Three-dimensional laminar and turbulent convection in separated flow

Three-dimensional laminar and turbulent separated flow and heat transfer in plane symmetric sudden expansion and plane backward facing step is examined in this dissertation. In Papers I, II, and III, simulations of 3-D laminar forced convection in plane symmetric expansion is studied...In Paper IV, 3-D turbulent flow measurements using Laser Doppler Velocimeter are made in a backward facing step flow and the three velocity components and the Reynolds stresses are measured in the separated and redeveloping flow region...In Paper V, the 2-D behavior of a thin film that is shear driven by turbulent air flow is simulated --Abstract, page iv

Rigid Multi-Body Kinematics of Shovel Crawler-Formation Interactions

Large capacity shovels are deployed in surface mining operations for achieving economic bulk production targets. These shovels use crawler tracks for effective terrain engagement in these environments. Shovel reliability, maintainability, availability and efficiency depend on the service life of the crawler tracks. In rugged and challenging terrains, crawler wear, tear, cracks and failure are extensive resulting in prolonged downtimes with severe economic implications. In particular, crawler shoe wear, tear, cracks and fatigue failures can be expensive in terms of maintenance costs and production losses. No fundamental research has been undertaken to understand the crawler-formation interactions in challenging and rugged terrains in surface mining operations. This study forms the foundations for providing long-term solutions to crawler failure problems. The kinematic equations governing the crawler-formation interactions have been formulated to characterise the crawler motions during shovel production. These equations capture the motions governing the link pin joint, oil sand terrain joint and driving constraints based on the multi-body rigid theory. Crawler propel is achieved by using prescribed velocities along a translational degree of freedom (DOF) and a translational and rotational DOF. The crawler kinematic solutions show that the 3-D crawler—terrain model results in 132 DOFs and requires dynamic modelling to obtain the unknown degrees of freedom. A 3-D virtual prototype model is built to capture the crawler-formation interaction in MSC ADAMS based on the rigid body crawler kinematics. The virtual prototype simulator is supplied with mass properties of crawler shoe, mass, stiffness and damping characteristics of oil sand and external loads due to machine weight and contact forces to obtain the time variation of position, velocity and acceleration for the crawler—terrain engagement for given driving constraints. The results from the driving constraints yield a non-linear longitudinal motion of the crawler track assembly. The crawler track lateral and vertical displacements during translation-only motion fluctuates with maximum magnitudes of 0.7 and 3.6 cm. Similarly the fluctuating longitudinal, lateral and vertical velocities and accelerations have maximum magnitudes of 0.22, 0.046 and 0.56 m/s and 7.41, 1.73, and 34.9 m/s2, respectively. This research provides a strong foundation for further study on developing flexible crawler track model for predicting crawler shoes dynamic stress distributions, cracks development and propagation and fatigue analysis during shovel operations

Multibody Dynamic Stress Simulation of Rigid-Flexible Shovel Crawler Shoes

Electric shovels are used in surface mining operations to achieve economic production capacities. The capital investments and operating costs associated with the shovels deployed in the Athabasca oil sands formation are high due to the abrasive conditions. The shovel crawler shoes interact with sharp and abrasive sand particles, and, thus, are subjected to high transient dynamic stresses. These high stresses cause wear and tear leading to crack initiation, propagation and premature fatigue failure. The objective of this paper is to develop a model to characterize the crawler stresses and deformation for the P&H 4100C BOSS during propel and loading using rigid-flexible multi-body dynamic theory. A 3-D virtual prototype model of the rigid-flexible crawler track assembly and its interactions with oil sand formation is simulated to capture the model dynamics within multibody dynamics software MSC ADAMS. The modal and stress shapes and modal loads due to machine weight for each flexible crawler shoes are generated from finite element analysis (FEA). The modal coordinates from the simulation are combined with mode and stress shapes using modal superposition method to calculate real-time stresses and deformation of flexible crawler shoes. The results show a maximum von Mises stress value of 170 MPa occurring in the driving crawler shoe during the propel motion. This study provides a foundation for the subsequent fatigue life analysis of crawler shoes for extending crawler service life

Effects of Buoyancy on Flow Bifurcation and Heat Transfer in Three-Dimensional Plane Symmetric-Sudden Expansion

Simulations of three-dimensional laminar mixed convection in a vertical duct with plane symmetric sudden expansion are presented to illustrate the effects of the buoyancy assisting force on flow bifurcation and heat transfer. The stable laminar bifurcated flow regime that develops in this geometry at low buoyancy levels leads to non-symmetric temperature and heat transfer distributions in the transverse direction, but symmetric distributions with respect to the center width of the duct in the spanwise direction. As the buoyancy force increases, due to increases in wall heat flux, flow bifurcation diminishes and both the flow and the thermal fields become symmetric at a critical wall heat flux. The size of the primary recirculation flow region adjacent to the sudden expansion increases on one of the stepped walls and decreases on the other stepped wall as the wall heat flux increases. The maximum Nusselt number that develops on one of the stepped walls in the bifurcated flow regime is significantly larger than the one that develops on the other stepped wall. The critical wall heat flux increases as the duct\u27s aspect ratio increases for fixed Reynolds number. The maximum Nusselt number that develops in this bifurcated flow regime increases as the duct\u27s aspect ratio increases for fixed wall heat flux and Reynolds number

Three Dimensional Mixed Convection in Plane Symmetric-Sudden Expansion: Symmetric Flow Regime

Three-dimensional simulations of laminar buoyancy assisting mixed convection in a vertical duct with a plane symmetric sudden expansion are presented to illustrate the effects of the buoyancy assisting force and the duct\u27s aspect ratio on the flow and heat transfer. This geometry and flow conditions appear in many engineering applications, but 3-D heat transfer results have not appeared in the literature. This study focuses on the regime where the flow and thermal fields are symmetric in this geometry. The buoyancy force is varied by changing the heat flux on the stepped walls that are downstream from the sudden expansion, and the duct\u27s aspect ratio is varied by changing the width of the duct while keeping the expansion ratio constant. Results are presented for duct\u27s aspect ratio of 4, 8, 12, 16, and ∞ (2-D flow), and for wall heat fluxes between 5-35 W/m2. The Reynolds number and the range of wall heat flux are selected to insure that the flow remains laminar and symmetric in this geometry and reverse flow does not develop at the exit section of the duct. Results for the velocity, temperature, and the Nusselt number distributions are presented, and the effects of the buoyancy force and the duct\u27s aspect ratio on these results are discussed

Three-Dimensional Mixed Convection in Plane Symmetric-Sudden Expansion: Bifurcated Flow Regime

Simulations of three-dimensional laminar mixed convection in a vertical duct with plane symmetric sudden expansion are presented to illustrate the effects of the buoyancyassisting force and the duct\u27s aspect ratio on flow bifurcation and heat transfer. The stable laminar bifurcated flow regime that develops in this geometry at low buoyancy levels leads to nonsymmetric temperature and heat transfer distributions in the transverse direction, but symmetric distributions with respect to the center width of the duct in the spanwise direction. As the buoyancy force increases, due to increases in wall heat flux, flow bifurcation diminishes and both the flow and the thermal fields become symmetric at a critical wall heat flux. The size of the primary recirculation flow region adjacent to the sudden expansion increases on one of the stepped walls and decreases on the other stepped wall as the wall heat flux increases. The maximum Nusselt number that develops on one of the stepped walls in the bifurcated flow regime is significantly larger than the one that develops on the other stepped wall. The critical wall heat flux increases as the duct\u27s aspect ratio increases for fixed Reynolds number. The maximum Nusselt number that develops in the bifurcated flow regime increases as the duct\u27s aspect ratio increases for fixed wall heat flux and Reynolds number

Bifurcated Three-Dimensional Forced Convection in Plane Symmetric Sudden Expansion

Simulations of bifurcated three-dimensional laminar forced convection in horizontal duct with plane symmetric sudden expansion are presented to illustrate the effects of flow bifurcations on temperature and heat transfer distributions. The stable bifurcated flow that develops in this symmetric geometry leads to non-symmetric temperature and heat transfer distributions in the transverse direction, but symmetric distributions with respect to the center width of the duct in the spanwise directions for the Reynolds number of 400-800. A strong downwash develops at the corner of the step and a smaller reverse flow region develops adjacent to the lower stepped wall than the one that develops adjacent to the upper stepped wall. The downwash and the “jet-like” flow that develop near the sidewall create a strong swirling spanwise flow in the primary recirculating flow regions downstream from the sudden expansion. The magnitude of maximum Nusselt number that develops on the lower stepped walls is higher than the one that develops on the upper stepped wall. The locations of these maximum Nusselt numbers on the stepped walls are near the sidewalls and are upstream of the “jet-like” flow impingement regions. Results reveal that the locations where the streamwise component of wall shear stress is zero on the stepped walls do not coincide with the outer edge of the recirculation flow region near the sidewalls. Velocity, temperature, Nusselt number, and friction coefficient distributions are presented

Shear Driven Liquid Film in a Duct: Comparison with Measured Results

Two-dimensional flow simulations of shear driven liquid film by turbulent air flow in a duct is performed using the Reynolds Averaged Navier Stokes and continuity equations along with the k-ε turbulence model and the Volume of Fluid (VOF) model that are part of the FLUENT-CFD code. The purpose of this effort is to determine the suitability of using this model for predicting the measured results of Wittig et al. [1, 2]. In these studies, optical means are used to measure shear driven liquid film velocities along with the liquid film thickness, and measurements are reported for different air velocities and liquid film flow rates. The simulated results will be compared with measured values, and the suitability of the VOF model for simulating such flow will be assessed in this study

DPM Dissipation Experiment At MST\u27s Experimental Mine and Comparison with CFD Simulation

Diesel Particulate Matter (DPM) is regulated in the U.S. for both underground coal and metal/nonmetal mines. Today, many underground mines still face difficulty in compliance with DPM regulations. The DPM research carried out in Missouri University of Science and Technology (MST) is to use computational fluid dynamics (CFD) to study the DPM distribution in commonly used face areas. The result is expected to be used for selection of DPM reduction strategies and better working practices, which can help the underground mines to meet regulation limits and improve the working environment for the miners. An experiment was conducted at MST\u27s Experimental Mine to validate CFD simulation. DPM was collected at four locations downstream of a stationary diesel engine. The experiment data were then compared with the CFD simulation results. The comparison shows that CFD simulation can forecast the location of DPM concentration with practical accuracy (less than 0.15 m). CFD can be used to further study DPM distribution in commonly used working faces and give guidance to DPM reduction