 규명하고, 국부 가스 공급의 최적화 방안을 제시.

연구 방법

  1. 수치 모델링 및 시뮬레이션 설정
    • FLOW-3D (v11.2 update 6, WELD module v2.4.1.2.9) 사용.
    • VOF(Volume of Fluid) 기법을 통해 자유 표면 추적.
    • Navier-Stokes 방정식열 전달 방정식 적용.
    • 용융, 증발, 응고 과정을 모두 포함한 다중 물리 시뮬레이션.
    • 난류 모델:
      • RNG k-ε 모델을 사용하여 난류 효과 반영.
      • 기체 유동에 의한 동압(pgas)을 추가하여 국부 가스 공급의 기계적 효과 구현.
  2. 국부 가스 공급 조건
    • 가스 유동 속도에 따른 동압(pgas) 변화:
      • 최대 496 mbar에서 627 mbar까지 적용.
    • 가스 노즐 위치:
      • 키홀 개구부에서 5 mm 떨어진 지점에 48° 각도로 설치.
    • 보호 가스:
      • 공기(Bottled Air) 사용하여 화학-야금학적 효과를 최소화하고, 기계적 효과만 분석.
  3. 고속 X선 영상 및 실험 설정
    • 고속 싱크로트론 X선 영상: ESRF ID19 빔라인에서 수행.
    • AISI 304 고합금 강재 사용.
    • 레이저 용접 조건:
      • 싱글 웨이브 레짐(Single-Wave-Regime) 및 연장된 키홀 레짐(Elongated-Keyhole-Regime)에서 실험.
      • 용접 속도: 12 m/min, 레이저 출력: 2.3 kW.
    • 고속 비디오 촬영:
      • Photron SA-Z 고속 카메라를 사용하여 40,000 fps 촬영.

주요 결과

  1. 키홀 형상 및 용융 풀 동역학 분석
    • 국부 가스 공급이 없는 경우:
      • 키홀 후면벽에서 강한 진동 및 불안정한 형상이 관찰됨.
      • 키홀 목(necking) 형성기공(porosity) 발생.
      • 용융 풀 상승(swell) 및 스패터 분리(spatter detachment) 현상 확인.
    • 국부 가스 공급이 있는 경우:
      • 키홀 후면벽의 진동이 감소하고 안정화.
      • 키홀 개구부가 넓어지고, 스패터 발생이 크게 감소.
      • 용융 풀 속도 및 순환 유동이 감소하며, 안정된 유동 패턴 형성.
  2. 동압(pgas)의 효과
    • 496 mbar에서 키홀 후면 진동이 크게 감소.
    • 627 mbar에서는 키홀 개구부가 넓어지고, 스패터가 거의 발생하지 않음.
    • 동압이 300 mbar 이하에서는 키홀 형상 및 스패터 억제 효과가 미미.
  3. FLOW-3D 모델의 신뢰성 검증
    • 고속 싱크로트론 X선 영상 결과FLOW-3D 시뮬레이션 결과 간 높은 일치도 확인.
    • 시뮬레이션에서 예측한 키홀 후면벽 진동 패턴용융 풀 상승과 스패터 억제 현상이 실험 결과와 일관됨.

결론 및 향후 연구

  • 결론:
    • 국부 가스 공급에 의한 동압이 키홀 후면벽의 진동을 감소시키고, 스패터 발생을 효과적으로 억제함.
    • 496 mbar 이상의 동압이 적용될 때 키홀 형상이 안정화되고, 용융 풀 유동 속도가 감소하며, 스패터 억제에 가장 효과적임.
    • FLOW-3D 모델이 고속 X선 영상 데이터와 높은 정확도로 일치하며, 국부 가스 공급의 기계적 효과를 정량적으로 분석 가능함.
  • 향후 연구 방향:
    • 다양한 레이저 출력 및 용접 속도 조건에서 국부 가스 공급의 효과를 추가 검증.
    • 기계적 효과 외에도 화학-야금학적 효과를 고려한 모델 확장.
    • 다중 노즐 배열 및 동시 다중 가스 공급에 대한 연구를 통해 스패터 완전 억제 방안 모색.

연구의 의의

이 연구는 국부 가스 공급이 레이저 빔 용접에서 스패터 발생을 효과적으로 억제하는 메커니즘을 규명하고, FLOW-3D 시뮬레이션과 고속 X선 영상을 활용한 정량적 분석을 통해 최적화 설계 지침을 제공하며, 고속 레이저 용접의 품질 및 생산성을 향상시킬 수 있음을 시사한다.

Reference

  1. Fabbro R. Melt pool and keyhole behaviour analysis for deep penetrationlaser welding. Journal of Physics D: Applied Physics. 2010;43(44):445501.
  2. Fabbro R. Dynamic Approach Of The Keyhole And Melt Pool BehaviorFor Deep Penetration Nd ‐ Yag Laser Welding. AIP ConferenceProceedings. 2008;1047(1):18-24.
  3. Schmidt L, Hickethier S, Schricker K, Bergmann JP. Low-spatter highspeed welding by use of local shielding gas flows. Proceedings of SPIELASE Conference. 2019;10911.
  4. Schmidt L, Schricker K, Bergmann JP, Hickethier S. Effect of gas flow onspatter formation in deep penetration welding at high welding speeds.Proceedings of Lasers in Manufacturing Conference; Munich2019. p. 1-7.
  5. Schmidt L, Schricker K, Bergmann JP, Junger C. Effect of Local Gas Flowin Full Penetration Laser Beam Welding with High Welding Speeds.Applied Sciences. 2020;10(5):1867.
  6. Schmidt L, Schricker K, Diegel C, Sachs F, Bergmann JP, Knauer A, et al.Effect of partial and global shielding on surface-driven phenomena inkeyhole mode laser beam welding. Welding in the World. 2023.
  7. Kaplan AFH, Powell J. Spatter in laser welding. Journal of LaserApplications. 2011;23(3):032005.
  8. Diegel C, Mattulat T, Schricker K, Schmidt L, Seefeld T, Bergmann JP, etal. Interaction between Local Shielding Gas Supply and Laser Spot Size onSpatter Formation in Laser Beam Welding of AISI 304. Applied Sciences[Internet]. 2023; 13(18).
  9. Jovic G, Bormann A, Pröll J, Böhm S. Laser welding with side-gasapplication and its impact on spatter formation and weld seam shape.Procedia CIRP. 2020;94:649-54.
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  13. Chianese G, Hayat Q, Jabar S, Franciosa P, Ceglarek D, Patalano S. Amulti-physics CFD study to investigate the impact of laser beam shapingon metal mixing and molten pool dynamics during laser welding of copperto steel for battery terminal-to-casing connections. Journal of MaterialsProcessing Technology. 2023;322:118202.
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  18. Bachmann M. Numerische Modellierung einer elektromagnetischenSchmelzbadkontrolle beim Laserstrahlschweißen von nichtferromagnetischen Werkstoffen [PhD Thesis]: Technische UniversitätBerlin; 2014.
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Casting model

A Verification of Thermophysical Properties of a Porous Ceramic Investment Casting Mould Using Commercial Computational Fluid Dynamics Software

상용 전산유체역학 소프트웨어를 이용한 다공성 세라믹 주조 몰드의 열물성 검증

연구 목적

  • 본 논문은 FLOW-3D를 활용하여 다공성 세라믹 주조 몰드의 열물성을 검증하고 실험 결과와 비교함.
  • 기존 연구에서 실험적으로 도출된 몰드의 열물성이 CFD 시뮬레이션을 통해 검증될 수 있는지 평가함.
  • 실험적 측정값과 CFD 예측값을 비교하여 몰드의 열전도율, 비열 용량, 열팽창 계수의 정확성을 검토함.
  • 항공우주 산업에서 사용되는 몰드의 열적 거동을 보다 정확히 분석하여 고품질 주조 공정을 지원함.

연구 방법

  1. 실험적 주조 테스트
    • TPC Components AB 주조 공장에서 실제 크기의 Ni-초합금(IN718) 주조 실험 수행함.
    • 10층으로 구성된 테스트 몰드를 제작하고, 몰드 두께를 따라 여러 개의 열전대를 배치함.
    • 열전대 데이터를 기반으로 몰드 내부 및 금속 온도 프로파일을 분석함.
    • 실험 데이터를 CFD 시뮬레이션 결과와 비교하여 정확도를 평가함.
  2. FLOW-3D 시뮬레이션 설정
    • 실제 실험 조건을 반영하여 몰드 형상을 모델링하고, 압력 변화 경계를 설정함.
    • 몰드 내부와 외부의 온도 차이를 반영하여 공기층 형성을 고려함.
    • 몰드의 열전달 계수(HTC)와 방사율 값을 문헌 데이터를 기반으로 설정함.
    • Python 스크립트를 활용하여 시뮬레이션 데이터를 열전대 측정값과 비교함.
  3. 열물성 분석
    • 시차 주사 열량법(DSC)을 이용하여 몰드의 비열 용량을 측정함.
    • 레이저 플래시 분석(LFA)으로 열확산율을 평가하여 열전도율을 산출함.
    • 팽창계(dilatometry)를 사용하여 몰드의 열팽창 계수를 측정함.
    • 실험값과 시뮬레이션 예측값을 비교하여 몰드의 열물성을 검증함.
  4. 결과 검증
    • 실험 데이터와 FLOW-3D 시뮬레이션 결과를 비교하여 CFD 모델의 신뢰성을 평가함.
    • 실험값과 계산값 간 차이를 분석하고, 주요 원인을 규명함.
    • 몰드의 다층 구조에 따른 열적 거동을 평가하고, 추가 연구 방향을 제시함.

주요 결과

  1. 온도 프로파일 비교
    • 시뮬레이션 결과는 실험값과 높은 상관성을 보이며, 몰드 내부 온도 변화를 잘 재현함.
    • 금속이 주입될 때 온도 상승 패턴이 실험과 유사하게 나타남.
    • 열전대 측정값과 CFD 예측값 간 평균 오차는 약 2~5% 수준으로 나타남.
  2. 비열 용량 및 열팽창 계수
    • 실험 데이터를 기반으로 몰드의 평균 비열 용량을 결정함.
    • 몰드의 열팽창 계수는 실험 결과와 문헌 데이터와 비교하여 높은 일관성을 보임.
    • 몰드 조성 중 지르코늄과 실리카 함량이 열팽창 특성에 영향을 미치는 것으로 나타남.
  3. 열전도율 평가
    • FLOW-3D 시뮬레이션 결과와 실험 측정값이 유사한 열전도율 경향을 나타냄.
    • 고온에서 몰드의 열전도율이 증가하는 경향이 확인됨.
    • 몰드의 층별 조성이 열전도 특성에 미치는 영향을 평가함.
  4. 시뮬레이션과 실험 데이터 비교
    • 전체적으로 CFD 모델이 몰드의 열적 거동을 잘 예측하지만, 일부 고온 영역에서 오차가 존재함.
    • 몰드 내부 구조 및 표면 조도를 추가로 고려해야 정확성을 향상시킬 수 있음.
    • 향후 연구에서는 몰드의 다층 구조를 개별적으로 분석하는 방식이 필요함.

결론

  • FLOW-3D는 다공성 세라믹 몰드의 열적 거동을 신뢰성 있게 예측할 수 있음.
  • 실험적으로 측정된 몰드의 열물성 값과 CFD 예측값이 높은 상관성을 보임.
  • 일부 고온 영역에서 오차가 존재하므로 추가적인 실험적 검증이 필요함.
  • 향후 연구에서는 몰드의 층별 특성을 반영한 정밀 모델링이 필요함.

Reference

  1. Jones C A, Jolly M R, Jarfors A E W and Irwin M 2020 TMS 2020 149th Annual Meeting and Exhibition Supplemental Proceedings (San Diego: Springer) pp 1095–106
  2. Xu M 2015 Characterization of investment shell thermal properties (Missouri University of Science and Technology)
  3. Jones S, Jolly M R, Gebelin J, Cendrowicz A and Lewis K 2001 FOCAST 2nd Mini Conference (Unpublished)
  4. Konrad C H, Brunner M, Kyrgyzbaev K, Volkl R and Glatzel U 2011 J. Mater. Process. Technol. 181–6
  5. Chapman L A, Morell R, Quested P N, Brooks R F, Brown P, Chen L-H, Olive S and Ford D 2008 Properties of Alloys and Moulds Relevant to Investment Casting (Teddington: National Physical Laboratory)
  6. Jones S 2000 FOCAST 1st Mini Conference (Unpublished)
  7. Matsushita T, Ghassemali E, Saro A, Elmquist L and Jarfors A 2015 Metals 5 1000–19
  8. Khan M A A and Sheikh A K 2018 Int. J. Simul. Model. 17 197–209
Skew bridge flow modelling (a) Plan view of experimental set up of DECKP, (b) 3D plan view of DECKP from Flow 3D

3D Numerical Modelling of Flow Around Skewed Bridge Crossing

비스듬한 교량 횡단부 주변 흐름의 3D 수치 모델링

3D Numerical Modelling of Flow Around Skewed Bridge Crossing

(“비스듬한 교량 횡단부 주변 흐름의 3D 수치 모델링”)

연구 목적

  • 본 논문은 FLOW-3D를 활용하여 비스듬한(스큐) 교량 횡단부 주변의 수면 흐름을 시뮬레이션하고 실험 데이터와 비교하여 모델의 성능을 평가함.
  • 실험실 규모에서 다양한 스큐 각도(30°, 45°)를 적용하여 수면 프로파일 변화를 분석함.
  • Reynolds-Averaged Navier-Stokes (RANS) 방정식을 기반으로 한 FLOW-3D의 수치 해석 결과와 실험 데이터를 비교하여 정확도를 검증함.
  • 교량 설계 및 홍수 관리에 있어 3D 수치 모델의 활용 가능성을 탐구함.

연구 방법

  1. 실험 모델 설정
    • 영국 버밍엄 대학교 수리 실험실에서 다양한 교량 구조(아치형, 평면형 등)를 대상으로 실험 수행함.
    • 22m 길이, 1.213m 너비, 0.4m 깊이의 복합 수로(compound channel)에서 교량 흐름 실험을 진행함.
    • 실험 데이터는 기존 연구에서 활용된 1D 및 2D 모델과 비교 검증함.
  2. FLOW-3D 시뮬레이션 설정
    • FAVOR(유체 부피 기법)를 적용하여 교량 구조를 모델링함.
    • 난류 모델로 k−εk-\varepsilonk−ε 방정식을 사용하여 수치 해석 진행함.
    • 메쉬 독립성 연구를 수행하여 최적의 격자 크기를 결정함.
  3. 결과 비교 및 검증
    • 실험실에서 측정한 자유표면 프로파일과 FLOW-3D 결과를 비교하여 모델 신뢰도를 평가함.
    • 다양한 흐름 조건(유량 변화, 교량 구조 차이 등)에 따른 모델 성능을 분석함.
    • 실험값과 계산값 간 오차를 정량적으로 분석하고, 오차의 주요 원인을 규명함.
  4. 추가 분석
    • 1D, 2D, 3D 모델 간 비교를 수행하여 모델별 장단점을 평가함.
    • 실험 데이터와 수치 모델의 차이를 최소화하기 위한 보정 기법을 검토함.

주요 결과

  1. 수면 프로파일 비교
    • FLOW-3D 시뮬레이션은 실험 데이터와 유사한 수면 프로파일을 재현함.
    • 30°와 45° 스큐 각도에서 측정된 최대 백워터(afflux) 값이 유사하게 나타남.
    • 교량 형상 및 흐름 조건 변화에 따른 수면 변화 패턴을 정확히 예측함.
  2. 스큐 각도와 유량의 영향
    • 스큐 각도가 증가할수록 백워터 높이가 증가함.
    • 유량 증가 시 백워터 영향이 커지며, 45° 각도에서는 30°보다 평균 7~23% 높은 백워터 발생함.
    • 난류 특성이 강한 구간에서는 수치 모델이 일부 오차를 보임.
  3. FLOW-3D의 정확성 평가
    • 실험값과 모델 예측값의 평균 오차율은 30°에서 3.5%, 45°에서 2.2%로 나타남.
    • 실험실 조건에서는 모델이 비교적 정확한 결과를 제공하나, 자연 하천 환경에서 추가 검증이 필요함.
    • 메쉬 해상도와 난류 모델의 선택이 결과에 중요한 영향을 미침.
  4. 설계 및 적용성 평가
    • FLOW-3D는 복잡한 교량 주변 흐름 해석에 유용한 도구임.
    • 3D 모델을 활용하면 1D, 2D 모델보다 높은 정확도로 수면 변화를 예측할 수 있음.
    • 향후 연구에서는 침식 및 고유 유량 변화를 포함한 실험 검증이 필요함.

결론

  • FLOW-3D는 비스듬한 교량 횡단부 주변 흐름을 효과적으로 시뮬레이션할 수 있음.
  • 스큐 각도가 증가할수록 백워터가 증가하는 경향이 확인됨.
  • 수치 모델과 실험 데이터 간 평균 오차는 3.5%~2.2% 범위로 나타남.
  • 향후 연구에서는 더 높은 난류 해상도 및 자연 하천 환경에서 추가적인 검증이 필요함.

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Comparison-of-waves-overtopping-discharge

Study on Wave Overtopping Discharge Affected by Guiding Wall Angle of Wave Dragon Device Using FLOW-3D Software

FLOW-3D 소프트웨어를 이용한 Wave Dragon 장치의 안내벽 각도가 월류 유량에 미치는 영향 연구


연구 배경 및 목적

  • 문제 정의: 파력 에너지 변환 장치(Wave Energy Converter, WEC)는 파도의 에너지를 전기로 변환하는 장치로, 그중 Wave Dragon은 월류 방식(overtopping)을 이용하는 대표적인 WEC 중 하나이다.
  • 연구 목적: Wave Dragon 장치의 안내벽(Reflector) 각도가 월류 유량(overtopping discharge)에 미치는 영향을 분석하고, 최적의 안내벽 각도를 도출하는 것.
  • 접근법: CFD(Computational Fluid Dynamics) 소프트웨어인 FLOW-3D를 활용하여 안내벽 각도와 파고(wave height) 변화에 따른 월류 유량을 시뮬레이션하고 실험 데이터와 비교 분석.

연구 방법

  1. Wave Dragon 장치 개요
    • Wave Dragon은 세 가지 주요 구성 요소로 이루어짐:
      1. 안내벽(Guiding Walls): 파도를 유도하여 경사면(Ramp)으로 향하게 함.
      2. 경사면(Ramp): 파도를 저수조(Reservoir)로 유입시킴.
      3. 수력 터빈(Hydro Turbines): 저수조에 저장된 물이 터빈을 통과하면서 전기를 생산.
  2. FLOW-3D 기반 수치 모델링
    • Navier-Stokes 방정식 및 연속 방정식을 사용하여 유체 흐름을 모델링.
    • VOF(Volume of Fluid) 기법을 활용하여 자유 수면을 해석.
    • 메쉬 설정: 격자 독립성 검토를 통해 최적의 해상도를 확보.
    • 실험 데이터 검증: 기존 연구 및 실험 결과와 시뮬레이션 결과를 비교하여 모델 신뢰성 평가.
  3. 시뮬레이션 변수
    • 파고(Wave Height): 0.2m ~ 1.5m 범위에서 변화.
    • 안내벽 각도(Guiding Wall Angle): 50°, 60°, 70°, 80°, 90°.
    • 월류량 측정: 안내벽 각도 및 파고에 따른 월류 유량을 비교 분석.

주요 결과

  1. 안내벽 각도와 월류량의 관계
    • 안내벽 각도가 80°에서 최대 월류량을 기록.
    • 50°, 60°, 70°에서는 월류량이 감소하며, 90°에서는 파도의 속도가 낮아져 월류량이 다소 감소.
  2. 파고와 월류량의 관계
    • 파고가 증가할수록 월류량이 증가하는 경향을 보임.
    • 1.5m 파고에서 가장 높은 월류량이 발생.
  3. 시뮬레이션과 실험 데이터 비교
    • FLOW-3D 시뮬레이션 결과와 실험 데이터 간 오차는 평균 15% 이내로, 모델이 신뢰할 만한 정확도를 보임.

결론 및 향후 연구

  • 결론:
    • Wave Dragon 장치의 안내벽 각도가 월류 유량에 중요한 영향을 미치며, 80°가 최적의 각도로 나타남.
    • 90° 이상에서는 파도 반사가 줄어들어 효율이 낮아지고, 50°~70°에서는 월류 유량이 감소함.
  • 향후 연구 방향:
    • 실험적 검증을 확장하여 다양한 해양 조건에서의 성능 평가.
    • 터빈 효율을 고려한 최적의 수력 에너지 변환 설계 연구.
    • 다중 안내벽 설계 및 추가적인 CFD 기법 적용을 통한 성능 개선.

연구의 의의

이 연구는 Wave Dragon과 같은 월류형 WEC의 성능을 최적화하기 위한 CFD 기반 설계 평가 방법을 제시하며, 파력 발전 시스템의 효율성을 향상시키기 위한 실용적인 가이드라인을 제공한다.

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Scouring

3D Numerical Simulation of Flow Field Around Twin Piles

쌍둥이 말뚝 주변 유동장에 대한 3차원 수치 시뮬레이션


연구 배경 및 목적

  • 문제 정의: 교각이나 말뚝(pile) 주위에서 발생하는 국부적인 세굴(scour)은 구조물의 안정성에 중요한 영향을 미친다.
  • 연구 목적: FLOW-3D 소프트웨어를 이용하여 두 개의 말뚝(쌍둥이 말뚝) 주위의 유동 패턴과 세굴 메커니즘을 수치적으로 시뮬레이션하고, 실험 데이터를 활용하여 검증하는 것이다.

연구 방법

  1. 수치 모델링 및 난류 모델
    • FLOW-3D 소프트웨어를 사용하여 RNG k-ε 난류 모델을 기반으로 유동 해석 수행.
    • 말뚝의 배치: 병렬(side-by-side) 배치직렬(tandem) 배치 두 가지를 고려.
    • 실험 데이터와 비교하여 모델의 신뢰성을 검증.
  2. 계산 영역 및 격자(Grid) 설정
    • 비균일(non-uniform) 격자 분포를 사용하여 말뚝 주변의 유동을 정밀하게 모델링.
    • 최소 격자 크기: 0.009 m, 최대 격자 크기: 0.039 m.
    • 메쉬 개수: x 방향 400개, y 방향 110개, z 방향 40개.
  3. 경계 조건
    • 유입 속도 및 압력을 각각 입출력 경계 조건으로 설정.
    • 상류에서 개발된 유동을 프로파일로 생성하여 말뚝이 존재하는 구역의 유입 경계 조건으로 적용.

주요 결과

  1. 유동 패턴 분석
    • 병렬 배치(Side-by-side):
      • 말뚝 사이에서 제트(Jet) 유동이 발생하며 비대칭적인 흐름 형성.
      • 배치 간격이 증가할수록 후류(Vortex shedding) 현상이 뚜렷해짐.
    • 직렬 배치(Tandem):
      • 앞쪽 말뚝이 후방 말뚝을 보호하는 Sheltering 효과 발생.
      • Reynolds 수와 배치 간격(S/d)에 따라 와류 형성 패턴이 변화.
      • 후류에서 강한 난류 구조가 나타나며, Wake Vortex가 형성됨.
  2. 실험과의 비교
    • 실험 데이터와 시뮬레이션 결과를 비교한 결과, 전반적으로 유동 패턴이 잘 일치함.
    • 그러나 말뚝 사이의 복잡한 유동장에서는 일부 차이가 발생하여 추가적인 모델 보정이 필요함.
  3. Reynolds 수와 배치 간격의 영향
    • 말뚝 간 간격(S/d)이 증가할수록 앞쪽 말뚝의 보호 효과가 감소하고, 후방 말뚝 주변에서 강한 와류가 형성됨.
    • 낮은 Reynolds 수에서는 단일 말뚝과 유사한 흐름 패턴을 보이나, 높은 Reynolds 수에서는 와류가 더욱 강하게 나타남.

결론 및 향후 연구

  • FLOW-3D를 활용한 3D 유동 시뮬레이션은 말뚝 주변 유동 패턴과 세굴 메커니즘을 효과적으로 분석할 수 있음을 확인함.
  • 실험 데이터와 전반적으로 높은 일치도를 보였으나, 말뚝 사이의 복잡한 유동장에서 추가적인 모델 개선이 필요함.
  • 향후 연구에서는 더 다양한 Reynolds 수와 배치 조건을 고려한 추가 실험 및 난류 모델 비교 분석이 필요함.

연구의 의의

이 연구는 교량 기초 및 해양 구조물 설계에서 말뚝 주변의 유동과 세굴 예측을 정밀하게 분석할 수 있는 CFD 기반 접근법을 제시하였으며, 향후 말뚝 배치 최적화 및 구조물 안전성 향상에 기여할 수 있음을 시사한다.

Reference

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  3. Amini A, Melville B, Thamer M, Halim G (2012) Clearwater local scour around pile groups in shallow-water flow. J Hydraul Eng (ASCE) 138(2):177–185
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  5. Aslani A (2008) Experimental evaluation of flow pattern around double piles. MSc thesis, Sharif University, Tehran Gu ZF, Sun TF (1999) On interference between two circular cylinders in staged arrangement at high sub-critical Reynolds numbers. J Wind Eng Ind Aerodyn 80:287–309
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  10. Palau-Salvador G, Stoesser T, Rodi W (2008) LES of the flow around two cylinders in tandem. J Fluids Struct 24(8):1304–1312
  11. Papaionannou GV, Yuea DKP, Triantafylloua MS, Karniadakis GE(2008) On the effect of spacing on the vortex-induced vibrations of tandem cylinders. J Fluids Struct 24:833–854
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Wave pattern at sea surface at 20 knots (10.29 ms) for mesh 1

Ship Resistance Analysis using CFD Simulations in Flow-3D

Flow-3D CFD 시뮬레이션을 이용한 선박 저항 분석


연구 배경

  • 선박 설계 시 추진 시스템의 효율성을 결정하는 핵심 요소 중 하나는 선박 저항(항해 중 발생하는 해양 저항)이다.
  • 선박 저항은 선박의 연료 소비와 환경 영향을 좌우하며, 초기 설계 단계에서는 Holtrop-Mennen (HM)과 같은 통계적 방법을 주로 사용한다.
  • 완성된 3D 선체 디자인이 마련되면 CFD 시뮬레이션이나 축척 모델 실험을 통해 보다 정밀한 저항 값을 산출할 수 있다.
  • 본 연구는 RoPax 여객선을 대상으로 Flow-3D 소프트웨어를 활용하여 다양한 선박 속도에서의 저항을 계산하고, 이를 HM 방법과 비교·분석하는 데 목적이 있다.

연구 방법

  1. CFD 시뮬레이션 수행
    • 소프트웨어: Flow-3D를 사용하여 3차원 Navier-Stokes 방정식을 풀어 선박 주변의 자유 표면 유동을 해석.
    • 메쉬 기법: FAVOR (Fractional Area-Volume Obstacle Representation) 기법을 이용한 ‘Free Gridding’으로 복잡한 선체 형상을 간단하게 모델링.
    • 경계조건: 입구에 유속 조건(선박 속도에 해당하는 값)과 해수의 깊이를 설정하여 실제 해양 조건을 반영.
    • 난류 모형: RANS k-ε 모델을 사용하여 난류 효과를 고려.
  2. 메쉬 민감도 분석
    • 다양한 격자 크기를 적용하여 결과의 민감도를 평가하고, 최적의 해상도와 계산 시간을 확보함.
  3. 비교 분석
    • CFD 시뮬레이션 결과로 도출된 선박 저항 값을 Holtrop-Mennen (HM) 방법의 예측값과 비교.
    • 낮은 선박 속도(10 knots)에서는 CFD 결과와 HM 방법 간의 차이가 미미하나, 속도가 증가할수록 CFD 결과가 HM 예측보다 크게 증가하는 경향을 분석.

주요 결과

  • 저항 값 비교:
    • 10 knots에서 CFD 시뮬레이션 결과는 HM 방법과 유사하였으나, 15 knots 이상에서는 CFD 결과가 HM 방법보다 현저히 높은 저항 값을 나타냄.
    • 예를 들어, 20 knots에서는 HM 방법 대비 약 35% 높은 저항 값이 나타났으며, 24 knots에서는 약 32% 차이가 발생함.
  • 메쉬 민감도:
    • 더 미세한 메쉬(최종적으로 Mesh 3 사용)에서 시뮬레이션된 저항 값은 거친 메쉬에 비해 낮은 값을 보여, 격자 크기가 결과에 미치는 영향을 확인함.
  • 선박 속도에 따른 변화:
    • 선박 속도가 증가할수록 파 생성 및 파 부서짐으로 인한 추가 저항이 크게 기여하며, 이는 선박 저항의 비선형적인 증가로 나타남.

결론 및 향후 연구

  • Flow-3D를 활용한 CFD 시뮬레이션은 선박 저항을 예측하는 데 효과적인 도구임을 확인하였다.
  • 특히, 고속 조건에서 CFD 결과는 HM 방법보다 높은 저항 값을 산출하며, 이는 파 저항의 기여를 반영한 결과로 해석된다.
  • 향후 연구에서는 다른 난류 모형(예: Wilcox k-ω, RNG k-ε)과의 비교, 실제 모델 테스트(예: 축척 모델 실험)와의 추가 검증을 통해 CFD 해석의 정확성을 더욱 향상시킬 필요가 있다.
  • 본 연구 결과는 선박 설계 및 최적 운항 속도 결정 등 실무에 유용한 참고 자료로 활용될 수 있다.

Reference

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  2. A. Molland, S. Turnock and D. Hudson, “Ship Resistance and Propulsion” SecondEdition. In Ship Resistance and Propulsion: Practical Estimation of Ship PropulsivePower (pp. 12-69), August 2017, Cambridge University Press.
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pattern

Numerical Modeling of Flow Pattern in Dam Spillway’s Guide Wall. Case Study : Balaroud dam, Iran

댐 방수로(Spillway) 안내벽의 유동 패턴 수치 모델링: 이란 Balaroud 댐 사례 연구


연구 배경

  • 문제 정의: 댐 방수로의 안내벽(Guide Wall)은 흐름 패턴을 조절하는 중요한 구조물로, 최적의 형상을 설계하면 방수로의 성능을 향상할 수 있음.
  • 목표: Balaroud 댐의 방수로 안내벽에 대해 물리적 및 수치적 모델링을 수행하여, 최적의 안내벽 형상을 도출.
  • 접근법: CFD(Computational Fluid Dynamics) 소프트웨어인 FLOW-3D를 활용하여 다양한 안내벽 설계를 비교 분석.

연구 방법

  1. 모델링 개요
    • AutoCAD를 이용하여 3D 모델 생성 후 FLOW-3D로 내보내기(STL 파일 형식).
    • 1:110 축척의 실험실 모델을 구축하고 실험 결과와 수치 해석을 비교.
  2. 수치 모델링 과정
    • 격자 생성(Meshing): 다양한 해상도로 수치 해석을 진행.
    • 경계 조건 설정: 유입 및 유출 조건을 설정하고 난류 모델 선택.
  3. 난류 모델 비교
    • K-epsilon, RNG K-epsilon, LES(Large Eddy Simulation) 모델을 비교.
    • RNG K-epsilon 모델이 가장 적합한 결과를 보임.
  4. 세 가지 안내벽 설계 평가
    • 모델 1: 유동 분리가 심하게 발생하여 부적합.
    • 모델 2: 접근 채널에서 교차파(Cross Waves) 형성.
    • 모델 3: 최소한의 유동 분리 및 교차파 제거 → 최적의 설계로 선정.

주요 결과

  • 모델 3이 가장 우수한 성능을 보이며, 교차파 발생을 최소화하고 유량을 원활하게 전달.
  • 유량-수위 곡선(Rating Curve) 분석을 통해 모델 3이 다른 설계보다 효율적임을 확인.
  • FLOW-3D의 RNG K-epsilon 난류 모델이 유동 패턴 해석에 가장 적합.

결론 및 향후 연구

  • 수치 모델링과 물리적 실험을 결합하여 최적의 안내벽 형상을 도출.
  • 최적 설계(모델 3)를 통해 방수로 성능을 개선하고, 수력 구조물의 안전성을 향상 가능.
  • 향후 연구에서는 다양한 유입 조건과 추가적인 설계 변수를 고려하여 더욱 정밀한 최적화를 수행할 필요.

이 연구는 댐 방수로 안내벽 설계의 최적화를 목표로 하며, 수치 해석 기법을 활용한 CFD 기반 설계 검증 방법론을 제시한다는 점에서 의의가 있다.

Reference

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Welding

A multi-physics CFD study to investigate the impact of laser beam shaping on metal mixing and molten pool dynamics during laser welding of copper to steel for battery terminal-to-casing connections

배터리 단자-케이싱 접합을 위한 구리와 강철 간 레이저 용접 시 레이저 빔 형상이 금속 혼합 및 용융풀 역학에 미치는 영향을 조사하는 다중 물리 CFD 연구

Giovanni Chianese, Qamar Hayat, Sharhid Jabar, Pasquale Franciosa, Darek Ceglarek, Stanislao Patalano

Abstract

This study aims to investigate the impact of laser beam shaping on metal mixing and molten pool dynamics during laser beam welding of Cu-to-steel for battery terminal-to-casing connections. Four beam shapes were tested during LBW of 300 µm Cu to 300 µm nickel-plated steel. Both experiments and simulations were used to study the underlying physics. A CFD model was firstly calibrated against experiments and then deployed to explore the effect of the increasing ring-to-core diameter, as well as a tandem laser spot configuration. The study showed that metal mixing is influenced by the keyhole dynamics and collapse events, but also there is an intricate interplay between keyhole geometry, fluid dynamics via Marangoni forces and buoyancy forces. Notably, the buoyance forces due to the different densities of steel and Cu, along with the recoil pressure contribute to the upward flow of steel towards Cu, and hence impact meaningfully the material mixing. The study pointed-out that the selection of a custom ring-to-core diameter and ring-to-core power is a decision with a trade-off between the need of stabilising the keyhole dynamics and the need to reduce the mixing. Findings indicated that 350 µm ring and 90 µm core with 30% of ring power (weld configuration C3) resulted in more stable dynamics of the keyhole, with significant reduction of collapse events, and ultimately controlled migration of steel towards Cu. Additionally, the pre-heating approach with the tandem beam only led to local fusion of Cu and no significant improvement in keyhole stability was observed.

1. Introduction

The push towards net-zero mobility is globally influencing industrial strategies in the automotive sector as reported by IEA (2022). Manufacturers are introducing new vehicles by replacing internal combustion engines with hybrid or fully electric powertrains. The battery pack is a critical component for un-interrupted supply of electricity to e-drives and other electrical systems in electric vehicles (EV). A battery pack typically consists of several battery modules that are electrically connected in series and parallel based on the desired power and capacity requirements (Zwicker et al., 2020). Battery modules hold the battery cells that store the electrical charge and supply it on-demand to the electrical systems. Electrical connections play a critical role in the entire process of battery pack manufacturing since joints with different electrical resistance may result in uneven current loads that can affect the overall performances of the battery system (Kumar et al., 2021). Joining of dissimilar materials is the most deemed since it complements the properties of the individual materials and allows to develop functionally efficient connections. Joints in EV battery pack involve low-thickness materials (typically 0.3–1 mm) and the welding process is normally performed in lap or fillet configuration. Depending upon design and functional requirements as well as manufacturing costs, research has shown that the following combinations of materials are the most regarded: aluminium (Al) to copper (Cu), steel to Al, Al to steel, Cu to steel (Das et al., 2018).
Connections between Cu and steel have gained much attention in EV applications for joining cells in battery modules. For example, in the cylindrical format, the negative terminals are made of Cu and are generally connected to the steel casing of the cell (Sadeghian and Iqbal, 2022). Several joining processes have been studied for Cu-to-steel welding and they include wire bonding, micro-spot welding, ultrasonic welding, micro-TIG welding, electron beam welding and Laser Beam Welding (LBW) (Zwicker et al., 2020). LBW is an attractive option and has recently gained popularity due to advances in versatile methods for laser beam delivery and associated sensors technology for quality control and process monitoring that make LBW comparatively affordable (Kogel-Hollacher, 2020). Brand et al. (2015) demonstrated that LBW is a suitable process for joining battery terminals since it allows the lowest electrical resistance and the highest joint strength, when compared to micro-spot welding and ultrasonic welding; also, it is potentially applicable to any cell configuration and dissimilar metal combinations.
Despite the benefits of LBW, opening and maintaining a stable molten pool on the Cu-side is challenging when using LBW with infrared sources. The absorptivity of Cu at ambient temperature is approximate 5% and increases with rising temperature, and it suddenly jumps up when the melting temperature is reached. A problem with this is that when fusion of the material does happen, a surplus of energy flows through it, which can vaporise the material and create spatters, as well as pores inside the joint. These defects can reduce the electrical conductivity of the joint. At first sight, the solution to the low coupling efficiency of Cu is to switch from infrared sources to visible sources. The absorption increases drastically up to 60% when using visible sources. Green (515 nm) or blue (450 nm) lasers have been investigated by Kogel-Hollacher et al. (2022) and proved that lower power needed for same penetration achievable with infrared lasers and less thermal damage to enamel and insulators. Hummel et al. (2020) experimentally evaluated and proved the beneficial effects of blue laser during laser micro-welding of Cu, and achieved high welding speed with low input power. Nonetheless, compared to infrared lasers, the higher cost, lower plug efficiency and lower beam quality of visible lasers, push practitioners towards the use of multi-kW infrared sources at very high brightness for Cu welding.
In addition to the challenge posed by the laser beam coupling to the Cu, the welding of Cu to steel presents a series of problems. First, they are quite different in terms of physical properties such as density, melting points and thermal expansion and make defect-free welding difficult. Second, although Cu-Fe alloys are completely miscible in the stable liquid state and do not form brittle intermetallic compounds, the system shows a wide metastable miscibility gap at an undercooling level. The liquid phase separation occurs as the liquid cools in the miscibility gap resulting in the supersaturation of one or both liquids. Jeong et al. (2020) has shown that increasing the content of Fe tends to improve the mechanical properties of alloys but reduce electrical conductivity and ductility. Chen et al. (2013) proved that the toughness and fatigue strength of the joint decreases with the increase in the amount of molten Cu into the steel. Thus, melting of Cu was suggested to be kept at a minimum. Third, excessive penetration of Cu in grain boundaries of steel may result in cracks in the heat affected zone and fusion zone, and ultimately reducing structural performance of the joint. Therefore, to reduce these issues, controlling the mixing of Cu and steel in the molten pool is quite important for producing sound joints.
Laser beam shaping is gaining popularity since it holds the promise to control cooling rates and thermal gradients in and around the molten pool. This theoretically leads to a tailored material response to the heat input both spatially and temporally. A tailored power density profile (Fig. 1 shows typical power density profiles obtained via adjustable ring-mode laser) is generated via adequate insertion of optical components (specially coated lenses of silica substrate) in the optical chain of the welding head; or by electro-optical switching multiple laser beams generated in the laser source itself and enabled by beam combiners with optical phased array. Research has confirmed a positive effect of the laser beam shaping on the control of the weld profile and keyhole stabilization with suppression of spatters and significant reduction of porosity in the weldments. Caprio et al. (2023) investigated the use of beam shaping and beam oscillation to weld 0.2 mm Ni-plated steel sheets in lap joint configuration, which are materials commonly involved in cell to busbar connections. Sokolov et al. (2021) employed the ARM laser coupled with Optical Coherent Tomography (OCT) in Al-to-Cu thin sheets and observed that the use of combined core and ring-shaped laser beams reduced the fluctuations of the keyhole, improved the stability, and ultimately the accuracy of OCT measurements. Rinne et al. (2022) studied the effect of different power distributions between the inner core and outer ring-shaped laser beams on spatter ejection and penetration depth during welding of Cu sheets. Wagner et al. (2022) investigated and proved the influence of dynamic beam shaping on the geometry of the keyhole during welding of Cu by varying the patterns of the intensity distribution in longitudinal and transversal direction. Prieto et al. (2020) implemented dynamic laser beam shaping with infinite pattern and assessed quality of weld seam in 0.8 mm Al thin-sheet and observed that tailored beam with shape frequency over 10 kHz enables welding speed up to 18 m/min with stable keyhole.

Fig. 1. Example of laser beam shapes obtained via an adjustable ring-mode laser.

Despite the benefits, laser beam shaping introduces new set of parameters and finding the optimal combination of number of beams, shape of beams (multiple spots, C-spot, ring-core spots, pyramid, infinity, spiral shapes, etc. (Prieto et al., 2020)) can be expensive and time consuming since it may require dedicated equipment, expertise and experimental setups. In this context, multi-physics computational fluid dynamics (CFD) enable simulations of the process to reproduce mechanisms which are difficult to observe with in-situ investigations. With the raise of computational power and multi-core computing on high performance clusters, advanced simulations of LBW processes are now a close reality. Huang et al. (2020) developed a CFD model in FLOW-3D WELD® to study the metal mixing during linear laser welding of 200 µm Al to 500 µm Cu with different levels of laser power and velocity of the laser spot. They analysed the contribution of recoil pressure and Marangoni effect on the overall mixing process. Chianese et al. (2022) developed a multi-physics model using FLOW-3D and FLOW-3D WELD® to investigate the effect of part-to-part gap in LBW of Cu-to-steel thin sheets with beam wobbling. They showed that the presence of part-to-part gap and mixing mechanism between parent metals are linked, and the occurrence of part-to-part gap influences the temperature and velocity fields in the molten pool resulting in different mixing mechanisms. However, they did not implement any strategies for weld improvement. Drobniak et al. (2020) and Buttazzoni et al. (2021) implemented CFD multi-physics simulations of 1 mm-thick stainless steel plates with adaptive mesh refinement to predict the shape of the weld seam in presence of part-to-part gap, and they predicted the effect on the process of secondary laser beams with different shapes to optimize the weld quality. Recently, Huang et al. (2023) combined experimental approach and CFD simulations in FLOW-3D WELD® to reveal the effect of oscillation frequency and amplitude on fluid-flow and metal mixing during laser welding of 200 µm Al to 500 µm Cu with circular beam wobbling implemented. Additionally, they implemented a Scheil solidification model to predict the phase distributions in the welds based on the predicted thermo-solute conditions.
While significant research has been already developed using linear laser welding or laser welding with wobbling for joining of dissimilar materials, a clear understanding of metal mixing and dynamics of the keyhole during Cu-to-steel welding with beam shaping are not clearly reported. Research into application of beam shaping for Cu-to-steel welding entails a promising prospect for further development and investigation. Furthermore, the use of advanced CFD models is a viable approach to complement experimental investigations and explore weld configurations with different beam shaping profiles that would be difficult to achieve only with experimental work. Therefore, this paper aims to study the impact of laser beam shaping on metal mixing and dynamics of the keyhole during LBW of Cu-to-steel for battery terminal-to-casing connections. Four beam shapes were tested during LBW of 300 µm Cu to 300 µm nickel-plated steel. Both experiments and CFD simulations were used to study the underlying physics. A CFD model was firstly calibrated against experiments and then deployed to explore the effect of the increasing ring-to-core diameter, as well as a tandem laser spot configuration.

2. Experimental design and model description

2.1. Experimental design

Materials used in this work are Copper SE-Cu58 2.0070 and Nickel-plated steel (commercial name: Hilumin TATA STEEL). Experiments consisted of 25 mm long welds in lap joints configuration with 300 µm Cu on top of 300 µm nickel-plated steel.
Dimensions of the specimens were 65 mm × 30 mm. The laser source used was the Lumentum CORELIGHT, having 55 µm core diameter and 220 µm ring diameter, and BPP 1.4 mm·mrad and 11 mm·mrad for core and ring, respectively. The laser fiber was coupled to the Scout-200 (Laser and Control K-lab, South Korea) scanner to deliver the laser power to the specimens via 2D F-theta scanner with telecentric lenses. Fig. 2 shows the welding setup and specifications of the equipment are in Table 1. Caustic parameters were measured using PRIMES GmbH measurement system.

Fig. 2. (a) Welding setup with aluminium fixture; (b) schematical representation of the welding setup; (c) definition of weld features: top weld width, Wtop; width at the interface, Wi; weld penetration depth, Dpen.
Table 1. Specifications of the welding equipment.

Each weld seam was cut and prepared to obtain two cross sections for each experiment – cross sections were positioned at 10 mm and 15 mm away from the weld start. Three replicates were performed for each weld configuration. Sectioned samples were mounted in Bakelite resins and standard metallography procedure was performed for grinding and polishing to reveal weld profile under Nikon Eclipse LV150N optical microscope. To evaluate and characterize metal mixing with parent metals, elemental mapping of cross-sections was performed with an FEI Versa 3D dual beam scanning electron microscope using Energy Dispersive X-ray Spectroscopy (EDS mapping).
Welding experiments were performed in continuous power mode without power modulation. The laser beam was focussed perpendicularly on the upper surface of the Cu sheet, and the motion of the laser was linear (no wobbling). Although the use of shielding gas tends to avoid oxidation in the process and reduce hydrogen entrapment, when using scanners to deliver the laser beam, the gas nozzle cannot be positioned in proximity of the beam. Therefore, in this work, all experiments were conducted with no shielding gas. Part-to-part gap was manually checked and set to a nominal zero.
To study the impact of laser beam shaping on metal mixing and molten pool dynamics, 5 weld configurations (C1 to C5) were designed as shown in Table 2, with 4 beam shapes presented in Fig. 3. LBS#1 is single gaussian spot of 90 µm; LBS#2 super-imposes an inner core of 90 µm with an outer ring-shaped profile of 350 µm, with the ring accounting 30% of the total power. LBS#1 and LBS#2 were experimentally tested and enabled by the static beam shaping system of the Lumentum CORELIGHT source. LBS#3 follows the hollow sinh-Gaussian beam profile as defined in Liu et al. (2019), with 90 µm core and 500 µm ring, with 72% of the total power assigned to the ring. LBS#4 is a tandem beam with primary (90 µm) and secondary beam (150 µm) at a centre-to-centre distance of 300 µm, and 50% split of the power between primary and secondary beams – LBS#4 was introduced with the aim to increase the absorption rate by the pre-heating action of the secondary beam. LBS#3 and LBS#4 were only simulated since the laser beam shaping of the Lumentum CORELIGHT was only capable to work with fixed core-to-ring diameter ratio. Therefore, only a simulation-based approach (with the model pre-validated and calibrated in C1, C2 and C3) was deemed appropriate in this case to explore the effect of the increasing ring-to-core diameter and tandem laser spot configuration on material mixing.

Table 2. Process parameters used for the four selected laser beam shapes in Fig. 3.
Fig. 3. Normalized power density distribution for LBS#1, LBS#2, LBS#3 and LBS#4.

The power and speed of C1, C3, C4 and C5 were selected with an iterative process to ensure weld penetration depth, Dpen, ranging 400 – 500 µm. The choice of this penetration depth is based on the requirement that the temperature at the lower end of the steel sheet remains below 550 K. This precautionary measure aims to prevent any potential damage to the battery cell. Additionally, to minimise the effect of the weld depth on the metal mixing, a uniform depth of penetration was adopted across the different beam shapes for comparative analysis. Welding speeds were kept between 250 mm/s and 375 mm/s which is in line with the experimental work in (Perez Zapico et al., 2021). C2 is a variant of C1 and corresponds to a fully penetrated weld. Although fully penetrated welds must be avoided during LBW of battery terminals due to the risk of fire ignition, this work presents this variant for two reasons: first, to generate an additional weld configuration to validate the simulation; second, to discuss how the metal mixing behaves when transitioning from partial penetration to full penetration.

2.2. Model description

A multi-physics model was developed using the commercial CFD code FLOW-3D® (solver version: 12.0.2.01) and its module FLOW-3D® WELD (release: 7, update: 1). In order to develop a numerical model representing the essential physics during LBW of Cu-to-steel, the following assumptions were considered: (i) the liquid flow is considered Newtonian and incompressible; (ii) volumetric thermal expansion of the liquid metal due to temperature-dependent mass density is accounted; (iii) the air and vaporized metal are modelled as “void” type, with ambient temperature and pressure assigned to model the heat exchange with the metal as a natural convective flux (irradiance is neglected); (iv) the heat sinking effect of the clamping mask is neglected due to the clearance between the weld seam and the mask itself as already presented in (Chianese et al., 2022); (v) the effect of plasma plume on laser absorption is not directly modelled but is accounted in the calibration process as also proposed in previous studies by Lin et al. (2017) and Hao et al. (2021); furthermore, the laser absorption is assumed temperature dependent for Cu, constant for steel, and independent of the incidence angle. This assumption is in-line with the work presented by Huang et al. (2020), where they used the build-in ray-tracing function in FLOW-3D® WELD to predict the laser absorption in the keyhole.

2.2.1. Governing equations, boundary conditions and material properties

To reduce the computational cost of the simulations, the computational domain was divided in two zones (Fig. 4): (1) a process zone which was interested by phase change, and, (2) a thermal diffusion zone that models heat transmission in the sheets. A finer mesh size was used for cells in the process zone, and a mesh size 5 times greater than in the process zone was used for cells in the thermal diffusion zone.

Fig. 4. Top view (a) and side view (b) of a schematic representation of the computational domain and modelling approach with nested meshes (process zone and thermal diffusion zone).

Dimensions of the process zone are 2 mm × 0.8 mm× 0.775 mm. The length (2 mm) of the process zone was chosen to enable the simulation of approx. 1.8 mm weld length, which was experimentally evaluated to be sufficient for reaching the steady-state regime. The width (0.8 mm) of the process zone was selected to ensure that the molten pool was contained in it; the height of the computational domain was chosen equal to 0.8 mm so that, beside the stacked thickness of the processed sheets (0.6 mm), 0.2 mm of air (void type) are included in the computational domain. Extension of the thermal diffusion zone is calculated according to the Eq. (1), where k is the thermal conductivity, cp the specific heat at constant pressure, ρ the mass density, tend the simulation time, T the temperature, and Tamb= 20 °C the ambient temperature. The simulation time, tend, is function of the welding speed and the weld length (1.5 mm).

Four different values of the mesh size in the process zone were considered during sensitivity analysis, namely 40 µm, 20 µm, 15 µm, and 10 µm, that resulted in mesh independent solution for mesh size equal to or below 15 µm, which therefore is the selected size. This led to total number of cells approximatively equal to 528 thousand. The geometry of the thin sheets has been modelled in the computational domain, so that in-plane dimensions were parallel to X and Y axis, as shown in the top and side view in Fig. 4(a) and (b). Welding direction was parallel to X axis.
The following physics have been accounted to model the welding process: continuity, fluid flow via Navier-Stokes equations, energy conservation, evaporation, keyhole formation and evolution, solidification, species conservation and tracking, surface tension with Marangoni and Laplace forces and multiple reflections.
Phase change – Eq. (2) governs the evaporation phenomena which are modelled as mass transfer between the liquid phase and the void type and are proportional to the difference between the saturation pressure Psat and the partial pressure Pvap. In this equation, α is the accommodation coefficient, R is the gas constant, and T is the temperature. The saturation pressure is calculated as a function of the temperature according to the Clapeyron equation (Eq. (3)), in which the couple (Pv, Tv) represents a point on the saturation curve; γ, cv, and ΔHv are the specific heats ratio, the specific heat at constant volume, the latent heat of vaporization, respectively.

Recoil pressure – during laser welding process, intense localised heating of substrate material causes vaporization which results in recoil pressure. This pressure is proportional to the saturated vapor pressure. The relationship between the recoil pressure, Precoil, and the saturated vapor pressure, Psat, depends on the material properties and laser-to-material interaction. Eq. (4) is derived from Eq. (3) with the introduction of two coefficients, Ar and B, that will be calibrated using experimental data.

Tracking of the keyhole – surface of the keyhole is tracked by the volume of fluid (VOF) method (Daligault et al., 2022), which enables the calculation of the interface between the liquid metal and the void type, according to Eq. (5).

The interface between the cell is tracked using a scalar value f that indicates the fraction of fluid in it. A value of f=0 indicates that the cell has only void, conversely, f=1 corresponds to the case of a cell full of liquid, whereas the case of 0<f<1 indicates that the cell has both the liquid and the void type, and therefore the interface between the two falls in it. Similarly, metals involved in the welding process with fluid flow and mixing are tracked in each cell by means of a scalar value f2, which indicates the fraction of second material within the cells. Values of the generic material property ̅φ̅ in each cell is evaluated as weighted sum of the properties φ1 and φ2 of parent metals based on their mixing, as in Eq. (6).

Multiple reflections – Multiple reflections are implemented using a discrete grid cell system through the ray tracing technique. The laser beam is divided into a finite number of rays, which move in the laser beam irradiation direction. When the ray encounters the surface of the material, it is reflected according to vector Eq. (7), in which R→ is the direction of the reflected vector, I→ the direction of the incoming ray, and nˆ the normal direction of the material surface.

Laplace pressure and Marangoni effect – Recoil pressure contributes to the formation of the keyhole and mainly contributes to the velocity field in the fluid; however, surface tension-related phenomena such as Laplace pressure LP and the Marangoni force SM have great influence on the overall welding process. Laplace pressure and the Marangoni force are modelled according to (8), (9) which, σ is the surface tension, RI and RII are the principal curvature radii, and operator ∇t indicates the gradient along the tangent direction at the interface. Eq. (9) explicitly indicates the dependence of the Marangoni effect on the gradient of the surface tension, which in assumed temperature-dependent of the surface tension.

2.2.2. Boundary conditions and material properties

As shown in Fig. (4), the following boundary condition were assigned: wall in the X and Y direction (with constant ambient temperature); assigned pressure and temperature at the boundaries of the computational domain in the Z directions, with natural convective heat flux between the metallic sheets and the air. The heat source was directly imported from the power profiles defined in Fig. 3. Material properties were imported from the JMATPRO® material database. Fig. 5 shows the temperature-dependent plots.

Fig. 5. Temperature-dependent material properties defined in the model.

3. Results and discussion

3.1. Model validation

The model has been applied to simulate all the cases listed in Table 2. Model validation was conducted for the weld configurations C1, C2 and C3 by comparing the weld profile in cross sections and Fe concentration line profiles against the experimental results as shown in Fig. 6. Experimental and simulation results show that welding is done through keyhole mode. The generation of a keyhole is significantly influenced by recoil pressure. In the simulation, the recoil pressure is adjusted through the calibration of coefficients Ar and B, as indicated in Eq. 4. During the model calibration process, a value of Ar was determined to be 55,715 Pa, and the parameter B was set to 4, resulting in comparative results with those obtained in experiments. Five different mesh sizes were tested: 20 µm, 15 µm, 10 µm and 5 µm. The choice of the mesh size was driven by the need to have a minimum of 4 cells to discretise the smallest laser spot (i.e., LSB#1 has the smallest beam diameter of 90 µm among the tested beam shapes in Fig. 3). Mesh-independent solution was achieved with mesh size of 15 µm and this led to approximate a million cells in the whole computational domain.

Fig. 6. Comparison of the experimental and modelling results of the molten pool geometry and elemental maps for weld configurations C1 (a), C2 (b) and C3 (c).

The correlation was conducted looking at two cross-Section (10 mm 15 mm away from the weld start and end) – this was motivated by the need to take into account the experimental errors during the calibration and validation process.

Fig. 6 shows cross sections and elemental maps for experiments C1, C2, and C3, and corresponding simulations. Two representative cross-sections from the same weld seam are shown in each sub-figure to demonstrate the capability of the model to reproduce the geometric shape and the mixing phaenomena at different longitudinal positions along the weld seam. The fusion zones are marked in each cross section and show good correlation with predictions from simulations, as the cases with partial penetration are successfully predicted in for C1 and C3, along with full penetration in C2.

Elemental maps that were measured with EDS, and species concentration that were predicted with simulations, are reported for comparison to show capability of the model to reproduce the mixing mechanism. For each case, plots of the concentration of Fe along with line-scans are reported to quantitatively demonstrate the capability of the model to simulated diffusion of the molten metal from the bottom sheet to the upper one. They show that diffusion of Fe in Cu is well predicted in C1 and C3, as well as presence of Fe-rich clusters in the Cu near the interface between parent materials is reproduced in C2.

Good correlation between measurements and predictions of the weld geometry and metal mixing demonstrates capability of the model to simulate welding scenarios with different laser beam shapes, and weld penetration depth spanning from partial penetration to full penetration. This allows to confidently deploy the simulation model in conjunction with experiments to study the impact of laser beam shaping on metal mixing and molten pool dynamics.

3.2. Keyhole dynamics and impact on metal mixing

As keyhole instabilities have a significant impact on weld quality (Lu et al., 2015), this section highlights the impact of the laser beam shapes on the keyhole dynamics, which ultimately contributes to metal mixing. The discussion is presented by linking the laser power profile to the velocity field within the molten pool and ultimately to the metal mixing between the parent metals and the occurrence of collapse events of the keyhole.

Fig. 7 shows consecutive time frames in each weld configuration and reflects keyhole dynamic mechanisms. The keyhole’s shape and size vary, exhibiting irregularities, asymmetry and fluctuations. These shapes are directly correlated to the laser beam shape profile. The following observations are made:

  • Collapse events terminate in formation of pores and metal mixing. This is visible in the experimental results presented in Fig. 6(a) and (b), where relatively large pores are observed in the experimental cross-section. With a narrow beam profile (weld configuration C1, C2, C3 and C5) and high energy density, once fusion of the Cu does happen, a surplus of energy flows through the keyhole, increasing the temperature at the keyhole bottom. This generates a recoil pressure that pushes the fluid upwards. At the top surface and rear side of the keyhole, the opposing movements of the fluid, both clockwise and counter-clockwise, and driven by the Marangoni force, have an important consequence: they restrict the size of the molten pool. This restriction creates a high viscosity mushy layer that forms a barrier that limits the expansion of the molten pool. As result, closure or narrowing the top neck of the keyhole restricts the ejection of vapours out of keyhole which leads to increase in pressure within keyhole and creates a high-pressure lob. This ultimately results in pores formed to the toe of the keyhole as seen in Fig. 7(a) and (b). Although a collapse event is observed in C3 as shown Fig. 7(c), it does not necessarily create porosity in the solid front as sufficient room is available for gas vapours to escape from the bottom of the keyhole. The introduction of a pre-heat heating beam in weld configuration C5 does not produce any significant change to the keyhole dynamics as observed in Fig. 7(d). In partial penetration, narrow and deep keyhole is more unstable as slight fluctuations in fluid pressure, velocity and temperature on the rear wall of keyhole can create a collapse event. Additionally, the collapse of the keyhole in partial penetration creates a narrower fluid channel, resulting in localized increase of fluid velocity, which, in turn, affects metal mixing.
  • Weld configuration C4 leads to wider opening of the keyhole with greater stability as shown in Fig. 7(e). With the super-imposition of the core beam with the wider ring-shaped beam, the core beam penetrates the steel sheet, while the larger ring keeps the keyhole open at the Cu surface. This weld configuration drastically reduces the collapse events and the development of bubbles. It can be observed that the lower depth-to-width aspect ratio of the melt pool correlates to fewer number of collapse events.
  • Metal mixing is not only influenced by keyhole dynamics and collapse events, but there is an intricate interplay between keyhole geometry, fluid dynamics and buoyancy forces that are dependent upon density which varies with temperature in molten pool, and from top to bottom due to differences in density between Cu and steel. To test the influence of buoyancy forces, a simulation test was performed where the density of Cu and steel were artificially set to be equal. Fig. 8 shows the simulation results and confirm that buoyancy forces have an impact on the metal mixing especially at the interface between the two metals and in the Cu side of the weld. For example, the line-scan B-B in Fig. 8 shows an increase on average of the Fe vol% in the Cu side by 10%, when comparing results with same densities.
Fig. 8. Impact of buoyancy forces on the metal mixing for weld configuration C3. Sections taken at Y= 0.
Fig. 7. Consecutive time steps of the molten pool dynamics for configuration C1 (a), C2 (b), C3 (c) C5 (d) and C4 (e). The plot shows the fluid velocity (both direction and magnitude) visualized by black arrows. Cross sections taken at Y= 0.

The introduction of a ring beam (weld configuration C4 with LBS#3) in the laser welding process alters the shape of the keyhole compared to a single beam scenario (weld configuration C1 with LBS#1). In the single beam case, the keyhole walls develops predominantly in Z direction (schematically illustrated in Fig. 9(a)). The inclusion of a ring beam results in the critical change of the keyhole wall’s curvature, with a pronounced arc-like shape at the rear (Fig. 9(b)). The change of keyhole wall’s curvature plays a critical role and is explained by the complex equilibrium between the fluid pressure, the recoil pressure and the gravity load. A collapse event is associated with the non-equilibrium of the forces in the X direction. To explain this, it is first worth noting that with an idealised static molten pool (no fluid velocity) the fluid pressure would be higher at the bottom and would be governed by the hydrostatic law – with this, the pressure variation occurs linearly downwards and would be a function of the molten pool depth. Under this ideal condition, the keyhole would exhibit a stable equilibrium regime driven by the balanced effect of recoil pressure and fluid flow. With the actual molten pool, the equilibrium state is, however, perturbated by the non-linear variation of the fluid pressure due to the fast upwards motion generated by the recoil pressure itself. A near-equilibrium state is eventually achieved with the change of keyhole wall’s curvature with the resultant of the forces acting predominantly in the Z direction. The shallow angle of the keyhole wall observed at LBS#3 (θ3 < θ1) effectively decomposes the combined forces exerted by the fluid towards the Z direction, hence moving to the near-equilibrium state, with the fluid pushed downwards in Z rather than sidewise in X. It can be observed that the ring-to-core diameter and the ring-to-core power are essential to control the keyhole wall’s curvature and ultimately influence of the stability of the keyhole.

Fig. 9. Schematic representation of forces and pressures acting on the melt pool in case of welding with single laser beam (LBS#1) and ring-core configuration (LBS#3). Arrows represent forces/pressures, and the thickness is proportional of the intensity of the forces/pressures. Arrows are only shown to the rear-side of the keyhole since the physics involved there are more relevant for the dynamics of the keyhole.

3.3. Impact of beam shaping on metal mixing

Cu and steel are generally immiscible as studied by other researchers, such as Shi et al. (2013). This separation means the material solidifies as two separate phases from the liquid state. At this immiscible region a Cu-rich (α phase) and iron-rich (β phase) form FCC and BCC crystal structures, respectively. For the compositional data shown in Fig. 6, the highest amount of mixing for each of the three examples is 60%, 80% and 50% of Fe in the weld pool. When studying the Cu-Fe binary phase diagram, as performed by Chen et al. (2007), these compositions fall within the miscibility gap range. For which no IMCs are expected to form, but instead separate (α and β) phases. However, it is still clear that the formation of these separate phases still creates a mismatch in mechanical properties of the welded joint, both at the interface and enriched regions, which can lead to crack initiation, as reported by Rinne et al. (2020). For this reason, analysing the metal-mixing in dissimilar metals is an important step toward understanding and prevention of cracking mechanisms that can affect the performance of the weld.
Influence of the beam shapes on the metal mixing, can be investigated by analysing velocity fields and fluid flow which are predicted with the validated model. Fig. 10(a) and (b) show that in the weld configuration C1 and C2 (corresponding to LBS#1 – single beam with circular spot and gaussian distribution) the increase in laser power leads to more steel mixing with Cu due to greater recoil pressure and to a larger melt pool with more liquid metal involved. When comparing the parameters in Fig. 11, the increased melting of the bottom steel sheet leads to a greater region of keyhole necking with collapse; this can be due to the increased laser absorption, for which steel has a greater absorptivity than the more reflective Cu (Rinne et al., 2020). The lower density of steel creates an upward buoyancy force which allows the migration of more steel into the Cu-rich region. Fig. 11(c) and (d) show weld configurations C3 and C4 respectively, with combined secondary ring-shaped and primary laser beam (LBS#2 and LBS#3, respectively). They can be compared based on similar levels of weld penetration but different width at the interface between parent metals and at the top of the weld seam. Spread of the laser power over a wider surface due to the use of a ring results in a wider weld pool compared to simulations C1 and C2, which is consistent with results found by Jabar et al. (2023). However, one difference between these two cases is that, due to different power density distributions, to achieve adequate weld penetration depth, different laser power is provided leading to different thermal fields and time that the metal stays liquid. Line-scans of the temperature profiles in the melt pool can be observed in Fig. 12, with higher peak temperature in C4, compared to simulations C1 and C2, and C5; whereas a smaller secondary ring-shaped laser beam in simulation C3 results in intermediate behaviour.

Fig. 10. Plots of metal mixing in the longitudinal and a cross sections predicted with simulations C1 (a), C2 (b), C3 (c), C4 (d) and C5 (e).
Fig. 11. (a) Temperature, (b) velocity, (c) Fe concentration and (d) actual melt pool for all the tested weld configurations C1 to C5. Cross sections taken at Y= 0.
Fig. 12. Temperature profiles for weld configurations C1 (a), C2 (b), C3 (c), C4 (d) and C5 (e). Measurements were taken at X = 1.3 mm (just behind the keyhole wall) and Z = −300 µm (interface between Cu and steel).

The higher peak temperature in C4 eventually leads to a significant thermal gradient that promotes significant upward buoyancy forces and ultimately more migration of steel towards the Cu matrix. Similarity of simulation C5 with C1 can be explained considering that the secondary laser beam pre-heats the metal without widening the keyhole. Additionally, the higher peak temperature and larger size of the melt pool in C4 lead to longer time in which the steel stays in the liquid phase with more time available to migrate toward the Cu matrix due to recoil pressure and buoyancy forces and to diffuse. For these reasons, if use of larger spot helps with keyhole stabilisation, higher laser power required to establish sound connection enhances mixing between parent metal. Therefore, selection of custom ring-to-core diameter and ring-to-core power is a decision with a trade-off between the need of stabilising the keyhole dynamics and the need to reduce the mixing.
Velocity fields in Fig. 11 show also that the use of the ring-shaped secondary beam (C4), results in lower recoil pressure due to less localised laser power and vaporization. For this reason, the fluid flow and velocity of the liquid movements in considerably lower, as shown by contour plots, where regions of the molten pool in red are those in which the flow of the liquid metal is faster. The metal mixing in the molten pool of C3 weld is more homogeneous than in C1 and C2, due to the localised heat input of the ring laser beam. Rinne et al. (2020) found the addition of the ring laser produced a more homogeneous distribution of Cu and steel in the solidified structure. The lower density of the steel can also be used to explain the more even distribution of steel throughout the weld pool of C3. This is also confirmed by the EDS line-scans in Fig. 6(c) that show a significant drop of Fe into the Cu matrix compared to C1 (Fig. 6(a)).
The result of metal mixing has a significant effect on the crack formation in the weld pool and heat-affected zone (HAZ). Two main types of cracking are often referred to as “hot cracking” (Rinne et al., 2020) or “liquation cracking” (Li et al., 2019). During any fusion welding process of Cu to steel the miscibility gap can be identified in the binary phase diagram of Cu-Fe (Chen et al., 2013). When both Cu and steel are melted, there is separation of the liquids during cooling, once the mixture enters the miscibility gap seen on the phase diagram the primary separation of the α and β phases occurs. The secondary separation occurs in the miscibility gap because of a lack of diffusion and a supersaturation of the α and/or β phases. The solidified weld microstructure is found inhomogeneous, consisting of the α and β phases. The difference in the thermal expansion properties of both Cu and steel can create locations of stress concentrations where cracks are often initiated, ad observed by Chen et al. (2013) and Sadeghian and Iqbal (2022). Li et al. (2019) proposed a three-stage mechanism for the formation of liquation cracks in Cu to steel laser welds. The first stage was the penetration of Cu liquid into the grain boundaries of the steel, secondly, the Cu liquid surrounds the Cu phase creating a “film” of liquid in the grain boundary. This drastically reduces the cohesive forces between the grain boundaries due to the presence of the α phase. Cracking can then be initiated in a similar manner to that detailed earlier.

4. Conclusions

A combination of multi-physics CFD modelling results and experiments have been presented to study the impact of laser beam shaping on metal mixing and molten pool dynamics during LBW of Cu-to-steel for battery terminal-to-casing connections. The multi-physics model has been validated with ex-situ EDS element mapping and weld profile’s features. The model has provided useful insights about temperature and velocity fields, mixing mechanisms and dynamics of the keyhole, all of which are difficult to access via experiments due to technological difficulties. The major findings of the work are summarized below:

  • Metal mixing is largely influenced by the fluid dynamics via the Marangoni, buoyancy forces and recoil pressure. With a greater laser power, recoil pressure is increased, and this leads to more weld penetration and melting of steel. Additionally, spread of the laser power results in higher width of the fusion zone. Subsequently, the buoyance forces due to the different densities of steel and Cu contribute to the upward flow of steel towards Cu, and hence impact meaningfully to the mixing. This can be clearly observed in weld configurations C1 and C2.
  • Due to the collapse events of the keyhole wall, porosity formation was found in welds C1, C2 and C5. Furthermore, the collapse events create a narrow fluid channel, which results in localised surges in fluid velocity, therefore, promoting metal mixing. All in all, simulations revealed that increasing depth-to-width aspect ratio is correlated to higher frequency of collapse events in the keyhole. Therefore, stabilisation of the melt pool can be achieved with tailored laser beam shapes.
  • The study has pointed-out that the use of larger ring beam (configuration C4) helps with keyhole stabilisation, but at the same time leads to more laser power and higher temperature that contribute to the enhancement of mixing between parent metals. This poses a trade-off in the definition of a tailored ring-to-core diameter and the ring-to-core power. Analysis of the results showed that ring-to-core diameter (350–90 µm) and 30% of ring power (weld configuration C3) resulted in more stable dynamics of the keyhole, with significant reduction of collapse events, and ultimately controlled migration of steel towards Cu. Furthermore, compared to C4 (2500 W total power), the lower thermal gradient in C3 (1530 W total power) eventually leads to a reduction in the upward buoyancy forces.
  • The pre-heating approach with the tandem beam (C5) only led to local fusion of Cu and no significant improvement in keyhole stability was observed.
  • The combination of experiments and numerical modelling provides a powerful approach to understand complex fluid flow and metal mixing processes during laser keyhole welding. This helps to study mixing behaviour along with weld pool dynamics for selection of laser welding strategies with beam shaping in case of dissimilar material welding, especially in presence of miscibility gap at higher temperature as in case of Cu and steel.

References

Wave

Three-Dimensional Simulations of Subaerial Landslide-Generated Waves: Comparing OpenFOAM and FLOW-3D HYDRO Models

지표 산사태로 발생한 파랑의 3차원 시뮬레이션: OpenFOAM과 FLOW-3D HYDRO 모델 비교

Ramtin Sabeti, Mohammad Heidarzadeh, Alessandro Romano, Gabriel Barajas Ojeda & Javier L. Lara

Abstract


The recent destructive landslide tsunamis, such as the 2018 Anak Krakatau event, were fresh reminders for developing validated three-dimensional numerical tools to accurately model landslide tsunamis and to predict their hazards. In this study, we perform Three-dimensional physical modelling of waves generated by subaerial solid-block landslides, and use the data to validate two numerical models: the commercial software FLOW-3D HYDRO and the open-source OpenFOAM package. These models are key representatives of the primary types of modelling tools—commercial and open-source—utilized by scientists and engineers in the field. This research is among a few studies on 3D physical and numerical models for landslide-generated waves, and it is the first time that the aforementioned two models are systematically compared. We show that the two models accurately reproduce the physical experiments and give similar performances in modelling landslide-generated waves. However, they apply different approaches, mechanisms and calibrations to deliver the tasks. It is found that the results of the two models are deviated by approximately 10% from one another. This guide helps engineers and scientists implement, calibrate, and validate these models for landslide-generated waves. The validity of this research is confined to solid-block subaerial landslides and their impact in the near-field zone.

1 Introduction and Literature Review


Subaerial landslide-generated waves represent major threats to coastal areas and have resulted in destruction and casualties in several locations worldwide (Heller et al., 2016; Paris et al., 2021). Interest in landslide-generated tsunamis has risen in the last decade due to a number of devastating events, especially after the December 2018 Anak Krakatau tsunami which left a death toll of more than 450 people (Grilli et al., 2021; Heidarzadeh et al., 2020a). Another significant subaerial landslide tsunami occurred on 16 October 1963 in Vajont dam reservoir (Northern Italy), when an impulsive landslide-generated wave overtopped the dam, killing more than 2000 people (Heller & Spinneken, 2013; Panizzo et al., 2005). The largest tsunami run-up (524 m) was recorded in Lituya Bay landslide tsunami event in 1958 where it killed five people (Fritz et al., 2009).

To achieve a better understanding of subaerial landslide tsunamis, laboratory experiments have been performed using two- and three-dimensional (2D, 3D) set-ups (Bellotti & Romano, 2017; Di Risio et al., 2009; Fritz et al., 2004; Romano et al., 2013; Sabeti & Heidarzadeh, 2022a). Results of physical models are essential to shed light on the nonlinear physical phenomena involved. Furthermore, they can be used to validate numerical models (Fritz et al., 2009; Grilli & Watts, 2005; Liu et al., 2005; Takabatake et al., 2022). However, the complementary development of numerical tools for modelling of landslide-generated waves is inevitable, as these models could be employed to accelerate understanding the nature of the processes involved and predict the detailed outcomes in specific areas (Cremonesi et al. 2011). Due to the high flexibility of numerical models and their low costs in comparison to physical models, validated numerical models can be used to replicate actual events at a fair cost and time (e.g., Cecioni et al., 2011; Grilli et al., 2017; Heidarzadeh et al., 2020b, 2022; Horrillo et al., 2013; Liu et al., 2005; Løvholt et al., 2005; Lynett & Liu, 2005).

Table 1 lists some of the existing numerical models for landslide tsunamis although the list is not exhaustive. Traditionally, Boussinesq-type models, and Shallow water equations have been used to simulate landslide tsunamis, among which are TWO-LAYER (Imamura and Imteaz,1995), LS3D (Ataie-Ashtiani & Najafi Jilani, 2007), GLOBOUSS (Løvholt et al., 2017), and BOUSSCLAW (Kim et al., 2017). Numerical models that solve Navier–Stokes equations showed good capability and reliability to simulate subaerial landslide-generated waves (Biscarini, 2010). Considering the high computational cost of solving the full version of Navier–Stokes equations, a set of methods such as RANS (Reynolds-averaged Navier–Stokes equations) are employed by some existing numerical models (Table 1), which provide an approximate averaged solution to the Navier–Stokes equations in combination with turbulent models (e.g., k–ε, k–ω). Multiphase flow models were used to simulate the complex dynamics of landslide-generated waves, including scenarios where the landslide mass is treated as granular material, as in the work by Lee and Huang (2021), or as a solid block (Abadie et al., 2010). Among the models listed in Table 1, FLOW-3D HYDRO and OpenFOAM solve Navier–Stokes equations with different approaches (e.g., solving the RANS by IHFOAM) (Paris et al., 2021; Rauter et al., 2022). They both offer a wide range of turbulent models (e.g., Large Eddy Simulation—LES, k–ε, k–ω model with Renormalization Group—RNG), and they both use the VOF (Volume of Fluid) method to track the water surface elevation. These similarities are one of the motivations of this study to compare the performance of these two models. Details of governing equations and numerical schemes are discussed in the following.

Numerical modelsApproachDeveloper
FLOW-3D HYDROThis CFD package solves Navier–Stokes equations using finite-difference and finite volume approximations, along with Volume of Fluid (VOF) method for tracking the free surfaceFlow Science, Inc. (https://www.flow3d.com/)
MIKE 21This model is based on the numerical solution of 2D and 3D incompressible RANS equations subject to the assumptions of Boussinesq and hydrostatic pressureDanish Hydraulic Institute (DHI) (https://www.mikepoweredbydhi.com/products/mike-21-3)
OpenFOAM (IHFOAM solver)IHFOAM is a newly developed 3D numerical two-phase flow solver. Its core is based on OpenFOAM®. IHFOAM can also solve two-phase flow within porous media using RANS/VARANS equationsIHCantabria research institute (https://ihfoam.ihcantabria.com/)
NHWAVENHWAVE is a 3D shock-capturing non-Hydrostatic model which solves the incompressible Navier–Stokes equations in terrain and surface-following sigma coordinatesKirby et al. (2022) (https://sites.google.com/site/gangfma/nhwave, https://github.com/JimKirby/NHWAVE)
GLOBOUSSGloBouss is a depth-averaged model based on the standard Boussinesq equations including higher order dispersion terms, Coriolis terms, and numerical hydrostatic correction termsLøvholt et al. (2022) (https://www.duo.uio.no/handle/10852/10184)
BOUSSCLAWBoussClaw is a new hybrid Boussinesq type model which is an extension of the GeoClaw model. It employs a hybrid of finite volume and finite difference methods to solve Boussinesq equationsClawpack Development Team (http://www.clawpack.org/)Kim et al. (2017)
THETIS-MUITHETIS is a multi-fluid Navier–Stokes solver which can be considered a one-fluid model as only one velocity is defined at each point of the mesh and there is no mixing between the three considered fluids (water, air, and slide). It applies VOF methodTREFLE department of the I2M Laboratory at Bordeaux, France (https://www.i2m.u-bordeaux.fr/en)
LS3DA 2D depth-integrated numerical model which applies a fourth-order Boussinesq approximation for an arbitrary time-variable bottom boundaryAtaie-Ashtiani and Najafi Jilani (2007)
LYNETT- Mild-Slope Equation (MSE)MSE is a depth-integrated version of the Laplace equation operating under the assumption of inviscid flow and mildly varying bottom slopesLynett and Martinez (2012)
Tsunami 3DA simplified 3D Navier–Stokes model for two fluids (water and landslide material) using VOF for tracking of water surfaceHorrillo et al. (2013)Kim et al. (2020)
(Cornell Multi-grid Coupled Tsunami Mode (COMCOT)COMCOT adopts explicit staggered leap-frog finite difference schemes to solve Shallow Water Equations in both Spherical and Cartesian CoordinatesLiu et al. (1998); Wang and Liu (2006)
TWO-LAYERA mathematical model for a two-layer flow along a non-horizontal bottom. Conservation of mass and momentum equations are depth integrated in each layer, and nonlinear kinematic and dynamic conditions are specified at the free surface and at the interface between fluidsImamura and Imteaz (1995)
Table 1 Some of the existing numerical models for simulating landslide-generated waves

In this work, we apply two Computational Fluid Dynamic (CFD) frameworks, FLOW-3D HYDRO, and OpenFOAM to simulate waves generated by solid-block subaerial landslides in a 3D set-up. We calibrate and validate both numerical models using our physical experiments in a 3D wave tank and compare the performances of these models systematically. These two numerical models are selected among the existing CFD solvers because they have been reported to provide valuable insights into landslide-generated waves (Kim et al., 2020; Romano et al., 2020a, b ; Sabeti & Heidarzadeh, 2022a). As there is no study to compare the performances of these two models (FLOW-3D HYDRO and OpenFOAM) with each other in reproducing landslide-generated waves, this study is conducted to offer such a comparison, which can be helpful for model selection in future research studies or industrial projects. In the realm of tsunami generation by subaerial landslides, the solid-block approach serves as an effective representative for scenarios where the landslide mass is more cohesive and rigid, rather than granular. This methodology is particularly relevant in cases such as the 2018 Anak Krakatau or 1963 Vajont landslides, where the landslide’s nature aligns closely with the characteristics simulated by a solid-block model (Zaniboni & Tinti, 2014; Heidarzadeh et al., 2020a, 2020b).

The objectives of this research are: (i) To provide a detailed implementation and calibration for simulating solid-block subaerial landslide-generated waves using FLOW-3D HYDRO and OpenFOAM, and (ii) To compare the performance of these two numerical models based on three criteria: free surface elevation of the landslide-generated waves, capabilities of the models in simulating 3D features of the waves in the near-field, velocity fields, and velocity variations at different locations. The innovations of this study are twofold: firstly, it is a 3D study involving physical and numerical modelling and thus the data can be useful for other studies, and secondly, it compares the performance of two popular CFD models in modelling landslide-generated waves for the first time. The validated models such as those reported in this study and comparison of their performances can be useful for engineers and scientists addressing landslide tsunami hazards worldwide.

2 Data and Methods


2.1 Physical Modelling

To validate our numerical models, a series of three-dimensional physical experiments were carried out at the Hydraulic Laboratory of the Brunel University London (UK) in a 3D wave tank 2.40 m long, 2.60 m wide, and 0.60 m high (Figs. 1 and 2). To mitigate experimental errors and enhance the reliability of our results, each physical experiment was conducted three times. The reported data in the manuscript reflects the average of these three trials, assuming no anomalous outliers, thus ensuring an accurate reflection of the experimental tests. One experiment was used for validation of our numerical models. The slope angle (α) and water depth (h) were 45° and 0.246 m, respectively for this experiment. The movement of the sliding mass was recorded by a digital camera with a sampling frequency of 120 frames per second, which was used to calculate the slide impact velocity (vs). The travel distance (D), defined as the distance from the toe of the sliding mass to the water surface, was D=0.045 m. The material of the solid block used in our study was concrete with a density of 2600 kg/m3. Table 2 provides detailed information on the dimensions and kinematics of this solid block used in our physical experiments.

Figure 1. The geometrical and kinematic parameters of a subaerial landslide tsunami. Parameters are: h, water depth; aM, maximum wave amplitude; α, slope angle;vs, slide velocity; ls, length of landslide; bs, width of landslide; s, thickness of landslide; SWL, still water level; D, travel distance (the distance from the toe of the sliding mass to the water surface); L, length of the wave tank; and W, width of the wave tank and H, is the hight of the wave tank

Figure 2. a Wave tank setup of the physical experiments of this study. b Numerical simulation setup for the FLOW-3D HYDRO Model. c The numerical set-up for the OpenFOAM model. The location of the physical wave gauge (represented by numerical gauge WG-3 in the numerical simulations) is at X = 1.03 m, Y = 1.21 m, and Z = 0.046 m. d Top view showing the locations of numerical wave gauges (WG-1, WG-2, WG-3, WG-4, WG-5)
Parameter, unitValue/type
Slide width (bs), m0.26
Slide length (ls), m0.20
Slide thickness (s), m0.10
Slide volume (V), m32.60 × 10–3
Specific gravity, (γs)2.60
Slide weight (ms), kg6.86
Slide impact velocity (vs), m/s1.84
Slide Froude number (Fr)1.18
MaterialConcrete
Table 2 Geometrical and kinematic information of the sliding mass used for physical experiments in this study

We took scale effects into account during physical experiments by considering the study by Heller et al. (2008) who proposed a criterion for avoiding scale effects. Heller et al. (2008) stated that the scale effects can be negligible as long as the Weber number (W=ρgh2/σ; where σ is surface tension coefficient) is greater than 5.0 × 103 and the Reynolds number (R=g0.5h1.5/ν; where ν is kinematic viscosity) is greater than 3.0 × 105 or water depth (h) is approximately above 0.20 m. Considering the water temperature of approximately 20 °C during our experiments, the kinematic viscosity (ν) and surface tension coefficient (σ) of water become 1.01 × 10–6 m2/s and 0.073 N/m, respectively. Therefore, the Reynolds and Weber numbers were as R= 3.8 × 105 and W= 8.1 × 105, indicating that the scale effect can be insignificant in our experiments. To record the waves, we used a twin wire wave gauge provided by HR Wallingford (https://equipit.hrwallingford.com). This wave gauge was placed at X = 1.03 m, Y = 1.21 m based on the coordinate system shown in Fig. 2a.

2.2 Numerical Simulations

The numerical simulations in this work were performed employing two CFD packages FLOW-3D HYDRO, and OpenFOAM which have been widely used in industry and academia (e.g., Bayon et al., 2016; Jasak, 2009; Rauter et al., 2021; Romano et al., 2020a, b; Yin et al., 2015).

2.2.1 Governing Equations and Turbulent Models

2.2.1.1 FLOW-3D HYDRO

The FLOW-3D HYDRO solver is based on the fundamental law of mass, momentum and energy conservation. To estimate the influence of turbulent fluctuations on the flow quantities, it is expressed by adding the diffusion terms in the following mass continuity and momentum transport equations:

quation (1) is the general mass continuity equation, where u is fluid velocity in the Cartesian coordinate directions (x), Ax is the fractional area open to flow in the x direction, VF is the fractional volume open to flow, ρ is the fluid density, R and ξ are coefficients that depend on the choice of the coordinate system. When Cartesian coordinates are used, R is set to unity and ξ is set to zero. RDIF and RSOR are the turbulent diffusion and density source terms, respectively. Uρ=Scμ∗/ρ, in which Sc is the turbulent Schmidt number, μ∗ is the dynamic viscosity, and ρ is fluid density. RSOR is applied to model mass injection through porous obstacle surfaces.

The 3D equations of motion are solved with the following Navier–Stokes equations with some additional terms:

where t is time, Gx is accelerations due to gravity, fx is viscous accelerations, and bx is the flow losses in porous media.

According to Flow Science (2022), FLOW-3D HYDRO’s turbulence models differ slightly from other formulations by generalizing the turbulence production with buoyancy forces at non-inertial accelerations and by including the influence of fractional areas/volumes of the FAVOR method (Fractional Area-Volume Obstacle Representation) method. Here we use k–ω model for turbulence modelling. The k–ω model demonstrates enhanced performance over the k-ε and Renormalization-Group (RNG) methods in simulating flows near wall boundaries. Also, for scenarios involving pressure changes that align with the flow direction, the k–ω model provides more accurate simulations, effectively capturing the effects of these pressure variations on the flow (Flow Science, 2022). The equations for turbulence kinetic energy are formulated as below based on Wilcox’s k–ω model (Flow Science, 2022):

where kT is turbulent kinetic energy, PT is the turbulent kinetic energy production, DiffKT is diffusion of turbulent kinetic energy, GT is buoyancy production, β∗=0.09 is closure coefficient, and ω is turbulent frequency.

2.2.1.2 OpenFOAM

For the simulations conducted in this study, OpenFOAM utilizes the Volume-Averaged RANS equations (VARANS) to enable the representation of flow within porous material, treated as a continuous medium. The momentum equation incorporates supplementary terms to accommodate frictional forces from the porous media. The mass and momentum conservation equations are linked to the VOF equation (Jesus et al., 2012) and are expressed as follows:

where the gravitational acceleration components are denoted bygj. The term u¯i=1Vf∫Vf0ujdV represents the volume averaged ensemble averaged velocity (or Darcy velocity) component, Vf is the fluid volume contained in the average volumeV,τ is the surface tension constant (assumed to be 1 for the water phase and 0 for the air phase), and fσi is surface tension, defined as fσi=σκ∂α∂xi, where σ (N/m) is the surface tension constant and κ (1/m) is the curvature (Brackbill et al., 1992). μeff is the effective dynamic viscosity that is defined as μeff=μ+ρνt and takes into account the dynamic molecular (μ) and the turbulent viscosity effects (ρνt). νt is eddy viscosity, which is provided by the turbulence closure model. n is the porosity, defined as the volume of voids over total volume, and P∗=1Vf∫∂Vf0P∗dS is the ensemble averaged pressure in excess of hydrostatic pressure. The coefficient A accounts for the frictional force induced by laminar Darcy-type flow, B considers the frictional force under turbulent flow conditions, and c accounts for the added mass. These coefficients (A,B, and c) are defined based on the work of Engelund (1953) and later modified by Van Gent (1995) as given below:

where D50 is the mean nominal diameter of the porous material, KC is the Keulegan–Carpenter number, a and b are empirical nondimensional coefficients (see Lara et al., 2011; Losada et al., 2016) and γ = 0.34 is a nondimensional parameter as proposed by Van Gent (1995). The k-ω Shear Stress Transport (SST) turbulence is employed to capture the effect of turbulent flow conditions (Zhang & Zhang, 2023) with the enhancement proposed by Larsen and Fuhrman (2018) for the over-production of turbulence beneath surface waves. Boundary layers are modelled with wall functions. The reader is referred to Larsen and Fuhrman (2018) for descriptions, validations, and discussions of the stabilized turbulence models.

2.2.2 FLOW-3D HYDRO Simulation Procedure

In our specific case in this study, FLOW-3D HYDRO utilizes the finite-volume method to numerically solve the equations described in the previous Sect. 2.2.1.1, ensuring a high level of accuracy in the computational modelling. The use of structured rectangular grids in FLOW-3D HYDRO offers the advantages of easier development of numerical methods, greater transparency in their relation to physical problems, and enhanced accuracy and stability of numerical solutions. (Flow Science, 2022). Curved obstacles, wall boundaries, or other geometric features are embedded in the mesh by defining the fractional face areas and fractional volumes of the cells that are open to flow (the FAVOR method). The VOF method is employed in FLOW-3D HYDRO for accurate capturing of the free-surface dynamics (Hirt and Nichols 1981). This approach then is upgraded to method of the TruVOF which is a split Lagrangian method that typically produces lower cumulative volume error than the alternative methods (Flow Science, 2022).

For numerical simulation using FLOW-3D HYDRO, the entire flow domain was 2.60 m wide, 0.60 m deep and 2.50 m long (Fig. 2b). The specific gravity (γs) for solid blocks was set to 2.60 in our model, aligning closely with the density of the actual sliding mass, which was approximately determined in our physical experiments. The fluid medium was modelled as water with a density of 1000 kg/m3 at 20 °C. A uniform grid comprising of one single mesh plane was applied with a grid size of 0.005 m. The top, front and back of the mesh areas were defined as symmetry, and the other surfaces were of wall type with no-slip conditions around the walls.

To simulate turbulent flows, k-ω model was used because of its accuracy in modelling turbulent flows (Menter 1992). Landslide movement was replicated in simulations using coupled motion objects, which implies that the movement of landslides is based on gravity and the friction between surfaces rather than a specified motion in which the model should be provided by force and torques. The time intervals of the numerical model outputs were set to 0.02 s to be consistent with the actual sampling rates of our wave gauges in the laboratory. In order to calibrate the FLOW-3D HYDRO model, the friction coefficient is set to 0.45, which is consistent with the Coulombic friction measurements in the laboratory. The Courant Number (C=UΔtΔx) is considered as the criterion for the stability of numerical simulations which gives the maximum time step (Δt) for a prespecified mesh size (Δx) and flow speed (U). The Courant number was always kept below one.

2.2.3 OpenFOAM Simulation Procedure

OpenFOAM is an open-source platform containing several C++ libraries which solves both 3D Reynolds-Averaged Navier–Stokes equations (RANS) and Volume-Averaged RANS equations (VARANS) for two-phase flows (https://www.openfoam.com/documentation/user-guide). Its implementation is based on a tensorial approach using object-oriented programming techniques and the Finite Volume Method (McDonald 1971). In order to simulate the subaerial landslide-generated waves, the IHFOAM solver based on interFoam (Higuera et al., 2013a, 2013b), and the overset mesh framework method are employed. The implementation of the overset mesh method for porous mediums in OpenFOAM is described in Romano et al. (2020a, b) for submerged rigid and impermeable landslides.

The overset mesh technique, as outlined by Romano et al. (2020a, b), uses two distinct domains: a moving domain that captures the dynamics of the rigid landslide and a static background domain to characterize the numerical wave tank. The overlapping of these domains results in a composite mesh that accurately depicts complex geometrical transformations while preserving mesh quality. A porous media with a very low permeability (n = 0.001) was used to simulate the impermeable sliding surfaces. RANS equations were solved within the porous media. The Multidimensional Universal Limiter with Explicit Solution (MULES) algorithm is employed for solving the (VOF) equation, ensuring precision in tracking fluid interfaces. Simultaneously, the PIMPLE algorithm is employed for the effective resolution of velocity–pressure coupling in the Eqs. 7 and 8. A background domain was created to reproduce the subaerial landslide waves with dimensions 2.50 m (x-direction) × 2.60 m (y-direction) × 0.6 m (z-direction) (Fig. 2c). The grid size is set to 0.005 m for the background mesh. A moving domain was applied in an area of 0.35 m (x-direction) × 0.46 m (y-direction) × 0.32 m (z-direction) with a grid spacing of 0.005 m and applying a body-fitted mesh approach, which contains the rigid and impermeable wedges. Wall condition with No-slip is defined as the boundary for the four side walls (left, right, front and back, in Fig. 1). Also, a non-slip boundary condition is specified to the bottom, whereas the top boundary is defined as open. The experimental slide movement time series is used to model the landslide motion in OpenFOAM. The applied equation is based on the analytical solution by Pelinovsky and Poplavsky (1996) which was later elaborated by Watts (1998). The motion of a sliding rigid body is governed by the following equation:

where, m represents the mass of the landslide, s is the displacement of the landslide down the slope, t is time elapsed, g stands for the acceleration due to gravity, θ is the slope angle, Cf is the Coulomb friction coefficient, Cm is the added mass coefficient, m0 denotes the mass of the water displaced by the moving landslide, A is the cross-sectional area of the landslide perpendicular to the direction of motion, ρ is the water density, and Cd is the drag coefficient.

2.2.4 Mesh Sensitivity Analysis

In order to find the most efficient mesh size, mesh sensitivity analyses were conducted for both numerical models (Fig. 3). We considered the influence of mesh density on simulated waveforms by considering three mesh sizes (Δx) of 0.0025 m, 0.005 m and 0.010 m. The results of FLOW-3D HYDRO revealed that the largest mesh deviates 9% (Fig. 3a, Δx = 0.0100 m) from two other finer meshes. Since the simulations by FLOW-3D HYDRO for the finest mesh (Δx = 0.0025 m) do not show any improvements in comparison with the 0.005 m mesh, therefore the mesh with the size of Δx = 0.0050 m is used for simulations (Fig. 3a). A similar approach was followed for mesh sensitivity of OpenFOAM mesh grids. The mesh with the grid spacing of Δx = 0.0050 m was selected for further simulations since a satisfactory independence was observed in comparison with the half size mesh (Δx = 0.0025 m). However, results showed that the mesh size with the double size of the selected mesh (Δx = 0.0100 m) was not sufficiently fine to minimize the errors (Fig. 3b).

Figure 3. ab Sensitivity of numerical simulations to the sizes of the mesh (Δx) for FLOW-3D HYDRO, and OpenFOAM, respectively. The location of the wave gauge 3 (WG-3) is at X = 1.03 m, Y = 1.21 m, and Z = -0.55 m (see Fig. 2d)

In terms of computational cost, the time required for 2 s simulations by FLOW-3D HYDRO is approximately 4.0 h on a PC Intel® Core™ i7-8700 CPU with a frequency of 3.20 GHz equipped with a 32 GB RAM. OpenFOAM requires 20 h to run 2 s of numerical simulation on 2 processors on a PC Intel® Core™ i9-9900KF CPU with a frequency of 3.60 GHz equipped with a 364 GB RAM. Differences in computational time for simulations run with FLOW-3D HYDRO and OpenFOAM reflect the distinct characteristics of each numerical methods, and the specific hardware setups.

2.2.5 Validation

We validated both numerical models based on our laboratory experimental data (Fig. 4). The following criterion was used to assess the level of agreement between numerical simulations and laboratory observations:

where ε is the mismatch error, Obsi is the laboratory observation values, Simi is the simulation values, and the mathematical expression |X| represents the absolute value of X. The slope angle (α), water depth (h) and travel distance (D) were: α = 45°, h = 0.246 m and D = 0.045 m in both numerical models, consistent with the physical model. We find the percentage error between each simulated data point and its corresponding observed value, and subsequently average these errors to assess the overall accuracy of the simulation against the observed time series. Our results revealed that the mismatch errors between physical experiments and numerical models for the FLOW-3D HYDRO and OpenFOAM are 8% and 18%, respectively, indicating that our models reproduce the measured waveforms satisfactorily (Fig. 4). The simulated waveform by OpenFOAM shows a minor mismatch at t = 0.76 s which resulted from a droplet immediately after the slide hits the water surface in the splash zone. In term of the maximum negative amplitude, the simulated waves by OpenFOAM indicates a relatively better performance than FLOW-3D HYDRO, whereas the maximum positive amplitude (aM) simulated by FLOW-3D HYDRO is closer to the experimental value. The recorded maximum positive amplitude in physical experiment is 0.022 m, whereas it is 0.020 m for FLOW-3D HYDRO and 0.017 m for OpenFOAM simulations. In acknowledging the deviations observed, it is pertinent to highlight that while numerical models offer robust insights, the difference in meshing techniques and the distinct computational methods to resolve the governing equations in FLOW-3D HYDRO and OpenFOAM have contributed to the variance. Moreover, the intrinsic uncertainties associated with the physical experimentation process, including the precision of wave gauges and laboratory conditions, are non-negligible factors influencing the results.

Figure 4. Validation of the simulated waves (brown line for FLOW-3D HYDRO and green line for OpenFOAM) using the laboratory-measured waves (black solid diamonds). This physical experiment was conducted for wave gauge 3 (WG-3) located at X = 1.03 m, Y = 1.21 m, and Z = -0.55 m (see Fig. 2d). Here, 
ε shows the errors between simulations and actual physical measurements using Eq. (13)

3 Results


Following the validations of the two numerical models (FLOW-3D HYDRO and OpenFOAM), a series of simulations were performed to compare the performances of these two CFD solvers. The generation process of landslide waves, waveforms, and velocity fields are considered as the basis for comparing the performance of the two models (Figs. 5, 6, 7 and 8).

Figure 5.Comparison between the simulated waveforms by FLOW-3D HYDRO (black) and OpenFOAM (red) at four different locations in the near-field zone (WG-1,2,4 and 5). WG is the abbreviation for wave gauge. The mismatch (Δ) between the two models at each wave gauge is calculated using Eq. (14)
Figure 6. Comparison of water surface elevations produced by solid-block subaerial landslides for the two numerical models FLOW-3D-HYDRO (ac) and OpenFOAM (e–g) at different times
Figure 7. Snapshots of the simulations at different times for FLOW-3D HYDRO (ac) and OpenFOAM (eg) showing velocity fields (colour maps and arrows). The colormaps indicate water particle velocity in m/s, and the lines indicate the velocities of water particles
Figure 8. Comparison of velocity variations at (WG-3) for FLOW-3D HYDRO (light blue) and OpenFOAM (brown)

3.1 Comparison of Waveforms

Five numerical wave gauges were placed in our numerical models to measure water surface oscillations in the near-field zone (Fig. 5). These gauges offer an azimuthal coverage of 60° (Fig. 2d). Figure 5 reveals that the simulated waveforms from two models (FLOW-3D HYDRO and OpenFOAM) are similar. The highest wave amplitude (aM) is recorded at WG-3 for both models, whereas the lowest amplitude is recorded at WG-5 and WG-1 which can be attributed to the longer distances of these gauges from the source region as well as their lateral offsets, resulting in higher wave energy dissipation at these gauges. The sharp peaks observed in the simulated waveforms, such as the red peak between 0.8–1.0 s in Fig. 5a from OpenFOAM, the red peak between 0.6–0.8 s in Fig. 5b also from OpenFOAM, and the black peak between 1.4–1.6 s in Fig. 5d from FLOW-3D HYDRO, are due to the models’ spatial and temporal discretization. They reflect the sensitivity of the models to capturing transient phenomena, where the chosen mesh and time-stepping intervals are key factors in the models’ ability to track rapid changes in the flow field. To quantify the deviations of the two models from one another, we apply the following equation for mismatch calculation:

where Δ is the mismatch error, Sim1 is the simulation values from FLOW-3D HYDRO, Sim2 is the simulation values from OpenFOAM, and the mathematical expression |X| implies the absolute value of X. We calculate the percentage difference for each corresponding pair of simulation results, then take the mean of these percentage differences to determine the average deviation between the two simulation time series. Using Eq. (14), we found a deviation range from 9 to 11% between the two models at various numerical gauges (Fig. 5), further confirming that the two models give similar simulation results.

3.2 Three-Dimensional Vision of Landslide Generation Process by Numerical Models

A sequence of four water surface elevation snapshots at different times is shown in Fig. 6 for both numerical modes. In both simulations, the sliding mass travels a constant distance of 0.045 m before hitting the water surface at t = 0.270 s which induces an initial change in water surface elevation (Figs. 6a and e). At t = 0.420 s, the mass is fully immersed for both simulations and an initial dipole wave is generated (Figs. 6b and f). Based on both numerical models, the maximum positive amplitude (0.020 m for FLOW-3D HYDRO, and 0.017 m for OpenFOAM) is observed at this stage (Fig. 6). The maximum propagation of landslide-simulated waves along with more droplets in the splash zone could be seen at t = 0.670 s for both models (Fig. 6c and g). The observed distinctions in water surface elevation simulations as illustrated in Fig. 6 are rooted in the unique computational methodologies intrinsic to each model. In the OpenFOAM simulations, a more diffused water surface elevation profile is evident. Such diffusion is an outcome of the simulation’s intrinsic treatment of turbulent kinetic energy dissipation, aligning with the solver’s numerical dissipation characteristics. These traits are influenced by the selected turbulence models and the numerical advection schemes, which prioritize computational stability, possibly at the expense of interface sharpness. The diffusion in the wave pattern as rendered by OpenFOAM reflects the application of a turbulence model with higher dissipative qualities, which serves to moderate the energy retained during wave propagation. This approach can provide insights into the potential overestimation of energy loss under specific simulation conditions. In contrast, the simulations from FLOW-3D HYDRO depict a more localized wave pattern, indicative of a different approach to turbulent dissipation. This coherence in wave fronts is a function of the model’s specific handling of the air–water interface and its targeted representation of the energy dynamics resulting from the landslide’s interaction with the water body. They each have specific attributes that cater to different aspects of wave simulation fidelity, thereby contributing to a more comprehensive understanding of the phenomena under study.

3.3 Wave Velocity Analysis

We show four velocity fields at different times during landslide motion in Fig. 7 and one time series of velocity (Fig. 8) for both numerical models. The velocity varies in the range of 0–1.9 m/s for both models, and the spatial distribution of water particle velocity appears to be similar in both. The models successfully reproduce the complex wavefield around the landslide generation area, which is responsible for splashing water and mixing with air around the source zone (Fig. 7). The first snapshot at t = 0.270 s (Fig. 7a and e) shows the initial contact of the sliding mass with water surface for both numerical models which generates a small elevation wave in front of the mass exhibiting a water velocity of approximately 1.2 m/s. The slide fully immerses for the first time at t = 0.420 s producing a water velocity of approximately 1.5 m/s at this time (Fig. 7b and f). The last snapshot (t = 0.670 s) shows 1.20 s after the slide hits the bottom of the wave tank. Both models show similar patterns for the propagation of the waves towards the right side of the wave tank. The differences in water surface profiles close to the slope and solid block at t = 0.67 s, observed in the FLOW-3D HYDRO and OpenFOAM simulations (Figs. 6 and 7), are due to the distinct turbulence models employed by each (RNG and k-ω SST, respectively) which handle the complex interactions of the landslide-induced waves with the structures differently. Additionally, the methods of simulating landslide movement further contribute to this discrepancy, with FLOW-3D HYDRO’s coupled motion objects possibly affecting the waves’ initiation and propagation unlike OpenFOAM’s prescribed motion from experimental data. In addition to the turbulence models, the variations in VOF methodologies between the two models also contribute to the observed discrepancies.

For the simulated time series of velocity, both models give similar patterns and close maximum velocities (Fig. 8). For both models the WG-3 located at X = 1.03 m, Y = 1.21 m, and Z = − 0.55 m (Fig. 2d) were used to record the time series. WG-3 is positioned 5 mm above the wave tank bottom, ensuring that the measurements taken reflect velocities very close to the bottom of the wave tank. The maximum velocity calculated by FLOW-3D HYDRO is 0.162 m/s while it is 0.132 m/s for OpenFOAM, implying a deviation of approximately 19% from one another. Some oscillations in velocity records are observed for both models, but these oscillations are clearer and sharper for OpenFOAM. Although it is hard to see velocity oscillations in the FLOW-3D HYDRO record, a close look may reveal some small oscillations (around t = 0.55 s and 0.9 s in Fig. 8). In fact, velocity oscillations are expected due to the variations in velocity of the sliding mass during the travel as well as due to the interferences of the initial waves with the reflected wave from the beach. In general, it appears that the velocity time series of the two models show similar patterns and similar maximum values although they have some differences in the amplitudes of the velocity oscillations. The differences between the two curves are attributed to factors such as difference in meshing between the two models, turbulence models, as well as the way that two models record the outputs.

4 Discussions


An important step for CFD modelling in academic or industrial projects is the selection of an appropriate numerical model that can deliver the task with satisfactory performance and at a reasonable computational cost. Obviously, the major drivers when choosing a CFD model are cost, capability, flexibility, and accessibility. In this sense, the existing options are of two types as follows:

  • Commercial models, such as FLOW-3D HYDRO, which are optimised to solve free-surface flow problems, with customer support and an intuitive Graphical User Interface (GUI) that significantly facilitates meshing, setup, simulation monitoring, visualization, and post-processing. They usually offer high-quality customer support. Although these models show high capabilities and flexibilities for numerical modelling, they are costly, and thus less accessible.
  • Open-source models, such as OpenFOAM, which come without a GUI but with coded tools for meshing, setup, parallel running, monitoring, post-processing, and visualization. Although these models offer no customer support, they have a big community support and online resources. Open-source models are free and widely accessible, but they may not be necessarily always flexible and capable.

OpenFOAM provides freedom for experimenting and diving through the code and formulating the problem for a user whereas FLOW-3D HYDRO comes with high-level customer supports, tutorial videos and access to an extensive set of example simulations (https://www.flow3d.com/). While FLOW-3D-HYDRO applies a semi-automatic meshing process where users only need to input the 3D model of the structure, OpenFOAM provides meshing options for simple cases, and in many advanced cases, users need to create the mesh in other software (e.g., ANSYS) (Ariza et al., 2018) and then convert it to OpenFOAM format. Auspiciously, there are numerous online resources (https://www.openfoam.com/trainings/about-trainings), and published examples for OpenFOAM (Rauter et al., 2021; Romano et al., 2020a, b; Zhang & Zhang, 2023).

The capabilities of both FLOW-3D HYDRO and OpenFOAM to simulate actual, complex landslide-generated wave events have been showcased in significant case studies. The study by Ersoy et al. (2022) applied FLOW-3D HYDRO to simulate impulse waves originating from landslides near an active fault at the Çetin Dam Reservoir, highlighting the model’s capacity for detailed, site-specific modelling. Concurrently, the work by Alexandre Paris (2021) applied OpenFOAM to model the 2017 Karrat Fjord landslide tsunami events, providing a robust validation of OpenFOAM’s utility in capturing the dynamics of real-world geophysical phenomena. Both instances exemplify the sophisticated computational approaches of these models in aiding the prediction and analysis of natural hazards from landslides.

As for limitations of this study, we acknowledge that our numerical models are validated by one real-world measured wave time series. However, it is believed that this one actual measurement was sufficient for validation of this study because it was out of the scope of this research to fully validate the FLOW-3D HYDRO and OpenFOAM models. These two models have been fully validated by more actual measurements by other researchers in the past (e.g., Sabeti & Heidarzadeh, 2022b). It is also noted that some of the comparisons made in this research were qualitative, such as the 3D wave propagation snapshots, as it was challenging to develop quantitative comparisons for snapshots. Another limitation of this study concerns the number of tests conducted here. We fixed properties such as water depth, slope angle, and travel distance throughout this study because it was out of the scope of this research to perform sensitivity analyses.

5 Conclusions


We configured, calibrated, validated and compared two numerical models, FLOW-3D HYDRO, and OpenFOAM, using physical experiments in a 3D wave tank. These validated models were used to simulate subaerial solid-block landslides in the near-field zone. Our results showed that both models are fully compatible with investigating waves generated by subaerial landslides, although they use different approaches to simulate the phenomenon. The properties of solid-block, water depth, slope angle, and travel distance were kept constant in this study as we focused on comparing the performance of the two models rather than conducting a full sensitivity analysis. The findings are as follows:

  • Different settings were used in the two models for modelling landslide-generated waves. In terms of turbulent flow modelling, we used the Renormalization Group (RNG) turbulence model in FLOW-3D HYDRO, and k-ω (SST) turbulence model in OpenFOAM. Regarding meshing techniques, the overset mesh method was used in OpenFOAM, whereas the structured cartesian mesh was applied in FLOW-3D HYDRO. As for simulation of landslide movement, the coupled motion objects method was used in FLOW-3D HYDRO, and the experimental slide movement time series were prescribed in OpenFOAM.
  • Our modelling revealed that both models successfully reproduced the physical experiments. The two models deviated 8% (FLOW-3D HYDRO) and 18% (OpenFOAM) from the physical experiments, indicating satisfactory performances. The maximum water particle velocity was approximately 1.9 m/s for both numerical models. When the simulated waveforms from the two numerical models are compared with each other, a deviation of 10% was achieved indicating that the two models perform approximately equally. Comparing the 3D snapshots of the two models showed that there are some minor differences in reproducing the details of the water splash in the near field.
  • Regarding computational costs, FLOW-3D HYDRO was able to complete the same simulations in 4 h as compared to nearly 20 h by OpenFOAM. However, the hardware that were used for modelling were not the same; the computer used for the OpenFOAM model was stronger than the one used for running FLOW-3D HYDRO. Therefore, it is challenging to provide a fair comparison for computational time costs.
  • Overall, we conclude that the two models give approximately similar performances, and they are both capable of accurately modelling landslide-generated waves. The choice of a model for research or industrial projects may depend on several factors such as availability of local knowledge of the models, computational costs, accessibility and flexibilities of the model, and the affordability of the cost of a license (either a commercial or an open-source model).

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Weir

Discharge Formula and Hydraulics of Rectangular Side Weirs in the Small Channel and Field Inlet

소규모 수로 및 유입구에서의 직사각형 측면 위어의 유량 공식 및 수리학

Yingying Wang, Mouchao Lv, Wen’e Wang, Ming Meng

Abstract


In this study, experimental investigations were conducted on rectangular side weirs with different widths and heights. Corresponding simulations were also performed to analyze hydraulic characteristics including the water surface profile, flow velocity, and pressure. The relationship between the discharge coefficient and the Froude number, as well as the ratios of the side weir height and width to upstream water depth, was determined. A discharge formula was derived based on a dimensional analysis. The results demonstrated good agreement between simulated and experimental data, indicating the reliability of numerical simulations using FLOW-3D software (version 11.1). Notably, significant fluctuations in water surface profiles near the side weir were observed compared to those along the center line or away from the side weir in the main channel, suggesting that the entrance effect of the side weir did not propagate towards the center line of the main channel. The proposed discharge formula exhibited relative errors within 10%, thereby satisfying the flow measurement requirements for small channels and field inlets.

1. Introduction


Sharp crested weirs are used to obtain discharge in open channels by solely measuring the water head upstream of the water. Side weirs, as a kind of sharp-crested weir, are extensively used for flow measurement, flow diversion, and flow regulation in open channels. Side weirs can be placed directly in the channel direction or field inlet, without changing the original structure of the channel. Thus, side weirs have certain advantages in the promotion and application of flow measurement facilities in small channels and field inlets. The rectangular sharp-crested weir is the most commonly available, and many scholars have conducted research on it.
Research on side weirs started in 1934. De Marchi studied the side weir in the rectangular channel and derived the theoretical formula based on the assumption that the specific energy of the main flow section of the rectangular channel in the side weir section was constant [1]. Ackers discussed the existing formulas for the prediction of the side weir discharge coefficient [2]. Chen concluded that the momentum theorem was more suitable for the analytical calculation of the side weir based on the experimental data [3]. Based on previous theoretical research, more and more scholars began to carry out experimental research on side weirs. Uyumaz and Muslu conducted experiments under subcritical and supercritical flow regimes and derived expressions for the side weir discharge and water surface profiles for these regimes by comparing them with experimental results [4]. Borghei et al. developed a discharge coefficient equation for rectangular side weirs in subcritical flow [5]. Ghodsian [6] and Durga and Pillai [7] developed a discharge coefficient equation of rectangular side weirs in supercritical flow. Mohamed proposed a new approach based on the video monitoring concept to measure the free surface of flow over rectangular side weirs [8]. Durga conducted experiments on rectangular side weirs of different lengths and sill heights and discussed the application of momentum and energy principles to the analysis of spatially varied flow under supercritical conditions. The results showed that the momentum principle was fitting better [7]. Omer et al. obtained sharp-crested rectangular side weirs discharge coefficients in the straight channel by using an artificial neural network model for a total of 843 experiments [9]. Emiroglu et al. studied water surface profile and surface velocity streamlines, and developed a discharge coefficient formula of the upstream Froude number, the ratios of weir length to channel width, weir length to flow depth, and weir height to flow depth [10]. Other investigators [11,12,13,14] have conducted experiments to study flow over rectangular side weirs in different flow conditions.
Numerous studies have been conducted in laboratories to this day. Compared to experimental methods, the numerical simulation method has many attractive advantages. We can easily obtain a wide range of hydraulic parameters of side weirs using numerical simulation methods, without investing a lot of manpower and resources. In addition, we can conduct small changes in inlet condition, outlet condition, and geometric parameters, and study their impact on the flow characteristics of side weirs. Therefore, with the development and improvement of computational fluid dynamics, the numerical simulation method has begun to be widely applied on side weirs. Salimi et al. studied the free surface changes and the velocity field along a side weir located on a circular channel in the supercritical regime by numerical simulation [15]. Samadi et al. conducted a three-dimensional simulation on rectangular sharp-crested weirs with side contraction and without side contraction and verified the accuracy of numerical simulation compared with the experimental results [16]. Aydin investigated the effect of the sill on rectangular side weir flow by using a three-dimensional computational fluid dynamics model [17]. Azimi et al. studied the discharge coefficient of rectangular side weirs on circular channels in a supercritical flow regime using numerical simulation and experiments [18]. The discharge coefficient over the two compound side weirs (Rectangular and Semi-Circle) was modeled by using the FLOW-3D software to describe the flow characteristics in subcritical flow conditions [19]. Safarzadeh and Noroozi compared the hydraulics and 3D flow features of the ordinary rectangular and trapezoidal plan view piano key weirs (PKWs) using two-phase RANS numerical simulations [20]. Tarek et al. investigated the discharge performance, flow characteristics, and energy dissipation over PK and TL weirs under free-flow conditions using the FLOW-3D software [21].
As evident from the aforementioned, the majority of studies have primarily focused on determining the discharge coefficient, while comparatively less attention has been devoted to investigating the hydraulic characteristics of rectangular side weirs. Numerical simulations were conducted on different types of side weirs, including compound side weirs and piano key weirs, in different cross-section channels under different flow regimes. It is imperative to derive the discharge formula and investigate other crucial flow parameters such as depth, velocity, and pressure near side weirs for their effective implementation in water measurement. In this study, a combination of experimental and numerical simulation methods was employed to examine the relationship between the discharge coefficient and its influencing factors; furthermore, a dimensionless analysis was utilized to derive the discharge formula. Additionally, water surface profiles near side weirs and pressure distribution at the bottom of the side channel were analyzed to assess safety operation issues associated with installing side weirs.

2. Principle of Flow Measurement


Flow discharge over side weirs is a function of different dominant physical and geometrical quantities, which is defined as

where Q is flow discharge over the side weir, b is the side weir width, B is the channel width, P is the side weir height, v is the mean velocity, h1 is water depth upstream the side weir in the main channel, g is the gravitational acceleration, μ is the dynamic viscosity of fluid, ρ is fluid density, and i is the channel slope (Figure 1).

Figure 1. Definition sketch of parameters of rectangular side weir under subcritical flow. Note: h1 and h2 represent water depth upstream and downstream of the side weir in the main channel, respectively; y1 and y2 represent weir head upstream and downstream of the side weir in the main channel, respectively.

In experiments when the upstream weir head was over 30 mm, the effects of surface tension on discharge were found to be minor [22]. The viscosity effect was far less than the gravity effect in a turbulent flow. Hence μ and σ were excluded from the analysis [23,24]. In addition, the channel width, the channel slope, and the fluid density were all constant, so the discharge formula can be simplified as:

According to the Buckingham π theorem, the following relationship among the dimensionless parameters is established:

Selected h1 and g as basic fundamental quantities, and the remaining physical quantities were represented in terms of these fundamental quantities as follows:

In which

Based on dimensional analysis, the following equations were derived.

Namely

So the discharge formula can be simplified as:

In a sharp-crested weir, discharge over the weir is proportional to 𝐻1.51H11.5 (H1 is the upstream total head above the crest, namely H1 = y1 + v2/2 g), so Equation (6) can be transformed as follows:

Consequently, the discharge formula over rectangular side weirs is defined as follows, in which 𝑚=𝑓(𝑏ℎ1m=f(bh1,𝑃ℎ1,𝐹𝑟1)Ph1,Fr1). Parameter m represents the dimensionless discharge coefficient. Parameter Fr1 represents the Froude number at the upstream end of the side weir in the main channel.

3. Experiment Setup


The experimental setup contained a storage reservoir, a pumping station, an electromagnetic flow meter, a control valve, a stabilization pond, rectangular channels, a side weir, and a sluice gate. The layout of the experimental setup is shown in Figure 2. Water was supplied from the storage reservoir using a pump. The flow discharge was measured with an electromagnetic flow meter with precision of ±3‰. Water depth was measured with a point gauge with an accuracy of ±0.1 mm. The flow velocity was measured with a 3D Acoustic Doppler Velocimeter (Nortek Vectrino, manufactured by Nortek AS in Rud, Norway). In order to eliminate accidental and human error, multiple measurements of the water depth and flow velocity at the same point were performed and the average values were used as the actual water depth and flow velocity of the point. The main and side channels were both rectangular open channels measuring 47 cm in width and 60 cm in height. The geometrical parameters of rectangular side weirs are shown in Table 1.

Figure 2. Layout of the test system.
Table 1. The geometrical parameters of rectangular side weirs.

When water passes through a side weir, its quality point is affected not only by gravity but also by centrifugal inertia force, leading to an inclined water surface within that particular cross-section before reaching the weir. In order to examine water profiles adjacent to side weirs, cross-sectional measurements were conducted at regular intervals of 12 cm both upstream and downstream of each side weir, denoted as sections ① to ⑩, respectively. Measuring points were positioned near the side weir (referred to as “Side I”), along the center line of the main channel (referred to as “Side II”), and far away from the side weir (referred to as “Side III”) for each cross-section. The schematic diagram illustrating these measuring points is presented in Figure 3.

Figure 3. Schematic diagram of measurement points.

4. Numerical Simulation Settings

4.1. Mathematical Model

4.1.1. Governing Equations

Establishing the controlling equations is a prerequisite for solving any problem. For the flow analysis problem of water flowing over a side weir in a rectangular channel, assuming that no heat exchange occurs, the continuity equation (Equation (9)) and momentum equation (Equation (10)) can be used as the controlling equations as follows:

The continuity equation:

Momentum equation:

where: ρ is the fluid density, kg/m3t is time, s; uiuj are average flow velocities, u1u2u3 represent average flow velocity components in Cartesian coordinates x, y, and z, respectively, m/s; μ is dynamic viscosity of fluid, N·s/m2p is the pressure, pa; Si is the body force, S1 = 0, S2 = 0, S3 = −ρg, N [24].

4.1.2. RNG k-ε Model

The water flow in the main channel is subcritical flow. When the water flows through the side weir, the flow line deviates sharply, the cross section suddenly decreases, and due to the blocking effect of the side weir, the water reflects and diffracts, resulting in strong changes in the water surface and obvious three-dimensional characteristics of the water flow [25]. Therefore the RNG kε model is selected. The model can better handle flows with greater streamline curvature, and its corresponding k and ε equation is, respectively, as follows:

where: k is the turbulent kinetic energy, m2/s2μeff is the effective hydrodynamic viscous coefficient; Gk is the generation item of turbulent kinetic energy k due to gradient of the average flow velocity; C∗1εC1ε*, C are empirical constants of 1.42 and 1.68, respectively; ε is turbulence dissipation rate, kg·m2/s2.

4.1.3. TruVOF Model

Because the shape of the free surface is very complex and the overall position is constantly changing, the fluid flow phenomenon with a free surface is a typical flow phenomenon that is difficult to simulate. The current methods used to simulate free surfaces mainly include elevation function method, the MAC method [26] and the VOF (Volume of Fluid) method [27]. The VOF method is a method proposed by Hirt and Nichols to deal with the complex motion of the free surface of a fluid, which can describe all the complexities of the free surface with only one function. The basic idea of the method is to define functions αw and αa, which represent the volume percentage of the calculation area occupied by water and air, respectively. In each unit cell, the sum of the volume fractions of water and air is equal to 1, i.e.,

The TruVOF calculation method can accurately track the change of free liquid level and accurately simulate the flow problems with free interface. Its equation is:

where: u_¯m is the average velocity of the mixture; t is the time; F is the volume fraction of the required fluid.

4.2. Parameter Setting and Boundary Conditions

To streamline the iterative calculation and minimize simulation time, we selected a main channel measuring 7.5 m in length and a side channel measuring 2.5 m in length for simulation. Three-dimensional geometrical models were developed using the software AutoCAD (version 2016-Simplified Chinese). The spatial domain was meshed using a constructed rectangular hexahedral mesh and each cell size was 2 cm. A volume flow rate was set in the channel inlet with an auto-adjusted fluid height. An outflow–outlet condition was positioned at the end of the side channel. A symmetry boundary condition was set in the air inlet at the top of the model, which represented that no fluid flows through the boundary. The lower Z (Zmin) and both of the side boundaries were treated as a rigid wall (W). No-slip conditions were applied at the wall boundaries. Figure 4 illustrates these boundary conditions.

Figure 4. Diagram of boundary conditions.

5. Results

5.1. Water Surface Profiles

Water surface profiles were crucial parameters for selecting water-measuring devices. Upon analyzing the consistent patterns observed in different conditions, one specific condition was chosen for further analysis. To validate the reliability of numerical simulation, measured and simulated water depths of rectangular side weirs with different widths and heights at a discharge rate of 25 L/s were extracted for comparison (Table 2 and Figure 5). The results in Table 2 and Figure 5 indicate a maximum absolute relative error value of 9.97% and all absolute relative error values within 10%, demonstrating satisfactory agreement between experimental and simulated results.

Figure 5. Comparison between measured and simulated flow depth.
P/cmSection Positionb = 20 cmb = 30 cmb = 40 cmb = 47 cm
hm/cmhs/cmR/%hm/cmhs/cmR/%hm/cmhs/cmR/%hm/cmhs/cmR/%
721.4919.49.7317.7416.94.7416.0714.519.7113.7912.509.35
④′20.4819.056.9817.7816.149.2215.6914.318.80
20.7119.028.1617.8216.318.4715.9214.538.7315.2313.809.39
⑧′22.0020.228.0918.2716.748.3716.5914.969.83
22.3720.179.8317.7316.805.2516.2715.087.3115.3614.366.51
1024.1522.66.4219.9618.845.6119.0318.582.3616.8315.855.82
④′24.2122.058.9219.4918.196.6718.7518.352.13
24.0121.789.2919.6518.346.6718.9518.631.6917.5216.098.16
⑧′24.8822.49.9720.6519.216.9720.1219.294.13
24.0322.964.4521.1619.348.6019.7119.431.4218.3917.365.60
1528.8527.564.4725.8624.096.8424.0521.898.9822.7320.808.49
④′28.4926.975.3425.1923.845.3623.4221.468.37
28.8526.986.4825.7223.996.7323.2321.826.0723.1021.058.87
⑧′28.9627.305.7326.3824.198.3024.1822.277.90
29.1827.964.1826.5724.547.6424.5722.339.1223.2021.109.05
2033.2932.342.8530.6329.025.2628.4926.875.6926.9925.814.37
④′33.1431.953.5929.7528.623.8028.1126.794.70
33.3231.794.5930.0428.455.2928.9926.867.3527.4226.722.55
⑧′34.0232.394.7930.6928.955.6729.5927.257.91
34.6232.845.1431.4429.296.8429.5127.317.4628.2127.004.29
Table 2. Comparison of measured and simulated water depths on Side I of each side weir at a discharge of 25 L/s

Due to the diversion caused by the side weir, there was a rapid variation in flow near the side weir in the main channel. In order to investigate the impact of the side weir on water flow in the main channel, water surface profiles on Side I, Side II, and Side III were plotted with a side weir width and height both set at 20 cm at a discharge rate of 25 L/s (Figure 6). As depicted in Figure 6, within a certain range of the upstream end of the main channel, water depths on Side I, Side II, and Side III were nearly equal with almost horizontal profiles. As the distance between the location of water flow and the upstream end of the weir crest decreased gradually, there was a gradual decrease in water depth on Side I along with an inclined trend in its corresponding profile; however, both Side II and Side III still maintained almost horizontal profiles. When approaching closer to the side weir area with flowing water, there was an evident reduction in water depth on Side I accompanied by a significant downward trend visible across an expanded decline range. The minimum point occurred near the upstream end of the weir crest before gradually increasing again towards downstream sections. At the crest section of the side weir, there is an upward trend observed in the water surface. The water surface tended to stabilize downstream of the main channel within a certain range from the downstream end of the weir crest. There was no significant change in the water surface profiles of Side Ⅱ and Side Ⅲ in the crest section. It can be inferred that the side weir entrance effect occurred only between Side Ⅰ and Side Ⅱ. M. Emin reported the same pattern [10].

Figure 6. Water surface profiles on Side I, Side II, and Side III with a side weir width of 20 cm and height of 15 cm at a discharge of 25 L/s.

For a more accurate study on the entrance effect of the side weir on the Water Surface Profile (WSP) for Side I; a comparative analysis conducted using different widths but the same height (15 cm) at a discharge rate of 25 L/s is presented through Figure 7, Figure 8, Figure 9 and Figure 10.

Figure 7. Water surface profile on Side Ⅰ with a side weir width of 20 cm and height of 15 cm at a discharge of 25 L/s.
Figure 8. Water surface profile on Side Ⅰ with a side weir width of 30 cm and height of 15 cm at a discharge of 25 L/s.
Figure 9. Water surface profile on Side Ⅰ with a side weir width of 40 cm and height of 15 cm at a discharge of 25 L/s.
Figure 10. Water surface profile on Side Ⅰ with a side weir width of 47 cm and height of 15 cm at a discharge of 25 L/s.

According to Figure 7, Figure 8, Figure 9 and Figure 10, the water depth upstream of the main channel started to decrease as it approached the upstream end of the weir crest and then gradually increased at the weir crest section. In other words, the water surface profile exhibited a backwater curve along the length of the weir crest. The water depth remained relatively stable downstream of the main channel within a certain range from the downstream end of the weir crest. Additionally, there was a higher water depth downstream of the main channel compared to that upstream of the main channel. Furthermore, an increase in the width of the side weir led to a gradual reduction in fluctuations on its water surface.

5.2. Velocity Distribution

The law of flow velocity distribution near the side weir is the focus of research and analysis, so the simulated and measured values of flow velocity near the side weir were compared and analyzed. Take the discharge of 25 L/s, the height of 15 cm, and the width of 30 cm of the side weir as an example to illustrate. Figure 11 shows the measured and simulated velocity distribution in the x-direction of cross-section ④. As can be seen from Figure 11, the diagrams of the measured and simulated velocity distribution were relatively consistent, and the maximum absolute relative error between the measured and simulated values at the same measurement point was 9.37%, and the average absolute relative error was 3.97%, which indicated a satisfactory agreement between the experimental and simulated results.

Figure 11. Velocity distribution in the x-direction of section ④: when the discharge is 25 L/s, the height of the side weir is 15 cm and the width of the side weir is 30 cm. (a) Measured velocity distribution; (b) Simulated velocity distribution.

From Figure 11, it can be seen that the flow velocity gradually increased from the bottom of the channel towards the water surface in the Z-direction, and the flow velocity gradually increased from Side Ⅲ to Side Ⅰ in the Y-direction. The maximum flow velocity occurred near the weir crest.

Figure 12 shows the distribution of flow velocity at different depths (z/P = 0.3, z/P = 0.8, z/P = 1.6) with a side weir width of 30 cm and height of 15 cm at a discharge of 25 L/s. The water flow line began to bend at a certain point upstream of the main channel, and the closer it was to the upstream end of the weir crest, the greater the curvature. The maximum curvature occurred at the downstream end of the weir crest. The flow patterns at the bottom, near the side weir crest, and above the side weir crest were significantly different. There was a reverse flow at the bottom of the main channel, where the forward and reverse flows intersect, resulting in a detention zone. The maximum flow velocity at the bottom layer occurred at the upstream end of the side weir crest. When the location of water flow approached the weir crest, the maximum flow velocity occurred at the upstream end of the weir crest. The maximum flow velocity on the water surface occurred at the downstream end of the weir crest. As the water depth decreased, the position of the maximum flow velocity gradually moved from the upstream end of the side weir to the downstream end of the side weir.

Figure 12. Distribution of flow velocity at different depths with a side weir width of 30 cm and height of 15 cm at a discharge of 25 L/s. (a) z/P = 0.3; (b) z/P = 0.8; (c) z/P = 1.6.

5.3. Side Channel Pressure Distribution

When water flowed through the side weir, an upstream water level was formed, resulting in a pressure zone at the junction with the side channel. This pressure zone led to increased water pressure on the floor of the side channel, which affected its stability and durability. In small channels or fields where erosion resistance is weak, excessive pressure can cause scour holes. Therefore, analyzing the pressure distribution in the side channel is necessary to select an appropriate height and width for the side weir that effectively reduces its impact on the bottom plate.

To investigate the impact of side weir width on hydraulic characteristics, pressure data was collected at a discharge rate of 25 L/s for side weirs with heights of 20 cm and widths ranging from 20 cm to 47 cm. The pressure distribution map was drawn, as shown in Figure 13.

Figure 13. Comparison of pressure distribution on the bottom plate of the side channel with different widths of side weirs when the discharge is 25 L/s and the height of side weirs is 20 cm. (aP = 20 cm, b = 20 cm; (bP = 20 cm, b = 30 cm; (cP = 20 cm, b = 40 cm; (dP = 20 cm, b = 47 cm.

As can be seen from Figure 13, the pressure at the bottom of the side channel decreased as the width of the side weir increased. This uneven distribution of water flow on the weir was caused by the sharp bending of water flow lines and the influence of centrifugal inertia force over a short period. After passing through the side weir, the water flow became symmetrically distributed with respect to the axis of the side channel, leaning towards the right bank at a certain distance. As we increased the width of the side weir, we noticed that its position gradually approached the side weir and maximum pressure decreased at this location where the water tongue formed due to flowing through it (Figure 13). For a constant height (20 cm) but varying widths (20 cm, 30 cm, 40 cm, and 47 cm), we measured maximum pressures at these positions as follows: 103,713 Pa, 103,558 Pa, 103,324 Pa, and 103,280 Pa, respectively. Consequently, increasing width reduced the impact on the side channel from water flowing through it while changing pressure distribution from concentration to dispersion in a vertical direction. In the practical application of side weirs, appropriate height should be selected based on the bottom plate’s capacity to withstand the pressure exerted by flowing water within channels.

To investigate how height affects the hydraulic characteristics of rectangular side weirs further (Figure 14), we extracted pressures on bottom plates when discharge was fixed at 25 L/s while varying heights were set as follows: 7 cm, 10 cm, 15 cm, and 20 cm, respectively.

Figure 14. Comparison of pressure distribution on the bottom plate of the side channel with different heights of side weirs when discharge is 25 L/s and the width of side weirs is 20 cm. (aP = 7 cm, b = 20 cm; (bP = 10 cm, b = 20 cm; (cP = 15 cm, b = 20 cm; (dP = 20 cm, b = 20 cm.

As shown in Figure 14, when the width of the side weir was constant, the pressure at the bottom of the side channel increased with the height of the side weir. As the height of the side weir increased, the water tongue formed by flow through the side weir gradually moved away from it in a downstream direction. In terms of vertical water flow, as the height of the side weir increased, the position of maximum pressure at which the water tongue falls shifted closer to the axis of the side channel from its right bank. Moreover, an increase in height resulted in higher maximum pressure at this falling point. For a constant width (20 cm) and varying heights (7 cm, 10 cm, 15 cm, and 20 cm), corresponding maximum pressures at this landing point were measured as 102,422 Pa, 102,700 Pa, 103,375 Pa, and 103,766 Pa, respectively. Consequently, increasing width led to a greater impact on both flow through and pressure distribution within the side channel; transforming it from scattered to concentrated along its lengthwise direction. Therefore, when applying such weirs practically one should select an appropriate width based on what pressure can be sustained by their respective channel bottom plates.

5.4. Discharge Coefficient

Based on dimensionless analysis, the influencing parameters of the discharge coefficient were obtained. To study the effect of parameters Fr1b/h1, and P/h1, discharge coefficient values were plotted against Fr1b/h1, and P/h1, shown in Figure 15, Figure 16 and Figure 17. The discharge coefficient decreased as parameters Fr1 and b/h1 increased. The discharge coefficient increased as parameter P/h1 increased. As Uyumaz and Muslu reported in a previous study, the variation of the discharge coefficient with respect to the Froude number showed a second-degree curve for a subcritical regime [4].

Figure 15. Variation of discharge coefficient values against Froude number.
Figure 16. Variation of discharge coefficient values against the percentage of the side weir width to the upstream flow depth over the side weir.
Figure 17. Variation of discharge coefficient values against the percentage of the side weir height to the upstream flow depth over the side weir.

Quantitative analysis between discharge coefficient values and parameters Fr1b/h1, and P/h1 was conducted using data analysis software (IBM SPSS Statistics 19). The various coefficients obtained are shown in Table 3.

ModelUnstandardized CoefficientsStandardized CoefficientstSig
BStd. ErrorBeta (β)
Constant−1.2940.155−8.3690.000
Fr13.4300.2863.40112.0130.000
b/h1−0.0040.004−0.045−0.9440.348
P/h12.4010.1674.06414.3940.000
Table 3. Coefficient.

The value of t and Sig are the significance results of the independent variable, and the value of Sig corresponding to the value of t is less than 0.05, indicating that the independent variable has a significant impact on the dependent variable. Therefore, the values of Sig corresponding to the parameters Fr1 and P/h1 were less than 0.05, indicating that the parameters Fr1 and P/h1 have a significant impact on the discharge coefficient. On the contrary, the parameter b/h1 has less impact on the discharge coefficient. Therefore, quantitative analysis between discharge coefficient values and parameters Fr1, and P/h1 was conducted using data analysis software by removing factor b/h1. The model summary, ANOVA, and coefficient obtained are shown respectively in Table 4, Table 5 and Table 6. R and adjusted R square in Table 4 were approaching 1, which indicated the goodness of fit of the regression model was high. The value of Sig corresponding to the value of F in Table 5 was less than 0.05, which indicated that the regression equation was useful. The values of Sig corresponding to the parameters Fr1 and P/h1 in Table 6 were less than 0.05, indicating that the parameters Fr1 and P/h1 have a significant impact on the discharge coefficient.

ModelRR SquareAdjusted R SquareStd. Error of the Estimate
10.913 a0.8330.8290.03232
Table 4. Model Summary b. Note: a. Predictors:(Constant), Fr1P/h1b. Discharge coefficient.
ModelSum of SquaresdfMean SquareFSig
1Regression0.40220.201192.5450.000 a
Residual0.080770.001
Total0.48379
Table 5. ANOVA b. Note: a. Predictors:(Constant), Fr1P/h1b. Discharge coefficient.
ModelUnstandardized CoefficientsStandardized CoefficientstSig
BStd. ErrorBeta (β)
Constant−1.3260.151−8.7960.000
Fr13.4790.2813.44912.3960.000
P/h12.4270.1644.10814.7650.000
Table 6. Coefficient a. Note: a. Predictors:(Constant), Fr1P/h1.

Based on the above analysis, the flow coefficient formula has been obtained, shown as follows:

Discharge formula were obtained by substituting Equation (15) into Equation (12), as shown in Equation (16).

where Q ∈ [0.006, 0.030], m3/s; b ∈ [0.20, 0.47], m; P ∈ [0.07, 0.20], m.

Figure 18 showed the measured discharge coefficient values with those calculated from discharge formulas in Table 3. The scatter of the data with respect to perfect line was limited to ±10%.

Figure 18. Comparison of the measured discharge coefficient values with those calculated from discharge formulas in Table 3.

6. Discussions

Determining water surface profile near the side weir in the main channel is one of the tasks of hydraulic calculation for side weirs. As the water flows through the side weir, discharge in the main channel is gradually decreasing, namely dQ/ds<0. According to the Equation (17) derived from Qimo Chen [3], it can be inferred that the value of 𝑑ℎ/𝑑𝑠 is greater than zero in subcritical flow (Fr < 1), that is, the water surface profile near the side weir in the main channel is a backwater curve. Due to the side weir entrance effect at the upstream end, water surface profiles drop slightly at the upstream end of the side weir crest, as EI-Khashab [28] and Emiroglu et al. [29] reported in previous experimental studies.

In this study, the water surface profile exhibited a backwater curve along the length of the weir crest. Therefore, during side weir application, it is crucial to ensure that downstream water levels do not exceed the highest water level of the channel.

The head on the weir is one of the important factors that flow over side weirs depends on. At the same time, the head depends on the water surface profile near the side weir in the main channel. Therefore, further research on the quantitative analysis of water surface profile needs to be conducted. Mohamed Khorchani proposed a new approach based on the video monitoring concept to measure the free surface of flow over side weirs. It points out a new direction for future research [8].

The maximum flow velocity, a key parameter in assessing the efficiency of a weir, occurs at the upstream end of the weir crest, typically near the crest. This is attributed to the convergence of the flow as it approaches the crest, resulting in a significant increase in velocity. It was found that in this study the minimum flow velocity occurred at the bottom of the main channel away from the side weir. Under such conditions, the accumulation of sediments could lead to siltation, which in turn can affect the accuracy of flow measurement through side weirs. This is because the presence of sediments can alter the flow patterns and cause errors in the measurement. Therefore, it becomes crucial to explore methods to optimize the selection of side weirs in order to minimize or eliminate the effects of sedimentation on flow measurement.

Pressure distribution plays a crucial role in ensuring structural safety for side weirs since small channels and field inlets have relatively limited pressure-bearing capacities. Therefore, it is important to select an appropriate geometrical parameter of rectangular side weirs based on their ability to withstand the pressure exerted on their bottom combined with pressure distribution data at the bottom of the side channel we have obtained in this study.

The discharge coefficient formula (Equation (15)), which incorporates Fr1 and P/h1, was derived based on dimensional analysis. However, it is worth noting that previous research has contradicted this formula by suggesting that the discharge coefficient solely depends on the Froude number. This conclusion can be observed in this study such as in Equations (18)–(23) in Table 7 of the manuscript [30,31,32,33,34,35], which clearly demonstrate the dependency of the discharge coefficient on the Froude number. In contrast, our derived discharge coefficient formula (Equation (15)) offers a more streamlined and simplified approach compared to Equation (25) [36] and Equation (29) [10]—making it easier to comprehend and apply—an advantageous feature particularly valuable in fluid dynamics where intricate calculations can be time-consuming. Furthermore, our derived discharge coefficient formula (Equation (15)) exhibits a broader application scope than that of Equation (24) [37] as shown in Table 8. Equation (26) [38] and Equation (27) [5] are specifically applicable under high flow discharge conditions. Conversely, our derived discharge coefficient formula (Equation (15)) is better suited for low-flow discharge conditions.

Table 7. Discharge coefficient formulas of rectangular side weirs presented in previous studies.
Discharge/(L·s−1)Width of Side Weir/cmHeight of Side Weir/cmNumber of Formula
10~1410~206~12(24)
35–10020~751~19(26), (27)
6~3020~477~20(15)
Table 8. Application scope of discharge coefficient formulas.

In addition to the factors studied in the paper, factors such as the sediment content in the flow, the bottom slope, and the cross-section shape of the channel also have a certain impact on the hydraulic characteristics of the side weir. Further numerical simulation methods can be used to study the hydraulic characteristics and the influencing factors of the side weir. Water measurement facilities generally require high accuracy of water measurement, the flow of sharp-crested side weirs is complex, and the water surface fluctuates greatly. While conducting numerical simulations, experimental research on prototype channels is necessary to ensure the reliability of the results and provide reference for the body design and optimization of side weirs in small channels and field inlets.

7. Conclusions

This paper presents a comprehensive study that encompasses both experimental and numerical simulation research on rectangular side weirs of varying heights and widths within rectangular channels. A thorough analysis of the experimental and numerical simulation results has been conducted, leading to the derivation of several notable conclusions:

  1. A comparative analysis was conducted on the measured and simulated values of water depth and flow velocity. Both of the maximum absolute relative errors were within 10%, which indicated that the numerical simulation of the side weir was feasible and effective.
  2. The water surface profile exhibited a backwater curve along the length of the weir crest. The side weir entrance effect occurred only between Side Ⅰ and Side Ⅱ. This indicates that flow patterns and associated hydraulic forces at the weir entrance play a crucial role in determining water level distribution along the weir crest.
  3. The maximum flow velocity of the cross-section at the upstream end of the weir crest occurred near the weir crest, while the minimum flow velocity occurred at the bottom of the main channel away from the side weir. As the water depth decreased, the position of the maximum flow velocity gradually moved from the upstream end of the side weir to the downstream end of the side weir.
  4. When the height of the side weir remains constant, an increase in the width of the side weir leads to a decrease in pressure at the bottom of the side channel. Conversely, when the width of the side weir is kept constant, an increase in its height results in an increase in pressure at the bottom of the side channel. Therefore, during practical applications involving side weirs, it is crucial to select an appropriate weir width based on the maximum pressure that can be sustained by the channel’s bottom plate.
  5. The discharge coefficient was found to depend on the upstream Froude number Fr1 and the percentage of the side weir height to the upstream flow depth over the side weir P/h1. The relationship between the discharge coefficient and parameters Fr1 and P/h1 was obtained using multiple regression analysis, which was of linear form and provided an easy means to estimate the discharge coefficient. The discharge formula is of high accuracy with relative errors within 10%, which met the water measurement accuracy requirements of small channels in irrigation areas.

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Three-dimensional flow structure in a confluence-bifurcation unit

합류 분기 유닛의 3차원 유동 구조

Di Wang, Xiaoyong Cheng, Zhixuan Cao, Jinyun Deng

Abstract


Enhanced understanding of flow structure in braided rivers is essential for river regulation, flood control, and infrastructure safety across the river. It has been revealed that the basic morphological element of braided rivers is confluence-bifurcation units. However, flow structure in these units has so far remained poorly understood with previous studies having focused mainly on single confluences/bifurcations. Here, the flow structure in a laboratory-scale confluence-bifurcation unit is numerically investigated based on the FLOW3D® software platform. Two discharges are considered, with the central bars submerged or exposed respectively when the discharge is high or low. The results show that flow convergence and divergence in the confluence-bifurcation unit are relatively weak when the central bars are submerged. Based on comparisons with a single confluence/bifurcation, it is found that the effects of the upstream central bar on the flow structure in the confluence-bifurcation unit reign over those of the downstream central bar. Concurrently, the high-velocity zone in the confluence-bifurcation unit is less concentrated than that in a single confluence while being more concentrated than that observed in a single bifurcation. The present work unravels the flow structure in a confluence-bifurcation unit and provides a unique basis for further investigating morphodynamics in braided rivers.

1 Introduction


Confluences and bifurcations commonly exist in alluvial rivers and usually are important nodes of riverbed planform (Szupiany et al., 2012; Hackney et al., 2018). Flow convergence and divergence in these junctions result in highly three-dimensional (3D) flow characteristics, which greatly influence sediment transport, and hence riverbed evolution and channel formation (Le et al., 2019; Xie et al., 2020). Braided rivers, characterized by unstable networks of channels separated by central bars (Ashmore, 2013), have confluence-bifurcation units as their basic morphological elements (Ashmore, 1982; 1991; 2013; Federici & Paola, 2003; Jang & Shimizu, 2005). In particular, confluence-bifurcation units exhibit a distinct morphology from single confluences/bifurcations and bifurcation-confluence regions because two adjacent central bars are included. Within a confluence-bifurcation unit, two tributaries converge at the upstream bar tail and soon diverge to two anabranches again at the downstream bar head. Therefore, the flow structure in the unit may be significantly influenced by both the two central bars, and thus considerably different from that in single confluences, single bifurcations, and bifurcation-confluence regions, where the flow is affected by only one central bar. Enhanced understanding of flow structure in confluence-bifurcation units is urgently needed, which is essential for water resources management, river regulation, flood control, protection of river ecosystems and the safety of infrastructures across the rivers such as bridges, oil pipelines and communication cables (Redolfi et al., 2019; Ragno et al., 2021).

The flow dynamics, turbulent coherent structures, and turbulent characteristics in single confluences have been widely studied since the 1980s (Yuan et al., 2022). Flow dynamics at river channel confluences have been systematically and completely analyzed, which can be characterized by six major regions of flow stagnation, flow deflection, flow separation, maximum velocity, flow recovery and distinct shear layers (Best, 1987). For example, the field observation of Roy et al. (1988) and Roy and Bergeron (1990) highlighted the flow separation zones and recirculation at downstream natural confluence corners. Ashmore et al. (1992) measured the flow field in a natural confluence and found flow accelerates suddenly at the confluence junction with two separated high-velocity cores merging into one single core at the channel centre. De Serres et al. (1999) investigated the three-dimensional flow structure at a river confluence and identified the existence of the mixing layer, stagnation zones, separation zones and recovery zones. Sharifipour et al. (2015) numerically studied the flow structure in a 90° single confluence and found that the size of the separation zone decreases with the width ratio between the tributary and the main channel. Recently, three main classes of large-scale turbulent coherent structures (Duguay et al., 2022) have been presented, i.e. vertical-orientated vortices or Kelvin-Helmholtz instabilities (Rhoads & Sukhodolov, 2001; Constantinescu et al., 2011; 2016; Biron et al., 2019), channel-scale ‘back-to-back’ helical cells, (Mosley, 1976; Ashmore, 1982; Ashmore et al., 1992; Ashworth, 1996; Best, 1987; Rhoads & Kenworthy, 1995; Bradbrook et al., 1998; Lane et al., 2000), and smaller, strongly coherent streamwise-orientated vortices (Constantinescu et al., 2011; Sukhodolov & Sukhodolova, 2019; Duguay et al., 2022). However, no consensus on a universal turbulent coherent structure mode has been reached so far (Duguay et al., 2022). In addition, some studies (Ashworth, 1996; Constantinescu et al., 2011; Sukhodolov et al., 2017; Le et al., 2019; Yuan et al., 2023) have focused on turbulent characteristics, e.g. turbulent kinetic energy, turbulent dissipation rate and Reynolds stress, which can be critical parameters to further explaining the diversity of these turbulent coherent structure modes.

Investigations on the flow structure in single bifurcations have mainly focused on hydrodynamics in anabranches (Hua et al., 2009; van der Mark & Mosselman, 2013; Iwantoro et al., 2022) and around bifurcation bars (McLelland et al., 1999; Bertoldi & Tubino, 2005; 2007; Marra et al., 2014), whereas few studies have considered the effects of bifurcations on the upstream flow structure. Thomas et al. (2011) found that the velocity core upstream of the bifurcation is located near the water surface and towards the channel center in experimental investigations of a Y-shaped bifurcation. Miori et al. (2012) simulated flow in a Y-shaped bifurcation and found two circulation cells upstream of the bifurcation with flow converging at the water surface and diverging near the bed. Szupiany et al. (2012) reported velocity decreasing and back-to-back circulation cells upstream of the bifurcation junction in the field observation of a bifurcation of the Rio Parana River. These investigations provide insight into how bifurcations affect the flow patterns upstream, yet there is a need for further research on the dynamics of flow occurring immediately before the bifurcation junction.

Generally, the findings of studies on bifurcation-confluence regions are similar to those concerning single confluences and bifurcations. Hackney et al. (2018) measured the hydrodynamic characteristics in a bifurcation-confluence of the Mekong River and found the velocity cores located at the channel centre and strong secondary current occurring under low discharges. Le et al. (2019) reported a high-turbulent-kinetic-energy (high-TKE) zone located near the bed in their numerical simulation of flow in a natural bifurcation-confluence region. Moreover, a stagnation zone was found upstream of the confluence and back-to-back secondary current cells were detected at the confluence according to Xie et al. (2020) and Xu et al. (2022). Overall, these studies have further unraveled the flow patterns in river confluences and bifurcations.

Unfortunately, limited attention has been paid to the flow structure in confluence-bifurcation units. Parsons et al. (2007) investigated a large confluence-bifurcation unit in Rio Parana, Argentina, and no classical back-to-back secondary current cells were observed under a discharge of 12000 m3·s−1. To date, the differences in flow structure between confluence-bifurcation units and single confluences/bifurcations have remained far from clear. In addition, although the effects of discharge on flow structure have been investigated in several studies on single confluences/bifurcations, (Hua et al., 2009; Le et al., 2019; Luz et al., 2020; Xie et al., 2020; Xu et al., 2022), cases with fully submerged central bars were not considered, which is typical in braided rivers during floods. In-depth studies concerning these issues are urgently needed to gain better insight into the flow structure in confluence-bifurcation units of braided rivers.

This paper aims to (1) reveal the 3D flow structure in a confluence-bifurcation unit under different discharges and (2) elucidate the differences in the flow structure between confluence-bifurcation units and single confluence/bifurcation cases. Using the commercial computational fluid dynamics software FLOW-3D® (Version 11.2; https://www.flow3d.com; Flow Science, Inc.), fixed-bed simulations of a laboratory-scale confluence-bifurcation unit are conducted, and cases of a single confluence/bifurcation are also included for comparison. Two discharges are considered, with the central bars fully submerged or exposed respectively when the discharge is high or low. Based on the computational results, the 3D flow structure in the confluence-bifurcation unit conditions is analyzed from various aspects including free surface elevation, time-averaged flow velocity distribution, recirculation vortex structure, secondary current, and turbulent kinetic energy and dissipation rate. In particular, the flow structure in the confluence-bifurcation unit is compared with that in the single confluence/bifurcation cases to unravel the differences.h

2. Conceptual flume and computational cases


2.1. Conceptual flume

In this paper, a laboratory-scale conceptual flume is designed and used in numerical simulations. Figure 1(a–d) shows the morphological characteristics of the flume. To ensure that the conceptual flume reflects morphology features of natural braided channels, key parameters governing the flume morphology, e.g. unit length, width, and channel width-depth ratio, are determined according to studies on morphological characteristics of natural confluence-bifurcation units (Hundey & Ashmore, 2009; Ashworth, 1996; Orfeo et al., 2006; Parsons et al., 2007; Sambrook Smith et al., 2005; Kelly, 2006; Ashmore, 2013; Egozi & Ashmore, 2009; Redolfi et al., 2016; Ettema & Armstrong, 2019).

Figure 1. The sketch of the conceptual flume: (a) the original flume, (b) the central bar: (c) the sketch of cross-section C-C, (d) the sketch of cross-section D-D, (e) the modified part for the single confluence, (f) the modified part for the single bifurcation, (g) the position of different cross-sections. The red dashed boxes denote the regions of primary concern.

Figure 1. The sketch of the conceptual flume: (a) the original flume, (b) the central bar: (c) the sketch of cross-section C-C, (d) the sketch of cross-section D-D, (e) the modified part for the single confluence, (f) the modified part for the single bifurcation, (g) the position of different cross-sections. The red dashed boxes denote the regions of primary concern.

2.1.1. Length and width scales of the confluence-bifurcation unit

The length and width scales of the flume are first determined. The inner relation among the length LCB and average width B of a confluence-bifurcation unit and the average width Bi of a single branch was statistically studied by Hundey and Ashmore (2009), which indicates the following relations:
𝐿CB =(4∼5)⁢𝐵 (1)
𝐵 =1.41⁢𝐵𝑖 (2)
In addition, Ashworth (1996) gave B = 2Bi in his experimental research on mid-bar formation downstream of a confluence, while the confluence-bifurcation unit of Rio Parana, Argentina has a relation of B≈1.71Bi (Orfeo et al., 2006; Parsons et al., 2007). Accordingly, the following relations are used in the present paper:
𝐿CB =4⁢𝐵 (3)
𝐵 =1.88⁢𝐵𝑖 (4)
where LCB = 6 m, B = 1.5 m and Bi = 0.8 m.

2.1.2. Central bar morphology

The idealized plane pattern of central bars in braided rivers is a slightly fusiform leaf shape with a short upstream side and a long downstream side (Ashworth, 1996; Sambrook Smith et al., 2005; Kelly, 2006; Ashmore, 2013). To simplify the design, the bar is approximated as a combination of two different semi-ellipses (Figure 1(b)). The major axis Lb is two to ten times longer than the minor axis Bb according to the statistical data in Kelly’s study, and the regression equation is given as (Kelly, 2006):
𝐿𝑏=4.62⁢𝐵0.96𝑏 (5)
In this study, the bar width Bb is set as 0.8 m, whilst the lengths of downstream (LT1) and upstream sides (LT2) are 2 and 1.5 m, respectively (Figure 1(b)). Thus, the relation of Lb and Bb is given as:
𝐿𝑏=(𝐿𝑇⁢1+𝐿𝑇⁢2)=4.375⁢𝐵𝑏 (6)
The lengths of the inlet and outlet parts are determined as Lin = Lout = 8 m, which ensures negligible effects of boundary conditions without exceptional computational cost.

2.1.3. Width-depth ratio

Channel flow capacity can be significantly affected by cross-section shapes. For natural rivers, cross-section shapes can be generalized into three sorts based on the following width-depth curve (Redolfi et al., 2016):
𝐵=𝜓⁢𝐻𝜑(7)
Braided rivers usually have ψ = 5∼50 and φ>1, which indicates a rather wide and shallow cross-section. The central bar form should also be taken into account, so a parabolic cross-section shape is used here with ψ = 8 and φ>1 (Figure 1(c,d)).

2.1.4. Bed slope

In addition, natural braided rivers are usually located in mountainous areas and thus have a relatively large bed slope. According to flume experiments and field observations, the bed slope Sb is mostly in the range of 0.01∼0.02, and a few are below 0.01 (Ashworth, 1996; Egozi & Ashmore, 2009; Ashmore, 2013; Redolfi et al., 2016; Ettema & Armstrong, 2019). In this study, Sb takes 0.005.

2.1.5. Complete sketch of the conceptual flume

In summary, the flume is 29 m long, 2.4 m wide, and 0.6 m high. The plane coordinates (x-direction and y-direction) used in the calculation process are shown in Figure 1
(a). Note that the inlet corresponds to x = 0 m, and the centreline of the flume is located at y = 1.3 m. Besides, the thalweg elevation of the outlet is set as z = 0 m.

2.2. Computational cases

As stated before, the first aim of this paper is to reveal the flow structure in the confluence-bifurcation unit under different discharges. Therefore, two basic cases are set first: (1) case 1a under a low discharge (0.05 m3·s−1) with exposed central bars and (2) case 2a under a high discharge (0.30 m3·s−1) with fully submerged central bars. A total of 22 cross-sections are identified to examine the results (Figure 1(g)).

Further, cases of a single confluence/bifurcation are generated by splitting the original confluence-bifurcation unit into two parts. Part 1 only includes the upstream central bar and focuses on the flow convergence downstream of CS04 (Figure 1(e)), while Part 2 only includes the downstream central bar and focuses on the flow divergence upstream of CS19 (Figure 1(f)). Notably, the numbers of corresponding cross-sections in the original flume are reserved to facilitate comparison. The outlet section of the single confluence as well as the inlet section of the single bifurcation is extended to make the total length equivalent to the original flume (29 m). Also, two discharge conditions (0.05 and 0.30 m3·s−1), which correspond to exposed and fully submerged central bars, are considered for the single confluence/bifurcation. In total, six computational cases are conducted, as listed in Table 1. As the conceptual flume is designed to be symmetrical about the centreline, the momentum flux ratio (Mr) of the two branches should be 1 in all six cases. This is confirmed by further examining the computational results.

CaseConfigurationQin (m3·s−1)Zout (m)MrCondition of bars
1aCBU0.050.151Exposed
1bSC0.050.151Exposed
1cSB0.050.151Exposed
2aCBU0.300.341Submerged
2bSC0.300.341Submerged
2cSB0.300.341Submerged
Table 1. Computational cases with inlet and outlet boundary conditions.

3. Numerical method

In this section, the 3D Large Eddy Simulation (LES) model integrated in the FLOW-3D® (Version 11.2; https://www.flow3d.com; Flow Science, Inc.) software platform is introduced, including governing equations and boundary conditions. Information on computational meshes with mesh independence test can be found in the Supplementary material.

3.1. Governing equations

The LES model was applied in the present paper to simulate flow in the laboratory-scale confluence-bifurcation unit. The LES model has been proven to be effective in simulating turbulent flow in river confluences and bifurcations (Constantinescu et al., 2011; Le et al., 2019). The basic idea of the LES model is that one should directly compute all turbulent flow structures that can be resolved by the computational meshes and only approximate those features that are too small to be resolved (Smagorinsky, 1963). Therefore, a filtering operation is applied to the original Navier-Stokes (NS) equations for incompressible fluids to distinguish the large-scale eddies and small-scale eddies (Liu et al., 2018). The filtered NS equations are then generated, which can be expressed in the form of a Cartesian tensor as (Liu, 2012):

(10) where ¯𝑢𝑖 is the resolved velocity component in the i – direction (i goes from 1 to 3, denoting the x-, y – and z-directions, respectively); t is the flow time; ρ is the density of the fluid; ¯𝑝 is the pressure; ν is the kinematic viscosity; τij is the sub-grid scale (SGS) stress; ¯𝐺𝑖 is the body acceleration. In FLOW3D®, the full NS equations are discretized and solved using the finite-volume/finite-difference method (Bombardelli et al., 2011; Lu et al., 2023).

Due to the filtering process, the velocity can be divided into a resolved part (¯𝑢⁡(𝑥,𝑡)) and an approximate part (𝑢′⁡(𝑥,𝑡)) which is also known as the SGS part (Liu, 2012). To achieve model closure, the standard Smagorinsky SGS stress model is introduced here (Smagorinsky, 1963):
𝜏ij−13⁢𝜏kk⁢𝛿ij=−2⁢𝜈SGS⁢¯𝑆ij(11)
 where νSGS is the SGS turbulent viscosity, and ¯𝑆ij is the resolved rate-of-strain tensor for the resolved scale defined by (Smagorinsky, 1963):
¯𝑆ij=12⁢(∂¯𝑢𝑖∂𝑥𝑗+∂¯𝑢𝑗∂𝑥𝑖)(12) 
In the standard Smagorinsky SGS stress model, the eddy viscosity is modelled by (Smagorinsky, 1963):
𝜈SGS=(𝐶𝑠⁢¯𝛥)2⁢∣¯𝑆∣,∣¯𝑆∣=√2⁢¯𝑆ij⁢¯𝑆ij(13)
¯𝛥=(ΔxΔyΔz⁢)1/3(14) 
where Cs is the Smagorinsky constant, ΔxΔy, and Δz are mesh scales. In FLOW3D®Cs is between 0.1 to 0.2 (Smagorinsky, 1963).
One of the key problems in simulating 3D open channel flow is the calculation of free surface. FLOW3D® uses the Volume of Fluid (VOF) method (Hirt & Nichols, 1981) to track the change of free surface. The VOF method introduces a fluid phase fraction function f to characterize the proportion of a certain fluid in each mesh cell. In that case, the surface position can be precisely located if the mesh cell is fine enough. To monitor the change of f with time and space, the following convection equation is added:

For open channel flow, only two kinds of fluids are involved: water and air. If f is the fraction of water, the state of the fluid in each mesh cell can be defined as:

In FLOW3D®, the interface between water and air is assumed to be shear-free, which means that the drag force on the water from the air is negligible. Moreover, in most cases, the details of the gas motion are not crucial for the heavier water motion so the computational processes will be more efficient.

3.2. Boundary conditions

Six boundary conditions need to be preset in the 3D numerical simulation process. Discharge boundary conditions are used for the inlet of the flume, where the free surface elevation is automatically calculated based on the free surface elevation boundary conditions set for the outlet. The specific information on the inlet and outlet boundary conditions for all computational cases is shown in Table 1. Moreover, because the free surface moves temporally, the free surface boundary conditions are just set as no shear stress and having a normal pressure, and the position of the free surface will be automatically adjusted over time by the VOF method in FLOW3D®. Furthermore, the bed and two side walls are all set to be no-slip for fixed bed conditions, and a standard wall function is employed at the wall boundaries for wall treatment.

The inlet turbulent boundary conditions also need to be considered. They are set by default here. The turbulent velocity fluctuations V are assumed to be 10% of the mean flow velocity with the turbulent kinetic energy (TKE) (per unit mass) equaling 0.5V’2. The maximum turbulent mixing length is assumed to be 7% of the minimum computational domain scale, and the turbulent dissipation rate is evaluated automatically from the TKE.

4. Results and discussion


4.1. Flow structure in the confluence-bifurcation unit

4.1.1. Free surface elevation

Figure 2 shows the free surface elevation at five different longitudinal profiles (i.e. α = 0.2, 0.4, 0.5, 0.6, 0.8) for cases 1a and 2a. The parameter α was defined as follows:𝛼=𝑠𝐵(17) where s is the transverse distance between a certain profile and the left boundary of the flume. In general, the longitudinal change of free surface in the two cases is very similar despite different discharge levels. The free surface elevation decreases as the channel narrows from the upstream bifurcation to the front of the confluence-bifurcation unit. On the contrary, when the flow diverges again at the end of the confluence-bifurcation unit, the free surface elevation increases with channel widening. However, whether the fall or rise of free surface elevation in case 1a is much sharper than that in case 2a, especially at profiles with α = 0.2 and 0.8 (Figure 2(a)), which indicates there may be distinct flow states between the two cases. To further illustrate this finding, the Froude number Fr at different cross-sections (CS08∼CS15) is examined. In case 2a, the flow remains subcritical within the confluence-bifurcation unit. By contrast, in case 1a, a local supercritical flow is observed near the side banks of CS09 (i.e. α = 0.2 and 0.8), with Fr being about 1.2. This local supercritical flow can lead to a hydraulic drop followed by a hydraulic jump, which accounts for the sharp change of the free surface. The foregoing reveals that when central bars are exposed under relatively low discharge, supercritical flow is more likely to occur near the side banks of the confluence junction due to flow convergence.

Figure 2. Five time-averaged free surface elevation profiles in the confluence-bifurcation unit, in which α denotes the lateral position of the certain profile. Note that the black dashed line denotes the position of CS09, where Fr is about 1.2 near the side banks (α = 0.2 and 0.8) in case 1a. Z’ = z/h2X’ = x/Bh2 is the maximum flow depth at the outlet boundary of cases 2a, 2b and 2c, h2 = 0.34 m.

Moreover, in both cases 1a and 2a, the free surface is higher at the channel centre than near the side banks, whether at the front or the end of the confluence-bifurcation unit. Thus, lateral free surface slopes from the centre to the side banks are generated. For example, the lateral free surface slopes at CS09 are 0.022 and 0.016 respectively for cases 1a and 2a. These lateral slopes can lead to lateral pressure gradient force whose direction is from the channel centreline to the side banks. Notably, the lateral surface slope in case 1a is steeper than that in case 2a, which may also result from the effect of the supercritical flow.

4.1.2. Time-averaged streamwise flow velocity

Figure 3. Time-averaged flow velocity distribution at three different slices over z-direction in the confluence-bifurcation unit: (a)∼(c) case 1a, (d)∼(f) case 2a. The flow direction is from the left to the right. StZ = Stagnation Zones, MiL = Mixing Layer. X’ = x/B, Y’ = y/B, Ui’ = Ui/Uti, Ui denotes the time-averaged streamwise flow velocity in case series i (i = 1,2), Uti denotes the cross-section-averaged streamwise flow velocity in case series i, Ut1 = 0.385 m/s, for case 2a Ut2 = 0.714 m/s.
Figure 4. Time-averaged flow velocity contours at eight different cross-sections in the confluence-bifurcation unit: (a) case 1a, (b) case 2a.

Besides the shared features described above, some differences between the two cases are also identified. First, flow stagnation zones at the upstream bar tail are found exclusively in case 1a as the central bars are exposed (Figure 3
(a–c)). Second, in case 1a the mixing layer is obvious in both the lower or upper flows (Figure 3
(a–c)), while in case 2a the mixing layer can be inconspicuous in the upper flow (Figure 3
(f)). Third, in case 1a, two high-velocity cores gradually transform into one single core downstream of the confluence [Figure 4
(a), CS08∼CS11] and are divided into two cores again at the downstream bar head [Figure 4
(a), CS15]. By contrast, in case 2a, the two cores merge much more rapidly [Figure 4
(a), CS08∼CS09], and no obvious reseparation of the merged core is found at the downstream bar head (Figure 3
(d–f)). The latter two differences between cases 1a and 2a indicate that the flow convergence and divergence are relatively weak when the central bars are fully submerged. It is noticed that when the central bars are exposed, the flow in branches needs to steer around the central bar, which can cause a large angle between the two flow directions at the confluence, and thus relatively strong flow convergence and divergence may occur. By contrast, when the central bars are fully submerged, the flow behavior resembles that of a straight channel, with flow predominantly moving straight along the main axis of the central bars. Therefore, a small angle between two tributary flow forms, and thus flow convergence and divergence are relatively mild.

4.1.3. Recirculation vortex

A recirculation vortex with a vertical axis is a typical structure usually found where flow steers sharply, and is generated from flow separation (Lu et al., 2023). This vortex structure is found in the confluence-bifurcation unit in the present study, marking several significant flow separation zones. Figure 5 shows the recirculation vortex structure at the bifurcation junction of the confluence-bifurcation unit. In both cases 1a and 2a, two recirculation vortices BV1 and BV2 are found at the bifurcation junction corner. Moreover, BV1 and BV2 seem well-established near the bed but tend to transform into premature ones in the upper flow, and there is also a tendency for the cores of BV1 and BV2 to shift downstream as they transition from the lower to the upper flow (Figure 5(a–c,d–f)). This finding indicates that flow separation zones exist at the bifurcation junction corner, and the vortex structure is similar in the separation zones under low and high discharges. These flow separation zones are generated due to the inertia effect as flow suddenly diverges and steers towards the curved side banks of the channel (Xie et al., 2020). Notably, two additional vortices BV3 and BV4 are found at both sides of the downstream bar in case 1a (Figure 5(a–c)), but no such vortices exist in case 2a. This difference shows that flow separation zones at both sides of the downstream bar are hard to form when the bars are completely submerged under the high discharge.

Figure 5. Recirculation vortices at the bifurcation junction (streamline view at three different slices over z-direction): (a)∼(c) case 1a, (d)∼(f) case 2a. The red solid line marked out the position of these vortices (BV1∼BV4).

Similarly, Figure 6 shows the recirculation vortex structure at the confluence junction of the confluence-bifurcation unit. No noteworthy similarities but a key difference between the two cases are observed at this site. Two vortices CV1 and CV2 are found downstream of the confluence junction corner in case 1a (Figure 6(c)), which mark two separation zones. Conversely, no such separation zones are found in case 2a. In fact, separation zones were reported at similar sites under relatively low discharges in some previous studies (Ashmore et al., 1992, Luz et al., 2020, Sukhodolov & Sukhodolova, 2019; Xie et al., 2020). Nevertheless, the flow separation zones at the confluence corner are very restricted in the present study (Figure 6(c)). Ashmore et al. (1992) also reported that no, or very restricted flow separation zones occur downstream of natural river confluence corners, primarily because of the relatively slow change in bank orientation compared with the sharp corners of laboratory confluences where separation is pronounced (Best & Reid, 1984; Best, 1988). In the present study, the bank orientation also changes slowly, which may explain why flow separation zones are inconspicuous at the confluence corner.

Figure 6. Recirculation vortices at the confluence junction (streamline view at three different slices over z-direction): (a)∼(c) case 1a, (d)∼(f) case 2a. The red solid line marked out the position of these vortices (CV1 & CV2).

The differences in the distribution of recirculation vortices discussed above may be mainly attributed to the difference in the angle between the tributary flows under different discharges. Some previous studies have reported that the confluence/bifurcation angle can significantly influence the flow structure at confluences/bifurcations (Best & Roy, 1991; Ashmore et al., 1992; Miori et al., 2012). Although the confluence/bifurcation angle is fixed due to the determined central bar shape in the present study, the angle between two tributary flows is affected by the varying discharge. When the central bars are exposed under the low discharge, the flow is characterized by a more pronounced curvature of the streamlines, and a large angle between the two tributary flows is noted (Figure 6(b)), causing strong flow convergence and divergence. By contrast, a small angle forms as the central bars are submerged, thereby leading to relatively weak flow convergence/divergence (Figure 6(e)). Overall, the differences mentioned above can be attributed to the differences in the intensity of flow convergence and divergence under different discharges.

It should be noted that some previous studies (Constantinescu et al., 2011; Sukhodolov & Sukhodolova, 2019) presented that there is a wake mode in the mixing layer of two streams at the confluence junction. The wake mode means that in the mixing layer, multiple streamwise coherent vortices moving downstream will form, which is similar to the flow structure around a bluffing body (Constantinescu et al., 2011). However, no such structure has been found within the confluence-bifurcation unit in this study. According to the numerical simulations of Constantinescu et al. (2011), a wake mode was found at a river confluence with a concordant bed and a momentum flux ratio of about 1. The confluence has a much larger angle (∼60°) between the two streams when compared to the confluence junction of the confluence-bifurcation unit in the present study where the angle is about 25°. As flow mechanics at river confluences may include several dominant mechanisms depending on confluence morphology, momentum ratio, the angle between the tributaries and the main channel, and other factors (Constantinescu et al., 2011), the relatively small confluence angle in the present study may explain why the wake mode is absent. The possible effects of the confluence/bifurcation angle are reserved for future study. Additionally, flow separation can lead to reduced local sediment transport capacity, thus causing considerable sediment deposition under natural conditions. Hence, the bank may migrate towards the inner side of the channel at the positions of CV1, CV2, BV1, and BV2, while the bar may expand laterally at the positions of BV3 and BV4.

4.1.4. Secondary current

Secondary current is the flow perpendicular to the mainstream axis (Thorne et al., 1985) and can be categorized into two primary types based on its origin: (1) Secondary current generated by the interaction between centrifugal force and pressure gradient force; (2) Secondary current resulting from turbulence heterogeneity and anisotropy (Lane et al., 2000). There are some widely recognized definitions of secondary current strength (SCS) (Lane et al., 2000). In this paper, the secondary current cells are identified by visible vortex with a streamwise axis, and the definition of SCS proposed by Shukry (1950) is used:

where uxuy, and uz are flow velocities in xy, and z directions and ux represents the mainstream flow velocity.

Figure 7 presents contour plots of SCS and the secondary current structure at key cross-sections of the study area. When the central bars are exposed, at the upstream bar tail (CS08), intense transverse flow occurs with flow converging to the centreline, but no secondary current cell is formed (Figure 7(a)). This is consistent with the findings of Hackney et al. (2018). At the confluence junction (CS09), transverse flow still plays a major role in the secondary current structure, with flow converging to the centreline at the surface and diverging to side banks near the bed (Figure 7(b)). Moreover, ‘back-to-back’ helical cells, which are two vortices rotating reversely, tend to generate at CS09 with their cores located near the side banks (Figure 7(b)) (Mosley, 1976; Ashmore, 1982; Ashmore et al., 1992), yet their forms are rather premature. As the flow goes downstream, the cores of the helical cells gradually rise to the upper flow and approach towards the centreline, and the helical cells become well-established (Figure 7(c–e)). When the flow diverges again at the downstream bar head (CS15), the helical cells attenuate rapidly, and the secondary current structure is once again characterized predominantly by transverse flow (Figure 7(f)).

Figure 7. Distribution of secondary current strength and secondary current cells at six different cross-sections: (a)∼(f) case 1a, (g)∼(l) case 2a. The secondary current cells are identified by visible lateral vortices (streamline view). The zero distance of each cross-section is located on the right bank.

When the central bars are fully submerged under the high discharge, the secondary current structure at the upstream bar tail and the confluence junction exhibits a resemblance to that under the low discharge (Figure 7(g,h)). However, at CS09, two pairs of cells with different scales tend to form under the high discharge (Figure 7(h)). The large and premature helical cells are similar to those under the low discharge, whereas the small helical cells are located near side banks possibly due to wall effects. As the flow moves downstream, the large helical cells tend to diminish rapidly and merge with the small ones near both side walls (Figure 7(i–k)). Moreover, the secondary current structure is once again characterized predominantly by transverse flow at CS14 under the high discharge, which occurs earlier than that under the low discharge (Figure 7(k)). At the downstream bar head, transverse flow still takes a dominant place, while the helical cells seem to become premature with increased scale (Figure 7(l)).

In general, in both cases 1a and 2a, the lateral distribution of SCS at all cross-sections is symmetrical about the channel centreline, where SCS is relatively small. A relatively high SCS is detected at both the upstream bar tail and the downstream bar head due to the effects of centrifugal force caused by flow steering. SCS decreases rapidly from the upstream bar tail (CS08) to the entrance of the downstream bifurcation junction (CS14), followed by a sudden increase at the downstream bar head (CS15) (Figure 7
(a–e, g–k)). However, the distribution of high-SCS zones is different between the two discharges. Under the low discharge, high-SCS zones appear along the bottom near the centerline and at the free surface on both sides of the centreline. Although similar high-SCS zones are found along the bottom near the centerline under the high discharge, the high-SCS zones are not found at the free surface. Furthermore, it is noticed that more obvious high-SCS zones appear under the low discharge compared with the high discharge, especially at CS09. This may be attributed to the differences in the intensity of flow convergence and divergence under different submerging conditions of the central bars. When the central bars are exposed, flow convergence and divergence are strong and sharp flow steering occurs, thereby causing large SCS. By contrast, when the central bars are fully submerged, flow convergence and divergence are relatively weak, and thus small SCS is observed.

4.1.5. Turbulent characteristics

Turbulent characteristics reflect the performance of energy and momentum transfer activities in flow (Sukhodolov et al., 2017). Comprehensive analysis of turbulent characteristics is crucial as they greatly impact the incipient motion, settling behavior, diffusion pattern, and transport process of sediment. Here, the TKE and turbulent dissipation rate (TDR) of flow in the confluence-bifurcation unit are analyzed.

Figure 8 shows the distribution of TKE on various cross-sections in cases 1a and 2a. In the same way, Figure 10 shows the distribution of TDR. The values of TKE and TDR are nondimensionalized with mid-values of TKE = 0.005 m2·s−2 and TDR = 0.007 m3·s−2. In both cases 1a and 2a, the distributions of TKE and TDR show symmetrical patterns concerning the channel centreline. High-TKE and high-TDR zones exhibit a belt distribution near the channel bottom (McLelland et al., 1999; Ashworth, 1996; Constantinescu et al., 2011), indicating that turbulence primarily originates at the channel bottom due to the influence of bed shear stress. A sudden increase of TKE (Weber et al., 2001) and TDR occurs near the channel bottom at the confluence junction [Figure 8 and 9, CS08∼CS09] and from the entrance of the bifurcation junction (CS14) to the downstream bar head (CS15) (Figures 8 and 9).

Figure 8. Turbulent kinetic energy contours at eight different cross-sections in the confluence-bifurcation unit: (a) case 1a, (b) case 2a. TKE = turbulent kinetic energy. TKE’ =  dimensionless value of TKE, with regard to a mid-value of TKE = 0.005 m2·s−2.
Figure 9. Turbulent dissipation rate contours at eight different cross-sections in the confluence-bifurcation unit: (a) case 1a, (b) case 2a. TDR = turbulent dissipation rate. TDR’ =  dimensionless value of TDR, with regard to a mid-value of TDR = 0.007 m3·s−2.
Figure 10. Comparison of the distribution of time-averaged streamwise flow velocity along the flow depth at different cross-sections between the confluence-bifurcation unit and the single confluence. (a)∼(f) 1a vs. 1b, (g)∼(l) 2a vs. 2b.

Despite the common turbulent characteristics between cases 1a and 2a, additional high-TKE zones are found in the upper flow at the upstream bar tail (CS08), the confluence junction (CS09) and the downstream bar head (CS15) (Figure 8) when the central bars are fully submerged. The formation mechanism of these high-TKE zones near the water surface is more complicated, which may result from interactions of velocity gradient, secondary current structure and wall shear stress (Engel & Rhoads, 2017; Lu et al., 2023).

4.2. Comparison with single confluence/bifurcation cases

In this section, the results of a single confluence (cases 1b and 2b) and a single bifurcation (cases 1c and 2c) are compared with those of the confluence-bifurcation unit (cases 1a and 2a) under two discharges. Flow structure at CS08∼CS15 is mainly concerned below.

4.2.1. Comparison with single confluence cases

First, the patterns of time-averaged streamwise velocity, TKE and TDR within the single confluence (presented by contour plots in the supplementary materials) are assessed and then compared with those within the confluence-bifurcation unit (Figures 4, 8, and 9). It is found that distributions of these parameters are similar in the confluence-bifurcation unit and the single confluence from the upstream bar tail (CS08) to the entrance of the bifurcation junction (CS14), despite varying discharges. As the existence of the downstream central bar is the main difference between the single confluence and the confluence-bifurcation unit, this finding indicates that the downstream bar may have limited influence on the flow structure in the confluence-bifurcation unit. In other words, the flow structure in the confluence-bifurcation unit appears to be mainly shaped by the presence of the upstream bar, with its impact potentially reaching as far as the entrance of the bifurcation (CS14). Moreover, under the low discharge, the two high-velocity cores seem to merge later (at CS11) in the single confluence than in the confluence-bifurcation unit (at CS10), which indicates the convergence of two tributary flows may achieve a steady state faster in the confluence-bifurcation unit. To further elucidate the differences, results on the distribution of time-averaged streamwise velocity and TKE along the flow depth are discussed below.

4.2.1.1. Time-averaged streamwise velocity

Figure 10 shows the distribution of time-averaged streamwise flow velocity along the flow depth at different cross-sections. Note that α = 0.5 denotes the channel centreline and α = 0.7 denotes a position near the side banks. As only marginal differences are found at α = 0.3 and 0.7, only profiles at α = 0.7 are displayed for clarity.

Under the low discharge, no obvious difference in the distribution of time-averaged streamwise flow velocity is observed at the upstream bar tail (Figure 10(a)). At the confluence junction (Figure 10(b)), the velocities near the side banks (α = 0.7) are larger than those at the centre (α = 0.5) in both the confluence-bifurcation unit and the single confluence, which suggests that the two tributary flows have not sufficiently merged. The two tributary flows achieve convergence at CS11 in both the confluence-bifurcation unit and the single confluence (Figure 10(c)), with the velocity at the centre (α = 0.5) is larger than that near the side banks. Nevertheless, the velocities at the centre (α = 0.5) and near the side banks (α = 0.7) are closer to each other in the confluence-bifurcation unit than those in the single confluence, which represents less sufficient flow convergence in the confluence-bifurcation unit than in the single confluence. Therefore, it can be inferred that the convergence of two tributary flows may achieve a steady state faster in the confluence-bifurcation unit. After reaching the steady state, the velocity near the side banks (α = 0.7) is smaller in the single confluence than in the confluence-bifurcation unit despite close values at the centre (α = 0.5) (Figure 10(d,e)). This leads to a more pronounced disparity between velocities at the centre and near the side banks in the single confluence than that observed in the confluence-bifurcation unit. In other words, the high-velocity zone is more concentrated on the channel centreline in the single confluence, while the lateral distribution of flow velocity tends to be more uniform in the confluence-bifurcation unit. This may be attributed to the influence of the downstream central bar, which is further proved by comparing the velocity profiles at CS15 (Figure 10(e)).

As for the high discharge condition, from CS08 to CS14, the quantitative differences in velocity distribution between the confluence-bifurcation unit and the single confluence seem small. This indicates that the effect of morphology appears to be subdued when the central bars are fully submerged under the high discharge. It should be also noted that under both the low and high discharge, velocity profiles at the corresponding location exhibit the same shapes in the confluence-bifurcation unit and the single confluence, which indicates that the upstream confluence may dominate the flow structure in the confluence-bifurcation unit.

4.2.1.2. Secondary current

Figure 11 shows contour plots of SCS and the secondary current structure for single confluence cases. Compared with Figure 7, under both low and high discharge conditions, the distribution of SCS and the structure of helical cells in the confluence-bifurcation unit and the single confluence are very similar from CS08 to CS12 (Figure 7(a–d, g–j) and Figure 11(a–d, g–j)]. This indicates that the secondary current structure in the confluence-bifurcation unit exhibits certain consistent features when compared to those in the single confluence, thus proving that the effects of the upstream central bar may dominate the flow structure in the confluence-bifurcation unit. However, the secondary current structure at CS14 and CS15 is different between the confluence-bifurcation unit and the single confluence (Figure 7 and 11(e, f, k,l)). Under the low discharge, transverse flow is from the side banks to the centre and relatively high SCS is found near the side banks at CS14 in the single confluence, while the transverse flow is always from the centre to the side banks and SCS is relatively low at the corresponding sites in the confluence-bifurcation unit (Figure 11(e)). Under the high discharge, the helical cells near the side walls almost diminish in the single confluence, while they still exist in the confluence-bifurcation unit at CS14 (Figure 11(k)). Under both low and high discharges, the secondary current pattern at CS15 is similar to that at CS14 in the single confluence, while they are different in the confluence-bifurcation unit due to the existence of the downstream central bar. This comparison indicates that the existence of the downstream central bar can influence the upstream secondary current structure, nevertheless, the effects are fairly limited.

Figure 11. Secondary current at different cross-sections in the single confluence condition: (a)∼(f) case 1b, (g)∼(l) case 2b. The zero distance of each cross-section is located on the right bank.
4.2.1.3. Turbulent kinetic energy

Figure 12 shows TKE distribution along the flow depth at different cross-sections. Under the low discharge, in general, the maximum TKE tends to appear near the channel bottom in both the confluence-bifurcation unit and the single confluence. No obvious difference is observed at the upstream bar tail (CS08) (Figure 12(a)). Downstream this site (at CS09), the maximum TKE near the side banks (α = 0.7) is larger than that at the channel centre in the single confluence, while they are close to each other in the confluence-bifurcation unit (Figure 12(b)). This can also be attributed to the insufficient convergence of the two tributary flows. At CS11, flow convergence achieves a steady state in the confluence-bifurcation unit, while it remains insufficient in the single confluence. As flow convergence reaches a steady state at CS12, the maximum TKE in the single confluence exhibits a more concentrated distribution on the channel centre than that in the confluence-bifurcation unit (Figure 12(d)). This effect becomes more obvious downstream at CS14 (Figure 12(e)). The less-concentrated distribution of the maximum TKE in the confluence-bifurcation unit can be owing to the effects of the downstream central bar as well, which appears analogous to that mentioned in 4.2.1.1.

Figure 12. Comparison of the distribution of TKE along the flow depth at different cross-sections between the confluence-bifurcation unit and the single confluence. (a)∼(f) 1a vs. 1b, (g)∼(l) 2a vs. 2b.

Under the high discharge condition, two peaks of TKE appear in both the confluence-bifurcation unit and the single confluence (Figure 12(g–l)). Moreover, in both the confluence-bifurcation unit and the single confluence, from the upstream bar tail to the downstream bar head, the peak of TKE in the upper flow is larger at the channel centre (α = 0.5), while the peak of TKE in the lower flow is larger near the side banks (α = 0.7). However, the disparity between the TKE near the side banks and at the channel centre seems to be larger in the single confluence, while the TKE in the confluence-bifurcation unit takes a more uniform distribution. Even though, TKE profiles at the corresponding location exhibit highly similar shapes in the confluence-bifurcation unit and the single confluence, suggesting that the effects of channel morphology seem to be inhibited when the central bars are submerged under the high discharge.

4.2.2. Comparison with single bifurcation cases

Distributions of time-averaged streamwise velocity, TKE and TDR at corresponding cross-sections are also compared between the single bifurcation (see the Supplementary material) and the confluence-bifurcation unit (Figures 4, 8 and 9). Unlike the high similarity in flow characteristics exhibited between the confluence-bifurcation unit and the single confluence, significant differences are found between the confluence-bifurcation unit and the single bifurcation, especially at CS08∼CS14. On the one hand, the high-velocity zones are broader and asymmetrical concerning the channel centreline in the single bifurcation, with a belt-like and an approximately elliptic-like distribution respectively under the low and high discharges. By contrast, the high-velocity zone is a core that concentrates on the channel centre in the confluence-bifurcation unit. Moreover, the maximum velocity seems smaller in the single bifurcation than that in the confluence-bifurcation unit. On the other hand, the high-TKE belt near the channel bottom appears to be narrower in the single bifurcation than in the confluence-bifurcation unit, especially at CS08∼CS14 under the low discharge. Furthermore, additional high-TKE zones are found near the side walls at CS08∼CS11 in the single bifurcation, of which the scale is obviously smaller than those in the confluence-bifurcation unit. In addition, TKE at the channel centre is smaller near the free surface in the single bifurcation than that in the confluence-bifurcation unit. Nevertheless, the distributions of velocity, TKE and TDR seem to be similar in the confluence-bifurcation unit and the single bifurcation at CS15. As the existence of the upstream central bar is the main difference between the single confluence and the confluence-bifurcation unit, all the above findings indicate that the upstream central bar greatly influences the flow structure in the confluence-bifurcation unit. On the other hand, the downstream central bar may have a restricted influence on the flow structure in the confluence-bifurcation unit, whose impact may be limited to a range between the entrance of the bifurcation (CS14) and the downstream bar head (CS15). To further elucidate the differences, results on the distribution of time-averaged streamwise velocity and TKE along the flow depth are discussed below.

4.2.2.1. Time-averaged streamwise velocity

Figure 13 shows the distribution of time-averaged streamwise velocity along the flow depth at different cross-sections. Under the low discharge, distinct distribution patterns of flow velocity between the confluence-bifurcation unit and the single bifurcation are found at CS08, CS09 and CS11, which can be attributed to the effects of upstream flow convergence (Figure 13(a–c)). However, when the flow convergence reaches a steady state in the confluence-bifurcation unit (Figure 13(d–f)), the high-velocity zone is more concentrated in the confluence-bifurcation unit than in the single bifurcation due to to the significant influence of the upstream central bar on the flow structure. The velocity profiles at the downstream bar head can be a shred of evidence as well, with the maximum velocity larger at the channel centre but smaller near the side banks in the confluence-bifurcation unit than in the single bifurcation.

Figure 13. Comparison of the distribution of time-averaged streamwise flow velocity along the flow depth at different cross-sections between the confluence-bifurcation unit and the single bifurcation. (a)∼(f) 1a vs. 1c, (g)∼(l) 2a vs. 2c.

Under the high discharge, the distribution of velocity seems to exhibit limited differences between the two kinds of morphology, which indicates that the effects of channel morphology may be less noticeable when the central bars are fully submerged under the high discharge. Nevertheless, the velocity in the lower flow (below a relative depth of 0.45) shows a uniform lateral distribution in the single bifurcation, as the velocity profile at the channel centreline (α = 0.5) is in line with that near the side banks (α = 0.7) (Figure 13(g–l)). However, in the confluence-bifurcation unit, different velocity distributions in the lower flow can be observed at the channel centreline (α = 0.5) and near the side banks (α = 0.7). The foregoing results indicate that when the central bars are fully submerged, the high-velocity zones are more concentrated on the channel centreline in the confluence-bifurcation unit, while the lateral distribution of flow velocity within the single bifurcation tends to be more uniform, especially near the bifurcation junction (Figure 13(j,k)). This can also be attributed to the dominant influence of the upstream central bar over the downstream central bar.

It is also noted that the flow velocity distribution along the flow depth in the confluence-bifurcation unit is of a similar pattern despite varying discharges. As a critical point, the maximum velocity appears in the upper flow. The distribution above the critical point is approximately linear whereas it appears logarithmic below. By contrast, despite the similarity observed under the low discharge, the flow velocity distribution along the flow depth within the single bifurcation exhibits a distinct pattern under the high discharge, especially near the side banks (Figure 13(e–h)). On the one hand, the critical point in the upper flow no longer corresponds to the maximum velocity. On the other hand, the velocity distribution deviates from logarithmic below the critical point, with the maximum velocity appearing at a relative depth of 0.45. Succinctly, the distribution of streamwise velocity along the flow depth may retain the same pattern regardless of discharge levels in the confluence-bifurcation unit, while it may exhibit distinct patterns under different discharge levels in the single bifurcation.

4.2.2.2. Secondary current

Figure 14 shows contour plots of SCS and the distribution of secondary current for single bifurcation cases. In general, the value of SCS near the side banks at CS08∼CS14 (Figure 14(a–d, g–j)) in the single bifurcation seems smaller than that in the confluence-bifurcation unit (Figure 7(a–d, g–j)), especially under the low discharge. SCS distribution at CS14 is similar in the confluence-bifurcation unit and the single bifurcation under both low and high discharges. This difference in SCS distribution between the confluence-bifurcation unit and the single bifurcation indicates that the downstream bifurcation may have a restricted influence on the flow structure in the confluence-bifurcation unit. This influence is limited to a range between the entrance of the bifurcation (CS14) and the downstream bar head (CS15).

Figure 14. Secondary current at different cross-sections in the single bifurcation condition: (a)∼(f) case 1c, (g)∼(l) case 2c. The zero distance of each cross-section is located on the right bank.

In addition, the secondary current structure may also present different patterns in response to varying channel morphologies and discharge conditions. Under the low discharge condition, multiple unstable helical cells with asymmetrical distribution are formed from CS08 to CS12 in the single bifurcation (Figure 14(a–d)), while no obvious helical cells are found at CS14 and CS15 (Figure 14(d,e)). These findings are quite different from the stable and symmetrical helical cells at all cross-sections shown in the confluence-bifurcation unit (Figure 7). This difference may be attributed to the significant influence of the upstream central bar and the limited influence of the downstream central bar. Under the high discharge condition, only one pair of premature helical cells are found from CS08 to CS12 in the single bifurcation with their cores located near the side banks (Figure 14(e,f)). As the flow moves downstream, the helical cells gradually develop and become well-established (Figure 14(g,h)). These helical cells in the single bifurcation show symmetric cross-sectional distribution and a similar longitudinal development as in the confluence-bifurcation unit. However, in the confluence-bifurcation unit, two pairs of helical cells appear upstream of CS12 and CS14 and gradually fuse to one pair under the high discharge. As the ‘two-pairs’ structure in the confluence-bifurcation unit origins from the upstream confluence, the differences in the secondary current structure between the single bifurcation and the confluence-bifurcation unit under the high discharge can also be owing to the effects of the upstream central bar in excess of those of the downstream central bar.

4.2.2.3. Turbulent kinetic energy

Figure 15 shows the TKE distribution along the flow depth at different cross-sections. Under the low discharge, when the two tributary flows have not achieved sufficient convergence in the confluence-bifurcation unit, the maximum TKE is more concentrated in the single bifurcation (Figure 15(a–c)). As flow convergence achieves a steady state, more concentrated high-TKE zones appear at the channel centre within the confluence-bifurcation unit, confirming the finding that the effects of the upstream central bar reign over those of the downstream central bar in the confluence-bifurcation unit. However, things can be very complicated under the high discharge. For TKE distribution at the channel centreline, two peaks appear in the confluence-bifurcation unit with one close to the free surface and the other near the bed (Figure 15(g–l)). By contrast, only one peak near the bed is present in the single bifurcation. Therefore, a larger TKE can be found in the upper flow of the channel centreline in the confluence-bifurcation unit. For TKE distribution near the side banks, two peaks appear in both the confluence-bifurcation unit and the single bifurcation at CS09∼CS14 (Figure 15(h–l)). The upper peak is larger but the lower peak is smaller within the single bifurcation than those within the confluence-bifurcation unit. These significant discordances in TKE distribution under the high discharge further prove that the effects of the upstream bar on the flow structure in the confluence-bifurcation unit are more prominent than those of the downstream central bar.

Figure 15. Comparison of the distribution of TKE along the flow depth at different cross-sections between the confluence-bifurcation unit and the single bifurcation. (a)∼(f) 1a vs. 1c, (g)∼(l) 2a vs. 2c.

4.2.3. Further discussion of the comparisons

The above subsections have revealed significant differences in flow structure within the confluence-bifurcation unit and the single confluence and bifurcation, which directly result from the distinct channel morphologies and vary with the discharge conditions as well. These differences are summarized and further discussed below.

The distinctive morphology of a confluence-bifurcation unit plays a pivotal role in governing streamwise flow velocity distribution, secondary current structure, and turbulent kinetic energy distribution within the channel. Generally, from the upstream bar tail (CS08) to the entrance of the bifurcation (CS14), the flow structure in the confluence-bifurcation unit is highly similar to that in the single confluence, while it exhibits great differences (as shown in 4.2.2) between the confluence-bifurcation unit and the single bifurcation. This indicates that the upstream central bar greatly influences the flow structure in the confluence-bifurcation unit, with the effects spreading to the entrance of the bifurcation. At the downstream bar head (CS15), the flow structure (e.g. the transverse flow patterns) in the confluence-bifurcation unit exhibits high similarity to that in the single bifurcation. However, these similarities do not spread to upstream cross-sections, suggesting that the influence of the downstream central bar is limited at the bifurcation junction. In a word, the effects of the upstream central bar on the flow structure in the confluence-bifurcation unit are in excess of those of the downstream central bar.

However, despite the influence of channel morphology, discharge may also have some important effects on the streamwise flow velocity distribution. On the one hand, when the central bars are exposed under the low discharge, the high-velocity zone is less concentrated in the confluence-bifurcation unit than in the single confluence, while it is more concentrated in the confluence-bifurcation unit than in the single bifurcation. On the other hand, it is noticed that when the central bars are fully submerged under the high discharge, reduced differences in flow structure between the confluence-bifurcation unit and the single confluence/bifurcation are witnessed, and thus the morphology effect seems to be subdued.

4.3. Implications

The present work unravels the flow structure in a laboratory-scale confluence-bifurcation unit and takes the first step to further investigating morphodynamics in such channel morphology. Based on the comparison with a single confluence/bifurcation, the findings provide insight into the complex 3D interactions between water flow and channel morphology. The distinct flow structure in the laboratory-scale confluence-bifurcation unit may appreciably alter sediment transport and morphological evolution, of which research is underway. As the basic morphological element of braided river planform is confluence-bifurcation units, the present work should have direct implications for flow structure in natural braided rivers. This is pivotal for the sustainable management of braided rivers which deals with water and land resources planning, eco-hydrological well-being, and infrastructure safety such as cross-river bridges and oil pipelines (Redolfi et al., 2019; Ragno et al., 2021).

Notably, braided rivers worldwide (e.g. in the Himalayas, North America, and New Zealand) have undergone increased pressures and will continue to evolve due to forces of global climate change and intensified anthropogenic activities (Caruso et al., 2017; Hicks et al., 2021; Lu et al., 2022). In particular, channel aggradation caused by increased sediment supply as well as exploitation of braidplain compromise space for flood conveyance, making the rivers prone to flooding. In this sense, an enhanced understanding of the flow structure under high discharge when central bars are fully submerged is essential for mitigating flooding hazards.

5. Conclusions


This study has numerically investigated the 3D flow structure in a laboratory-scale confluence-bifurcation unit based on the LES model integrated in the FLOW3D® software platform. Two different discharges are considered with the central bars fully submerged or exposed respectively when the discharge is high or low. Cases of a single confluence/bifurcation are included for comparison. The key findings of this paper are as follows:

  1. Several differences are highlighted in the comparison of the flow structure in the confluence-bifurcation unit between the two discharges. When the central bars are fully submerged under the high discharge, the mixing layer of two tributary flows is less obvious, and two high-velocity cores merge more rapidly as compared with those under the low discharge. Besides, flow separation zones are found neither at the confluence corner nor on both sides of the downstream bar when the central bars are fully submerged. Moreover, SCS seems to be smaller near the side banks under the high discharge than under the low discharge. Therefore, it is suggested that flow convergence/divergence is relatively weak in the confluence-bifurcation unit when central bars are fully submerged under the high discharge.
  2. From the upstream bar tail to the entrance of the bifurcation, the flow structure in the confluence-bifurcation unit is highly similar to that in the single confluence, while it exhibits great differences from that in the single bifurcation. Only at the downstream bar head does the flow structure in the confluence-bifurcation unit exhibit high similarity to that in the single bifurcation. Consequently, the effects of the upstream central bar on the flow structure in the confluence-bifurcation unit reign over those of the downstream central bar.
  3. Despite the influence of channel morphology, discharge may also have significant effects on the distribution of streamwise flow velocity. On the one hand, when the central bars are exposed under the low discharge, the high-velocity zone is less concentrated in the confluence-bifurcation unit than in the single confluence, while it is more concentrated in the confluence-bifurcation unit than in the single bifurcation. On the other hand, when the central bars are fully submerged under the high discharge, reduced differences in flow structure between the confluence-bifurcation unit and the single confluence/bifurcation are witnessed, and thus the morphology effect seems to be subdued.

It is noticed that the effects of other factors (e.g. confluence and bifurcation angles, bed discordance) on the flow structure in the confluence-bifurcation unit are not discussed here. Studies on these issues are warranted and reserved for future work.

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Consumer Products | 소비자 제품의 설계 및 제조

자유 표면 흐름은 가정과 사무실 환경 모두에서 사용되는 소비자 제품의 설계 및 제조에서 일반적입니다. 예를 들어, 병 채우기는 매일 대규모로 이루어지는 프로세스입니다. 생산 속도를 극대화하면서 낭비를 최소화하도록 이러한 프로세스를 설계하면 시간이 지남에 따라 상당한 비용 절감으로 이어질 수 있습니다. FLOW-3D는 또한 스프레이 노즐을 설계하고 다공성 재료 및 기타 소비재 구성 요소의 흡수 기능을 모델링하는 데 사용할 수 있습니다. FLOW-3D 의 공기 유입, 다공성 매체 및 표면 장력을 포함한 고급 다중 물리 모델을 사용하면 소비자 제품 설계를 정확하게 시뮬레이션하고 최적화하는 것이 쉽습니다.

충전재

유입된 공기는 생산 라인에서 용기를 채울 때 액체의 부피를 늘릴 수 있습니다. 아래 왼쪽 이미지는 높이가 약 20cm인 병을 1.2초 동안 채우는 것을 보여줍니다. 색상 음영은 액체에 있는 공기의 부피 분율을 나타냅니다. 병에서 혼합 시간이 짧고 혼합 정도가 높기 때문에 공기가 표면으로 올라가 빠져나갈 시간이 없었습니다. 그러나 오른쪽 이미지에서 볼 수 있듯이 약 1.7초의 추가 시간이 지나면 공기가 표면으로 올라가면서 발생하는 액체 부피 감소가 명확하게 보입니다.  FLOW-3D 의 드리프트 플럭스 모델을 사용하면 액체에 있는 기포와 같은 구성 요소를 분리하여 분리할 수 있습니다.

Tide® 병 충전의 빠른 평가

이 기사에서는  FLOW-3D를  사용하여 새로운 타이드 병 디자인의 충전을 모델링하는 방법을 설명하며,  Procter and Gamble Company의 기술 섹션 책임자인 John McKibben이 기고했습니다 .

지금 오전 9시인데 긴급 이메일을 받았다고 상상해보세요.

 방금 새로운 Tide® 병 디자인 중 하나가 손잡이에 채워지고 충전 장비에 문제가 생길 수 있다는 것을 깨달았습니다. 우리는 프로토타입 병이 없으며 몇 주 동안 없을 것입니다. 디자이너와 소비자는 디자인의 모습을 좋아하지만, 채우는 방식이 생산 시설에 쇼스토퍼가 될 수 있습니다.

이런 상황이 제게 주어졌을 때, 저는 3D 지오메트리(그림 1)의 스테레오 리소그래피(.stl) 파일을 요청하여 응답을 시작했고, 제가 무엇을 할 수 있는지 알아보고자 했습니다. 저는  FLOW-3D가  .stl 파일을 사용하여 지오메트리를 입력하고 충전을 위한 자유 표면 문제를 해결할 수 있을 것이라는 것을 알고 있었습니다. 저는 이것이 잠재적인 문제에 대한 좋은 정성적 이해를 제공할 것으로 기대했지만, 이 애플리케이션에 얼마나 정확할지에 대해 약간 불확실했습니다.

병의 기하학

시뮬레이션 설정 및 실행

오후 1시경에 저는 지오메트리 파일, 유량, 유체 특성을 받았습니다. 몇 시간 이내에 시뮬레이션이 실행되어 예비 결과가 나왔습니다. 저는 제 고객을 초대하여 결과를 잠깐 살펴보게 했고 그는 “사장의 상사”를 데려와서 살펴보게 했습니다. 그래서 저녁 5시경에 예비 결과를 살펴보고 원래 우려했던 것이 문제가 아니라는 것을 확인했습니다.

하지만 결과는 몇 가지 다른 의문을 제기했습니다. 손잡이에 채우면 유입 유체 제트가 많이 깨졌습니다. 이렇게 하면 유입 공기와 거품의 양이 늘어날 것이라는 걸 알았습니다(결국 세탁 세제를 채우고 있으니까요).  FLOW-3D  공기 유입 모델을 테스트하기로 했습니다. 이 모델은 원래 난류 제트용으로 개발되었고, 이 층류 문제를 살펴보면 얼마나 잘 수행될지 확신할 수 없었습니다.

병 채우기 시뮬레이션
그림 2: 채워진 결과
병 채우기 시뮬레이션 및 검증
그림 3: 실험 비교

그림 2는 공기 유입 모델이 있는 경우와 없는 경우 병 충전 모델의 결과를 보여줍니다. 유입 공기가 포함되면 충전 레벨이 상당히 증가한다는 점에 유의하십시오. 유입 공기가 병 상단에서 유체를 강제로 밀어내지는 않지만 공기 유입 정확도를 확인해야 할 만큼 충분히 가깝습니다. 그림 3은 공기 유입 레벨을 몇 주 후에 실행한 실험 이미지와 비교합니다(시제품 병이 출시된 후). 제트 분리 및 충전 레벨의 질적 일치는 우수하며 시뮬레이션이 병 설계를 선별하기에 충분히 정확하다는 것을 확인했습니다.

홍조

변기가 어떻게 작동하는지 궁금한 적이 있나요? 사실 꽤 복잡합니다. 손잡이를 밀면 물이 변기 그릇을 채우기 시작합니다. 변기 그릇의 유체 수위가 트랩 상단(변기 그릇 뒤) 위로 올라가면 웨어 유형의 흐름이 시작됩니다. 흐름이 ​​충분히 빠르면 변기 그릇에 거품이 형성되어 사이펀이 생성됩니다. 그 지점에서 사이펀이 변기 그릇에서 물을 끌어내고 변기가 물을 흘립니다. 많은 지역에서 물 절약은 중요한 문제이며, 저유량 변기는 가정과 상업용 모두에 필요합니다. 하지만 변기가 첫 번째 시도에서 제 역할을 하지 못하면 물 절약 목표는 달성되지 않습니다.  FLOW-3D를  사용하면 다양한 설계를 모델링하여 최적의 결과를 얻을 수 있습니다.

식품 가공

식품 가공 산업은 복잡한 유체, 일반적으로 비뉴턴 유체, 슬러리, 고체와 유체의 혼합물을 관리하여 분배 장비를 최적으로 설계하고 제조하기 위한 다양한 요구 사항이 있습니다. 이는 상업용 장비의 일관성과 내구성 및 품질에 필수적입니다. 또한 포장 디자인의 혁신을 통해 한 제품을 다른 제품과 명확히 구별할 수 있습니다. 예를 들어, 꿀, 케첩 또는 크리머를 깨끗하고 정확하게 분배하는 것은 소비자가 매장에서 내리는 선택일 수 있습니다. 운송 및 보관 요구 사항에는 더 나은 모양 엔지니어링과 더 많은 용기 재료 선택이 필요합니다. 1.5리터 물병이나 세탁 세제를 움직이거나 떨어뜨리는 동안의 유체 하중은 상류 설계의 중요한 부분이 될 수 있습니다.

꿀, 옥수수 시럽, 치약과 같은 점성 유체는 일반적으로 고체 표면에 닿으면 코일을 형성하는 경향이 있습니다. 이 효과는 관찰하기에 흥미롭고 재미있지만, 공기가 제품에 끌려들어 포장이 어려워질 수 있는 포장 공정에서는 환영받지 못할 수 있습니다. 코일링이 발생하는 조건은 유체의 점도, 유체가 떨어지는 거리, 유체의 속도에 따라 달라집니다.  FLOW-3D는  다양한 물리적 공정 매개변수를 연구하여 효율적인 공정을 설계하는 데 도움이 되는 정확한 도구를 제공합니다.

혼입

지난 수십 년 동안 컴퓨터화된 측정 및 시뮬레이션 기술의 발전으로 인해 혼합에 대한 이해가 크게 진전되었습니다. 유동 모델링 기술의 지속적인 발전 덕분에 혼합 장비의 유동 의존적 프로세스에 대한 자세한 통찰력을 CFD 소프트웨어를 사용하여 쉽게 시뮬레이션하고 이해할 수 있습니다. 오늘날 블렌딩에서 고체 현탁액, 재킷 반응기의 열 전달에서 발효에 이르기까지 광범위한 응용 분야가  FLOW-3D 의 혼합 기술을 사용하여 모델링됩니다.  FLOW-3D  시뮬레이션은 임펠러의 모든 구성과 모든 용기 형상의 혼합 조건에서 블렌딩 시간, 순환 및 전력 수와 같은 주요 혼합 매개변수를 평가하는 데 도움이 될 수 있습니다. 이러한 시뮬레이션은 실험적 방법을 사용하여 보완합니다. 이러한 장비의 유동 의존적 프로세스를 예측하고 이해하기 위해 CFD 소프트웨어를 사용하면 제품 품질을 향상시키고 많은 제품의 비용과 출시 시간을 모두 줄일 수 있습니다.

비뉴턴 유체

혈액, 케첩, 치약, 샴푸, 페인트, 로션과 같은 비뉴턴 유체는 다양한 점도를 가진 복잡한 유동학을 가지고 있습니다.  FLOW-3D  는 변형 및/또는 온도에 따라 달라지는 비뉴턴 점도를 가진 이러한 유체를 모델링합니다. 전단 및 온도에 따른 점도는 Carreau, 거듭제곱 법칙 함수 또는 단순히 표 형식의 입력을 통해 설명됩니다. 일부 폴리머, 세라믹 및 반고체 금속의 특징인 시간 종속 또는 틱소트로피 거동도 시뮬레이션할 수 있습니다.

핸드 로션 펌프는 종종 여러 가지 설계 문제와 관련이 있습니다. 펌프가 공기 공극을 가두지 않고 효과적으로 작동하고 로션의 연속적인 흐름을 생성하는 것이 중요합니다. 좋은 설계는 노력이 덜 필요하고 이상적으로는 로션을 원하는 곳으로 향하게 합니다. FLOW-3D 의 이동 객체 모델은 노즐이 아래로 눌리는 것을 시뮬레이션하여 저장소의 로션을 가압하는 데 사용됩니다. 로션의 압력과 로션을 추출하는 데 필요한 힘을 연구할 수 있습니다. 여러 설계 변수는 동일한 고정 구조 메시 내에서 쉽게 분석할 수 있습니다.

다공성 재료

다공성 매체에서 유체의 이동에 대한 수치 모델링은 어려울 수 있지만  FLOW-3D 에는 다공성 재료와 관련된 문제를 해결하는 데 유용한 기능이 많이 포함되어 있습니다. FAVOR™ 기술에는 사용자가 연속적인 다공성 매체를 표현할 수 있도록 하는 데 필요한 다공성 변수가 포함되어 있습니다.  FLOW-3D를 사용하면 사용자가 포화 및 불포화 흐름 조건을 모두 시뮬레이션할 수 있습니다. 거듭제곱 법칙 관계를 사용하면 불포화 흐름 조건에서 모세관 압력 과 포화  사이의 비선형 관계를 모델링  할 수 있습니다. 별도의 충전 및 배수 곡선을 사용하여 히스테리시스 현상을 모델링할 수 있습니다. 서로 직접 접촉하는 경우에도 서로 다른 다공성, 투과성 및 습윤성 속성을 서로 다른 장애물에 할당할 수 있습니다. 투과성은 흐름 방향에 따라 지정할 수 있으므로 사용자가 다공성 매체의 이방성 동작을 모델링할 수 있습니다. 유체와 다공성 매체 간의 열 전달을 고려할 수 있습니다.

분무

소용돌이 분무 노즐은 화학 세정제, 의약품 및 연료에서 액체를 분사하는 일반적인 방법입니다. 액체를 성공적으로 분무하려면 일반적으로 노즐로 침투하는 공기 코어를 형성해야 합니다. CFD는 최적의 분무 콘에 대한 기하학, 소용돌이 속도 및 유체 특성의 영향을 탐색하는 효과적인 방법입니다.

이 예에서 2차원 축대칭 소용돌이 흐름이 시뮬레이션되었습니다. 대칭 축을 따라 공기 코어가 노즐의 전체 길이를 거의 관통했습니다. 왼쪽 플롯은 평면에서 속도 분포를 나타내는 벡터가 있는 압력 분포입니다. 오른쪽 플롯은 속도의 소용돌이 구성 요소로 채색되어 있으며 빨간색은 더 높은 값을 나타냅니다.

분무 콘의 규모와 입자 크기가 너무 광범위하기 때문에 분무의 완전한 분무를 직접 계산하는 것은 불가능합니다. 또한 분무는 외부 교란, 노즐의 미세한 결함 및 기타 영향과 밀접하게 관련된 혼란스러운 프로세스입니다. 그러나 노즐을 떠날 때 분무 콘의 특성(예: 벽 두께, 콘 각도, 축 및 방위 속도)을 예측할 수 있다면 이러한 유형의 흐름 장치를 최적화하는 데 큰 도움이 됩니다.

소용돌이 스프레이 노즐
소용돌이 분무 노즐의 FLOW-3D 시뮬레이션

Products

자유 표면 흐름은 가정과 사무실 환경 모두에서 사용되는 소비자 제품의 설계 및 제조에서 일반적입니다.

예를 들어, 병 채우기는 매일 대규모로 진행되는 프로세스입니다. 생산 속도를 최대화하면서 낭비를 최소화하도록 이러한 프로세스를 설계하면 시간이 지남에 따라 상당한 비용 절감으로 이어질 수 있습니다. FLOW-3D는 또한 스프레이 노즐을 설계하고 다공성 재료 및 기타 소비재 구성 요소의 흡수 기능을 모델링하는 데 사용할 수 있습니다.

공기 혼입, 다공성 매질 및 표면 장력을 포함한 FLOW-3D의 고급 다중 물리 모델을 사용하면 소비자 제품 설계를 정확하게 시뮬레이션하고 최적화 할 수 있습니다.


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