Search Results (65)

With the growing requirements for multi-particle process simulation, improving computational accuracy, efficiency, and scalability has become a critical challenge. This study generally focused on comprehensive analyses of existing numerical methods for simulating particle–substrate interactions in gas–thermal spraying (including gas–dynamic spraying processes), covering both single-particle and multi-particle models to develop practical recommendations for the optimization of modern coating spraying processes. First of all, this paper systematically analyzes the key limitations of current approaches, including their inability to handle high deformations effectively or high computational complexity and their insufficient accuracy in dynamic scenarios. A comparative evaluation of four numerical methods (Lagrangian, Arbitrary Lagrangian–Eulerian (ALE), Coupled Eulerian–Lagrangian (CEL), and Smoothed Particle Hydrodynamics (SPH)) revealed their strengths and weaknesses in modeling of real gas–thermal spraying processes. Furthermore, this study identifies the limitations of the widely used Johnson–Cook (JC) constitutive model under extreme conditions. The authors considered the Zerilli–Armstrong (ZA), Mechanical Threshold Stress (MTS), and Preston–Tonks–Wallace (PTW) models as more realistic alternatives to the Jonson–Cook model. Finally, comparative analyses of theoretical and realistic deformation and defect-generation processes in gas–thermal coatings emphasize the critical need for fundamental changes in the simulation strategy for modern gas–thermal spraying processes. Full article

Smoothed particle hydrodynamics (SPHs) is a Lagrangian meshless method with distinct strengths in managing unstable and complex interface behaviors. This study develops an integrated multiphase SPH framework by merging multiple algorithms and techniques to enhance stability and accuracy. The multiphase model is validated by several benchmark examples, including square droplet deformation, single bubble rising, and two bubbles rising. The selection of numerical parameters for multiphase simulations is also discussed. The validated model is then applied to simulate oil–water–gas bubbly flows. Interface behaviors, such as coalescence, fragmentation, deformation, etc., are reproduced, which helps to take into account multiphysics interactions in industrial processes. The rising processes of many oil droplets for oil–water separation are first simulated, showing the advantages and stability of the SPH model in dealing with complex interface behaviors. To fully explore the potential of the model, the model is further extended to the field of wax removal. The melting process of the wax layer due to heat conduction is simulated by coupling the thermodynamic model and the phase change model. Interesting behaviors such as wax layer cracking, droplet detachment, and thermally driven flow instabilities are captured, providing insights into wax deposition mitigation strategies. This study provides an effective numerical model for bubbly flows in petroleum engineering and lays a research foundation for extending the application of the SPH method in other engineering fields, such as multiphase reactor design and environmental fluid dynamics. Full article

Growing environmental awareness has renewed interest in thorium as a nuclear fuel, underscoring the need for further studies to evaluate how reactors perform when conventional fuels are replaced with thorium-based alternatives. In this study, thermal hydraulics and solid mechanics computations were simulated using COMSOL multiphysics to investigate the safe operating conditions of a heavy water reactor with thorium-based fuel. The thermo-mechanical analysis of the fuel rod under transient heating conditions provides critical insights into strain, displacement, stress, and coolant flow behavior at elevated volumetric heat sources. After 3 s of heating, the strain distribution in the fuel exhibits a high-strain core surrounded by a low-strain rim, with peak volumetric strain increasing nearly linearly from 0.006 to 0.014 as heat generation rises. Displacement profiles confirm that radial deformation is concentrated at the outer surface, while axial elongation remains uniform and scales systematically with power. The resulting von Mises stress fields show maxima at the outer surface, increasing from ~0.06 to 0.15 GPa at the centerline with higher heat input but remaining within structural safety margins. Cladding simulations demonstrate nearly uniform axial expansion, with displacements increasing from ~0.012 mm to 0.03 mm across the investigated power range, and average strain remains negligible (≈10⁻⁴), while mean stresses increase moderately yet stay well below the yield strength of zirconium alloys, confirming safe elastic behavior. Hydrodynamic analysis shows that coolant velocity decreases smoothly along the axial direction but maintains stability, with only minor reductions under increased heat sources. Overall, the coupled thermo-mechanical and fluid-dynamic results confirm that both the fuel and cladding remain structurally stable under the studied conditions. By using COMSOL’s multiphysics capabilities, and unlike most legacy codes optimized for uranium-based fuel, this work is designed to easily incorporate non-traditional fuels such as thorium-based systems, including user-defined material properties, temperature-dependent thermal polynomial formulas, and mechanical response. Full article

This study numerically investigates laminar flow around two prismatic bodies, specifically square cylinders, arranged in tandem. The analysis covered gap ratios ($L/D=2$–7) and Reynolds numbers ($Re$ = 100–200), focusing on quantifying the aerodynamic characteristics and examining the wake flow structures within the established interference regimes. The time-averaged and unsteady parameters, including the drag and lift coefficients, RMS lift, vortex formation length, Strouhal number, recirculation length, wake width, and pressure distribution, were evaluated for both cylinders. A consistent critical spacing of $L/D\approx 4.5$ was observed across all Reynolds numbers, coinciding with the minimum Strouhal number, a sharp increase in unsteady lift, and divergence in wake width between cylinders. Notably, in the range $4.5\lesssim L/D\lesssim 6.5$ at higher $Re$, the DC exhibited a mean drag exceeding that of an isolated cylinder, attributed to base-pressure reduction and accelerated inflow from the upstream wake. A critical spacing in the co-shedding regime produced strong drag amplification on the DC, attaining an overall maximum value of 50.41% at $Re=200$ and $L/D=6.0$. To note, unlike mean drag, mean lift is found to be zero in all interference cases for both cylinders, irrespective of spacing ratio and Re, owing to the symmetry of the time-averaged pressure distribution on either side of the cylinders. Spectral and phase analyses reveal a transition from broadband, desynchronised oscillations to a frequency-locked state, with the phase angle between the cylinders reducing sharply to $\Delta \varphi \approx 0^{\circ }$ at the critical spacing. This indicates complete in-phase synchronisation or symmetry of the vortex-shedding process between the cylinders at the critical spacing. This confirmed the hydrodynamic transition between the coupled and independent shedding modes of the cylinders. The recirculation lengths for the DC reduce to as low as $0.6D$ in the co-shedding regime, highlighting rapid wake recovery. The research presented here offers new insights into force modulation, the evolution of wake structures, and the sensitivity to the Re that occurs when laminar flow occurs between two tandem square cylinders. These findings can be utilised to develop methods for controlling VIV and designing thermal-fluid systems. Full article

Cryogenic propellant sloshing presents significant challenges in aerospace systems, inducing vehicle instability, structural fatigue, energy losses, and complex thermal management issues. This review synthesizes experimental, analytical, and numerical advances with an emphasis on energy dissipation and conversion efficiency in propellant storage and transfer. Recent developments in computational fluid dynamics (CFD) and AI-driven digital-twin frameworks are critically examined alongside the influences of tank materials, baffle configurations, and operating conditions. Unlike conventional fluids, cryogenic propellants in microgravity and within composite overwrapped pressure vessels (COPVs) exhibit unique thermodynamic and dynamic couplings that remain only partially characterized. Prior reviews have typically treated these factors in isolation; here, they are unified through an integrated perspective linking cryogenic thermo-physics, reduced-gravity hydrodynamics, and fluid–structure interactions. Persistent research limitations are identified in the areas of data availability, model validation, and thermo-mechanical coupling fidelity, underscoring the need for scalable multi-physics approaches. This review’s contribution lies in consolidating these interdisciplinary domains while outlining a roadmap toward experimentally validated, AI-augmented digital-twin architectures for improved energy efficiency, reliability, and propellant stability in next-generation aerospace missions. Full article

Enhanced lubrication is critical for improving gear wear resistance. Current research on surface textures has overlooked the fundamental role of structural connectivity. Inspired by biological scales, a biomimetic hexagonal texture (BHT) was innovatively designed for tooth flanks, featuring dual-orientation grooves (perpendicular and inclined to the rolling-sliding direction) with bidirectional interconnectivity. This design synergistically combines hydrodynamic effects and directional lubrication to achieve tribological breakthroughs. A lubrication model for line contact conditions was established. Subsequently, the texture parameters were then optimized using response surface methodology and numerical simulations. FZG gear tests demonstrated the superior performance of the optimized BHT, which achieved a substantial 82.83% reduction in the average wear area ratio and a 25.35% decrease in tooth profile deviation variation. This indicated that the biomimetic texture can effectively mitigate tooth surface wear, thereby extending the service life of gears. Furthermore, it significantly improves thermal management by enhancing convective heat transfer and lubricant distribution, as evidenced by a 7–11 °C rise in bulk lubricant temperature. This work elucidates the dual-mechanism coupling effect of bio-inspired textures in tribological enhancement, thus establishing a new paradigm for gear surface engineering. Full article

Rotary lip seals serve as critical sealing components in industrial equipment, traditionally relying on the reverse pumping theory for their sealing mechanism. However, increasing operational demands characterized by high fluid pressure differentials, elevated speeds, and multi-physics coupling environments have revealed limitations in the applicability of the classical theory. This study aims to develop a comprehensive model to quantitatively characterize rotary lip seal performance, specifically frictional torque and reverse pumping rate, and to elucidate underlying mechanisms beyond classical theory. We developed a Mixed Thermo-Hydrodynamic Lubrication (MTHL) model that explicitly integrates fluid–solid–thermal coupling effects to simulate seal behavior under complex operating parameters. The simulations reveal that reverse pumping rate increases near-linearly with rotational speed from −8.54 mm³/s (0 m/s) to 122.82 mm³/s (3 m/s) and 220.27 mm³/s (6 m/s), validating classical theory, while under elevated fluid pressure differentials, a distinct non-monotonic trend emerges: rates evolve from 122.82 mm³/s (0.10 MPa) to 172.93 mm³/s (0.12 MPa), then decline to 52.67 mm³/s (0.18 MPa), and recover to 69.87 mm³/s (0.22 MPa), a phenomenon that cannot be explained by classical sealing mechanisms. Mechanistic analysis indicates that this anomaly stems from a competitive interaction between pressure-driven and shear-driven flow. This discovery not only enhances the reverse pumping theoretical system but also provides a theoretical foundation for optimizing sealing performance under diverse operational conditions. Full article

Understanding and modeling the effect of magnetic fields on flows that present separation properties, such as those over a backward-facing step (BFS), is critical due to its role in metallurgical processes, nuclear reactor cooling, plasma confinement, and biomedical applications. This study examines the hydrodynamic and magnetohydrodynamic numerical solution of an electrically conducting fluid flow in a backward-facing step (BFS) geometry under the influence of an external, uniform magnetic field applied at an angle. The novelty of this work lies in employing an in-house finite-volume solver with a collocated grid configuration that directly applies a Newton–like method, in contrast to conventional iterative approaches. The computed hydrodynamic results are validated with experimental and numerical studies for an expansion ratio of two, while the MHD case is validated for Reynolds number $Re=380$ and Stuart number $N=0.1$. One of the most important findings is the reduction in the reattachment point and simultaneous increase in pressure as the magnetic field strength is amplified. The magnetic field angle with the greatest influence is observed at $\phi =\pi /2$, where the main recirculation vortex is substantially suppressed. These results not only clarify the role of magnetic field orientation in BFS flows but also lay the foundation for future investigations of three-dimensional configurations and coupled MHD–thermal applications. Full article

Supercritical carbon dioxide (Sc-CO₂) thermal shock fracturing emerges as an innovative rock fragmentation technology combining environmental sustainability with operational efficiency. This study establishes a thermo-hydro-mechanical coupled model to elucidate how in situ stress magnitude and anisotropy critically govern damage progression and fluid dynamics during Sc-CO₂ thermal shock fracturing. Key novel findings reveal the following: (1) The fracturing mechanism integrates transient hydrodynamic shock with quasi-static pressure loading, generating characteristic bimodal pressure curves where secondary peak amplification specifically indicates inhibited interwell fracture coalescence under anisotropic stress configurations. (2) Fracture paths undergo spatiotemporal reorientation—initial propagation aligns with in situ stress orientation, while subsequent growth follows thermal shock-induced principal stress trajectories. (3) Stress heterogeneity modulates fracture network complexity through confinement effects: elevated normal stresses perpendicular to fracture planes reduce pressure gradients (compared to isotropic conditions) and delay crack initiation, yet sustain higher pressure plateaus by constraining fracture connectivity despite fluid leakage. Numerical simulations systematically demonstrate that stress anisotropy plays a dual role—enhancing peak pressures while limiting fracture network development. This demonstrates the dual roles of the technology in enhancing environmental sustainability through waterless operations and reducing carbon footprint. Full article

Solid particle thermal energy storage technology demonstrates extraordinary thermal stability across wide temperature ranges and possesses significant cost-effectiveness that meets stringent economic requirements for long-duration energy storage. These distinctive characteristics enable this technology to continuously support increasing decarbonization demands and drive the strategic progression of sustainable energy transformations. This review work conducts a thorough analysis of three representative reactor types: packed beds, moving beds, and fluidized beds, focusing on how particle thermophysical properties affect heat transfer and storage performance. The paper analyzes pressure drop and heat transfer correlations to reveal the coupling effects between particles and working fluids that impact system efficiency. By comparing hydrodynamic behavior across different reactor types, the study identifies optimization strategies and technical challenges. The review paper concludes by outlining future research directions for enhancing system efficiency, supporting industrial deployment, and facilitating integration with next-generation renewable energy technologies. Full article

Investigating the coupled hydrodynamic and thermal wakes induced by underwater vehicles is vital for non-acoustic detection and environmental monitoring. Here, the standard SUBOFF model is simulated under eight operating conditions—speeds of 10, 15, and 20 kn; depths of 10, 20, and 30 m; and both with and without thermal discharge—using Delayed Detached Eddy Simulation (DDES) coupled with the Volume of Fluid (VOF) method. Results indicate that, under heat emission conditions, higher speeds accelerate wake temperature decay, making the thermal wake difficult to detect downstream; without heat emission, turbulent mixing dominates the temperature field, and speed effects are minor. With increased speed, wake vorticity at a fixed location grows by about 30%, free-surface wave height rises from 0.05 to 0.15 m, and wavelength remains around 1.8 m, all positively correlated with speed. Dive depth is negatively correlated with wave height, decreasing from 0.15 to 0.04 m as depth increases from 5 to 20 m, while wavelength remains largely unchanged. At a 10 m submergence depth, the thermal wake is clearly detectable on the surface but becomes hard to detect beyond 20 m, indicating a pronounced depth effect on its visibility. These results not only confirm the positive correlation between vessel speed and wake vorticity reported in earlier studies but also extend those findings by providing the first quantitative evaluation of how submergence depth critically limits thermal wake visibility beyond 20 m. This research provides quantitative evaluations of wake characteristics under varying speeds, depths, and heat emissions, offering valuable insights for stealth navigation and detection technologies. Full article

The mechanism of low- to middle-rank coal seam gas accumulation in the Baode block on the eastern edge of the Ordos Basin is well understood. However, exploration efforts in the Shizuishan area on the western edge started later, and the current understanding of enrichment and accumulation rules is unclear. It is important to systematically study enrichment and accumulation, which guide the precise exploration and development of coal seam gas resources in the western wing of the basin. The coal seam collected from the Shizuishan area of Ningxia was taken as the target. Based on drilling, logging, seismic, and CBM (coalbed methane) test data, geological conditions were studied, and factors and reservoir formation modes of CBM enrichment were summarized. The results are as follows. The principal coal-bearing seams in the study area are coal seams No. 2 and No. 3 of the Shanxi Formation and No. 5 and No. 6 of the Taiyuan Formation, with thicknesses exceeding 10 m in the southwest and generally stable thickness across the region, providing favorable conditions for CBM enrichment. Spatial variations in burial depth show stability in the east and south, but notable fluctuations are observed near fault F1 in the west and north. These burial depth patterns are closely linked to coal rank, which increases with depth. Although the southeastern region exhibits a lower coal rank than the northwest, its variation is minimal, reflecting a more uniform thermal evolution. Lithologically, the roof of coal seam No. 6 is mainly composed of dense sandstone in the central and southern areas, indicating a strong sealing capacity conducive to gas preservation. This study employs a system that fuses multi-source geological data for analysis, integrating multi-dimensional data such as drilling, logging, seismic, and CBM testing data. It systematically reveals the gas control mechanism of “tectonic–sedimentary–fluid” trinity coupling in low-gentle slope structural belts, providing a new research paradigm for coalbed methane exploration in complex structural areas. It creatively proposes a three-type CBM accumulation model that includes the following: ① a steep flank tectonic fault escape type (tectonics-dominated); ② an axial tectonic hydrodynamic sealing type (water–tectonics composite); and ③ a gentle flank lithology–hydrodynamic sealing type (lithology–water synergy). This classification system breaks through the traditional binary framework, systematically explaining the spatiotemporal matching relationships of the accumulated elements in different structural positions and establishing quantitative criteria for target area selection. It systematically reveals the key controlling roles of low-gentle slope structural belts and slope belts in coalbed methane enrichment, innovatively proposing a new gentle slope accumulation model defined as “slope control storage, low-structure gas reservoir”. These integrated results highlight the mutual control of structural, thermal, and lithological factors on CBM enrichment and provide critical guidance for future exploration in the Ningxia Autonomous Region. Full article

A bioinspired vortex-inducing architecture was engineered within the hydrodynamic focusing region of membrane-based enthalpy exchangers (MEEs) to generate controlled Kármán vortex shedding, strategically enhancing thermal–hygric coupling through boundary layer modulation. Computational simulations employing ANSYS Fluent 2024R1 and grid-convergence validation (GCI < 1.8%) demonstrated that at Re = 392 (2.57 m/s flow velocity), the vortex-integrated configuration achieved temperature exchange efficiency enhancements of 3.91% (summer) and 3.58% (winter), latent efficiency gains of 3.71% and 3.53%, alongside enthalpy effectiveness improvements of 3.37% and 3.36%, respectively. The interconnected momentum–heat–mass analogies culminated in peaks of performance evaluation criterion (PEC) = 1.33 (heat transfer) and 1.22 (mass transfer), substantiating vortex-induced Reynolds analogy optimization under typical HVAC operational scenarios (summer: 27 °C/50.3% RH; winter: 21 °C/39.7% RH). Full article

The lubrication behavior and mechanical characteristics of the main bearing area of an aero-engine main shaft bearing determine the reliability and life of the main shaft bearing. In aero-engine main shaft bearings, the lubricant not only plays the role of lubrication but also affects the dynamic characteristics of the bearing; therefore, if the lubricant drag force is insufficient, it will lead to rolling body slipping. Slipping not only affects the reliability of the bearing operation but also will make the temperature of the contact area instantaneously increase, leading to the occurrence of gluing, scraping and other lubrication failure phenomena in the main bearing area. A lubricant under the shear conditions of traction characteristics is actually the external manifestation of rheological properties. Rheological properties are one of the elastic fluid power lubrication theories and are an important part of the study. Elasto-hydrodynamic lubrication theory of the oil film pressure, film thickness and temperature and solid domains interact to form a thermal–fluid–solid coupling relationship; this coupling relationship affects the main bearing area of the lubrication behavior and mechanical properties, thus affecting the lubrication state of the bearings and dynamic characteristics. With the continuous improvement of aero-engine performance requirements for main shaft bearings, it is of great significance to carry out a coupling study of the lubrication behavior and mechanical properties of the bearing contact zone under heavy load, high speed and high temperature conditions to improve the service performance, reliability and life of the bearings. Full article

The coordinated optimization of free-surface dynamics tracking and solid deformation computation remains a persistent challenge in casting filling simulations. While the traditional smoothed particle hydrodynamics (SPH) method suffers from prohibitive computational costs limiting practical applications, the delayed interface updates of the finite element method (FEM) compromise simulation fidelity. This study proposes a symmetric SPH-FEM coupling algorithm that integrates real-time particle-grid data exchange, and validation through ring filling simulations demonstrated close agreement with Schmid’s benchmark experiments, confirming flow field reconstruction reliability. Furthermore, bottom-injection plate experiments verified the method’s thermal modeling stability, achieving fully coupled flow–thermal–stress simulations with enhanced computational efficiency. The proposed symmetric coupling framework achieves engineering-ready simulation speeds without compromising accuracy, and this advancement establishes a novel computational tool for predicting casting defects including porosity and hot tears, significantly advancing the implementation of high-fidelity numerical simulation in foundry engineering applications. Full article