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DOE OSTI2021

Topology optimization of additively manufactured fluidic components free of internal support structures

This report integrates projection-based approaches for implementing overhang constraints with fluid topology optimization to design additively manufactured fluidic components that do not require internal support structures. Internal support structures are challenging, potentially impossible to remove in complex fluid networks, yet would degrade fluidic performance if left within the part. This presents a major challenge in coupling topology optimization with additive manufacturing in the design of fluid components. The proposed approach leverages past work in overhang constraints for solid mechanics, including projection formulations and adjoint sensitivity analysis, and considers incompressible Navier–Stokes equations for laminar fluid flow. The approach is demonstrated on 2D and 3D fluid topology optimization problems to minimize pressure drop and constrain mass flow rates in pipes and manifolds. Resulting designs are crisp, logical, satisfy performance constraints, and satisfy overhang constraints, eliminating the need for internal support structures.

42 ENGINEERING↗

NASA NTRS1997

Turbulence Modeling Validation, Testing, and Development

The primary objective of this work is to provide accurate numerical solutions for selected flow fields and to compare and evaluate the performance of selected turbulence models with experimental results. Four popular turbulence models have been tested and validated against experimental data often turbulent flows. The models are: (1) the two-equation k-epsilon model of Wilcox, (2) the two-equation k-epsilon model of Launder and Sharma, (3) the two-equation k-omega/k-epsilon SST model of Menter, and (4) the one-equation model of Spalart and Allmaras. The flows investigated are five free shear flows consisting of a mixing layer, a round jet, a plane jet, a plane wake, and a compressible mixing layer; and five boundary layer flows consisting of an incompressible flat plate, a Mach 5 adiabatic flat plate, a separated boundary layer, an axisymmetric shock-wave/boundary layer interaction, and an RAE 2822 transonic airfoil. The experimental data for these flows are well established and have been extensively used in model developments. The results are shown in the following four sections: Part A describes the equations of motion and boundary conditions; Part B describes the model equations, constants, parameters, boundary conditions, and numerical implementation; and Parts C and D describe the experimental data and the performance of the models in the free-shear flows and the boundary layer flows, respectively.

Bardina, J. E.↗

NASA NTRS1987

Stability and resonance in grooved-channel flows

Numerical simulation using the spectral element method is used to study the stability and resonant response of incompressible moderate-Reynolds-number flows in periodically-grooved channels. For Reynolds numbers below a critical value, the flow is shown to approach a stable steady-state, and the least stable modes resemble Tollmien-Schlichting channel waves. For Reynolds numbers greater than the critical value, self-sustained oscillations result. Oscillatory perturbation of the grooved-channel flow at the frequency of the least stable mode of the linearized system is found to result in subcritical resonant excitation as the critical Reynolds number is approached. The importance of nonhomogeneous geometry in the forced response of the flow is discussed.

Ghaddar, Nasreen K.↗

NASA NTRS1997

Reduced Navier Stokes Relaxation Procedures for Internal Flows

In spite of significant advancement in the field of high speed computing, flow calculations involving complex geometries and/or flow behavior still require large amounts of CPU time and memory. In order to predict such flows without sacrificing grid convergence and accuracy, adaptive gridding techniques that provide optimal resolution are highly desirable. The present work combines multigrid techniques and domain decomposition concepts to provide local, solution adaptive, grid refinement. Several viscous compressible and incompressible, two and three-dimensional, flows with strong inviscid interaction and/or axial flow reversal, are considered with a segmented multigrid domain decomposition (SMGDD) procedure for which uniform meshes result in each domain. A pressure-based form of flux-vector splitting is applied to the Navier-Stokes equations, which are represented by an implicit lowest-order reduced Navier-Stokes (RNS) system and a purely diffusive, higher-order, deferred-corrector. A trapezoidal or box-like form of discretization insures that all mass conservation properties are satisfied at interfacial and outflow boundaries, even for this primitive-variable non-staggered grid computation. The SMGDD technique presented herein has previously been applied for incompressible two dimensional flows. The present work offers improvement in the gridding strategy, by allowing for disjoint subdomains that provide optimal resolution of disparate flow features. It also extends the SMGDD technique to three dimensional compressible flows. Laminar and turbulent flow in a backward facing step channel is considered; although the procedure is applicable to more severe geometries. The standard K-epsilon model is applied for turbulence closure. For Re greater than 400, differences between two-dimensional theory and experiment are resolved through a three dimensional simulation, which confirms the experimentally observed three dimensionality of the recirculation patterns on the upper and lower surfaces.

Rubin, Stanley G.↗

NASA NTRS1980

Three-layer interactive method for computing supersonic laminar separated flows

An interactive model for numerical computation of complicated two-dimensional flowfields including regions of reversed flow is proposed. The present approach is one of dividing the flowfield into three regions, in each of which a simplified mathematical model is applied: (1) outer, supersonic flow for which the full potential equation (hyperbolic) is used; (2) viscous, laminar layer in which the compressible boundary-layer model (parabolic) is used; and (3) recirculating flow modeled by the incompressible Navier-Stokes equations (elliptic). For matching of the numerical solutions in the three layers, two interaction models are developed: one for pressure interaction, the other for interaction between the shear layer and the recirculating flow. The uniform solution for the whole flowfield is then obtained by iteration of the local solutions under the constraints imposed by matching. The three-layer interactive model is used for solution of the flowfield past an asymmetric cavity. The method is shown to be capable of dealing with backflow without encountering problems at separation, characteristic to the boundary-layer approach.

Brandeis, J.↗

NASA NTRS1986

Thermodynamic evaluation of transonic compressor rotors using the finite volume approach

A method was developed which calculates two-dimensional, transonic, viscous flow in ducts. The finite volume, time marching formulation is used to obtain steady flow solutions of the Reynolds-averaged form of the Navier Stokes equations. The entire calculation is performed in the physical domain. The method is currently limited to the calculation of attached flows. The features of the current method can be summarized as follows. Control volumes are chosen so that smoothing of flow properties, typically required for stability, is now needed. Different time steps are used in the different governing equations to improve the convergence speed of the viscous calculations. A new pressure interpolation scheme is introduced which improves the shock capturing ability of the method. A multi-volume method for pressure changes in the boundary layer allows calculations which use very long and thin control volumes. A special discretization technique is also used to stabilize these calculations. A special formulation of the energy equation is used to provide improved transient behavior of solutions which use the full energy equation. The method is then compared with a wide variety of test cases. The freestream Mach numbers range from 0.075 to 2.8 in the calculations. Transonic viscous flow in a converging diverging nozzle is calculated with the method; the Mach number upstream of the shock is approximately 1.25. The agreement between the calculated and measured shock strength and total pressure losses is good. Essentially incompressible turbulent boundary layer flow in a adverse pressure gradient is calculated and the computed distribution of mean velocity and shear stress are in good agreement with the measurements. At the other end of the Mach number range, a flat plate turbulent boundary layer with a freestream Mach number of 2.8 is calculated using the full energy equation; the computed total temperature distribution and recovery factor agree well with the measurements when a variable Prandtl number is used through the boundary layer.

Nicholson, S.↗

NASA NTRS1979

An energy and potential enstrophy conserving scheme for the shallow water equations

A three-dimensional finite difference scheme for the solution of the shallow water momentum equations which accounts for the conservation of potential enstrophy in the flow of a homogeneous incompressible shallow atmosphere over steep topography as well as for total energy conservation is presented. The scheme is derived to be consistent with a reasonable scheme for potential vorticity advection in a long-term integration for a general flow with divergent mass flux. Numerical comparisons of the characteristics of the present potential enstrophy-conserving scheme with those of a scheme that conserves potential enstrophy only for purely horizontal nondivergent flow are presented which demonstrate the reduction of computational noise in the wind field with the enstrophy-conserving scheme and its convergence even in relatively coarse grids.

Arakawa, A.↗

NASA NTRS2016

A Survey of Solver-Related Geometry and Meshing Issues

There is a concern in the computational fluid dynamics community that mesh generation is a significant bottleneck in the CFD workflow. This is one of several papers that will help set the stage for a moderated panel discussion addressing this issue. Although certain general "rules of thumb" and a priori mesh metrics can be used to ensure that some base level of mesh quality is achieved, inadequate consideration is often given to the type of solver or particular flow regime on which the mesh will be utilized. This paper explores how an analyst may want to think differently about a mesh based on considerations such as if a flow is compressible vs. incompressible or hypersonic vs. subsonic or if the solver is node-centered vs. cell-centered. This paper is a high-level investigation intended to provide general insight into how considering the nature of the solver or flow when performing mesh generation has the potential to increase the accuracy and/or robustness of the solution and drive the mesh generation process to a state where it is no longer a hindrance to the analysis process.

Masters, James↗

DOE OSTI2025

A discontinuous Galerkin spectral element method for compressible reacting flows

High-order methods have recently been shown to be an effective tool for high-fidelity flow computations like direct numerical simulations and large-eddy simulations because of their strong balance between accuracy and computational cost. In this work, a high-order discontinuous Galerkin spectral element method (DGSEM) is developed to solve the chemically reacting Navier-Stokes equations. To handle the disparate length and time scales associated with these equations, we develop a novel method which combines the spectral accuracy of the SEM with the flexibility of the DG approach. The framework, implemented in the spectral element code Nek5000, is well suited to capture turbulence in smooth regions of the flow, while maintaining numerical stability in the presence of shocks. An entropy-residual based artificial viscosity is added to smooth shocked regions of flow, and a positivity-preserving limiter is implemented to suppress non-physical oscillations. These enhancements support the numerical stability of the hydrodynamic sub-step, which is decoupled from the chemistry integration through a second-order operator splitting method. Here, a series of smooth and discontinuous validation cases are presented in increasing physical and computational complexity for both inviscid and viscous flows. In particular, simulations of canonical one-dimensional and two-dimensional detonations are performed, and the high-order numerical results are validated against available literature data. Additional validation studies are carried out for classical three-dimensional numerical simulations of incompressible and compressible turbulent flows.

Compressible reacting flows↗

NASA NTRS1985

General design method for 3-dimensional, potential flow fields. Part 2: Computer program DIN3D1 for simple, unbranched ducts

The general design method for three-dimensional, potential, incompressible or subsonic-compressible flow developed in part 1 of this report is applied to the design of simple, unbranched ducts. A computer program, DIN3D1, is developed and five numerical examples are presented: a nozzle, two elbows, an S-duct, and the preliminary design of a side inlet for turbomachines. The two major inputs to the program are the upstream boundary shape and the lateral velocity distribution on the duct wall. As a result of these inputs, boundary conditions are overprescribed and the problem is ill posed. However, it appears that there are degrees of compatibility between these two major inputs and that, for reasonably compatible inputs, satisfactory solutions can be obtained. By not prescribing the shape of the upstream boundary, the problem presumably becomes well posed, but it is not clear how to formulate a practical design method under this circumstance. Nor does it appear desirable, because the designer usually needs to retain control over the upstream (or downstream) boundary shape. The problem is further complicated by the fact that, unlike the two-dimensional case, and irrespective of the upstream boundary shape, some prescribed lateral velocity distributions do not have proper solutions.

Stanitz, J. D.↗

NASA NTRS1991

Computational study of three dimensional viscous flow through a turbine cascade using a multi-domain spectral technique

The three dimensional viscous flow through a planar turbine cascade is numerically simulated by direct solution of the incompressible Navier-Stokes equations. Flow dependence in the spanwise direction is represented by direct expansion in Chebyshev polynomials, while the discretization on planes parallel to the endwalls is accomplished using the spectral element method. Elemental mapping from the physical to the computational space uses an algebraic mapping technique. A fractional time stepping method that consists of an explicit nonlinear convective step, an implicit pressure correction step, and an implicit viscous step is used to advance the Navier-Stokes equations forward in time. Results computed at moderate Reynolds numbers show a three dimensional endwall flow separation, a midspan separation of the blade suction surface boundary layer, and other three-dimensional features such as the presence of a saddle point flow in the endwall region. In addition, the computed skin friction lines are shown to be orthogonal to the surface vorticity lines, demonstrating the accuracy achievable in the present method.

Renaud, Earl W.↗

NASA NTRS1992

Experiments on shock/vortex interactions

The interaction between a shock wave and a supersonic streamwise vortex is a fundamental fluid-dynamics problem with numerous practical applications. This paper describes an experimental study of this phenomenon. In particular, supersonic streamwise vortices of varying strength and Mach number were generated and measured using five-hole and total-temperature probes. In addition, the interactions between a vortex and either an oblique or a normal shock wave were visualized using schlieren and planar-laser-scattering techniques. The mean-flow measurements show both similarities and differences between the supersonic streamwise vortex and its incompressible counterpart, while the flow-visualization results show that the shock/vortex interaction is always unsteady and that, under certain conditions, the vortex can burst. The conditions necessary for supersonic vortex breakdown are presented.

Cattafesta, L. N., III↗

NASA NTRS1952

Generalization of Boundary-Layer Momentum-Integral Equations to Three-Dimensional Flows Including Those of Rotating System

The Navier-Stokes equations of motion and the equation of continuity are transformed so as to apply to an orthogonal curvilinear coordinate system rotating with a uniform angular velocity about an arbitrary axis in space. A usual simplification of these equations as consistent with the accepted boundary-layer theory and an integration of these equations through the boundary layer result in boundary-layer momentum-integral equations for three-dimensional flows that are applicable to either rotating or nonrotating fluid boundaries. These equations are simplified and an approximate solution in closed integral form is obtained for a generalized boundary-layer momentum-loss thickness and flow deflection at the wall in the turbulent case. A numerical evaluation of this solution carried out for data obtained in a curving nonrotating duct shows a fair quantitative agreement with the measures values. The form in which the equations are presented is readily adaptable to cases of steady, three-dimensional, incompressible boundary-layer flow like that over curved ducts or yawed wings; and it also may be used to describe the boundary-layer flow over various rotating surfaces, thus applying to turbomachinery, propellers, and helicopter blades.

Mager, Arthur↗

NASA NTRS1991

Numerical simulation of transition in wall-bounded shear flows

The current status of numerical simulation techniques for the transition to turbulence in incompressible channel and boundary-layer flows is surveyed, and typical results are presented graphically. The focus is on direct numerical simulations based on the full nonlinear time-dependent Navier-Stokes equations without empirical closure assumptions for prescribed initial and boundary conditions. Topics addressed include the vibrating ribbon problem, space and time discretization, initial and boundary conditions, alternative methods based on the triple-deck approximation, two-dimensional channel and boundary-layer flows, three-dimensional boundary layers, wave packets and turbulent spots, compressible flows, transition control, and transition modeling.

Kleiser, Leonhard↗

NASA NTRS1983

Continuation in a parameter - Experience with viscous and free surface flows

The results of modifications in continuation methods applied to obtain solutions to the Navier-Stokes systems of equations for incompressible, two-dimensional, steady flows are reported. It is shown that parameter continuation permits prediction of accurate, initial estimates for iterative processing of nonlinear finite difference and finite element equations of motions. The new parameter steps are derived from values of the preceding parameter steps. The accuracy of the estimates is ensured with appropriate choices of the step size. The continuation predictor/iterative corrector is demonstrated to trace the branches of parameter space along which steady flow states are found, and techniques are available for tracing multiply branching paths. The techniques are applied to solving the Navier-Stokes equations for flow through a rotating square channel, the formation of a falling liquid curtain, and gyrostatic equilibria of rotating cylindrical drops.

Kheshgi, H. S.↗

NASA NTRS1989

Viscous flow in simple curved gaps. I - An asymptotic theory. II - Viscous stress and shape function

The present asymptotic theory for generalized incompressible two-dimensional steady flow in curved channels has been constructed in the limit when gas thickness approaches zero with its lateral dimensions fixed; successive asymptotic solution terms are analytically generated by quadratures. In the second part of this work, the curvature of the gap treated is arbitrary. It is established that each term in the series solution of velocity and pressure is the product of a scale factor and a universal shape functions. Various interaction modes between the volume rate-of-flow, curvature, and its variations, are identified and quantitatively characterized.

Fan, D.-N.↗

NASA NTRS1977

Navier-Stokes solution for the laminar and turbulent supersonic flow near the trailing edge of a flat plate

The present paper deals with problems of two-dimensional laminar and turbulent flow of a viscous incompressible fluid near the trailing edge of a thin flat plate. The complete system of Navier-Stokes equations is solved by means of MacCormack's finite-difference scheme. In the laminar case, the results are compared with the triple deck solution of Daniels (1973). The comparisons indicate that the asymptotic triple deck theory for supersonic trailing-edge flow is accurate within five percent for Reynolds numbers greater than 1000. In the turbulent case, the Prandtl-Van Driest-Clausner algebraic eddy viscosity model is used, showing that the region of upstream influence is roughly of the order of the boundary layer thickness.

Hussaini, M. Y.↗

NASA NTRS1994

Turbulent Heat Transfer Characteristics in the Shear Layer of a Separated Flow

Experiments were performed to study the evolution of the heat transfer structure in a separated free shear layer region of an incompressible separated turbulent boundary layer flow behind a backward-facing step. While there is an abundance of velocity field measurements of separated flows, heat transfer measurements are rather scarce, thus limiting assessment of the heat transfer physics and its accurate modeling. The purpose of the paper is twofold: to improve an understanding of effects of flow separation on heat transfer characteristics, and to provide data for turbulence modeling and computation. The boundary layer upstream of the step was turbulent and fully developed. A constant temperature surface boundary condition was imposed upstream and downstream of the step for the heat transfer study. An internal mixing-layer like flow forms and grows from the step lip within the original boundary layer. The turbulent structure of the flow evolving downstream, however, does not switch immediately to that of a mixing layer over the entire shear layer thickness. Measurements of mean and fluctuating velocity and temperature fields indicate that the internal layer spreads gradually in the transverse direction while the outer part of the original boundary layer is effectively unperturbed. The results in this paper have not been previously reported.

Jovic, S.↗