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Review of Hydraulic Roughness

Karen A. Flack
Scales in the Fully Rough Regime
Department of Mechanical Engineering,
United States Naval Academy, A review of predictive methods used to determine the frictional drag on a rough surface
Annapolis, MD 21402 is presented. These methods utilize a wide range of roughness scales, including roughness
e-mail: flack@usna.edu height, pitch, density, and shape parameters. Most of these scales were developed for
regular roughness, limiting their applicability to predict the drag for many engineering
Michael P. Schultz flows. A new correlation is proposed to estimate the frictional drag for a surface covered
Department of Naval Architecture and Ocean with three-dimensional, irregular roughness in the fully rough regime. The correlation
Engineering, relies solely on a measurement of the surface roughness profile and builds on previous
United States Naval Academy, work utilizing moments of the surface statistics. A relationship is given for the equivalent
Annapolis, MD 21402 sandgrain roughness height as a function of the root-mean-square roughness height and
e-mail: mschultz@usna.edu the skewness of the roughness probability density function. Boundary layer similarity
scaling then allows the overall frictional drag coefficient to be determined as a function
of the ratio of the equivalent sandgrain roughness height to length of the surface.
关DOI: 10.1115/1.4001492兴

1 Introduction ing the appropriate roughness length scale to use as the roughness
height. The diagram was developed using the equivalent sandgrain
The most important unresolved issue regarding surface rough-
roughness height ks 关1兴. However, ks for a generic roughness can-
ness in fluids engineering practice is how frictional drag 共for ex-
not be accurately assigned a priori and must be determined experi-
ternal flows兲 or pressure drop 共for internal flows兲 relates to the
mentally. The roughness values listed on the diagram for copper,
particular roughness topography. In other words, which roughness
galvanized steel, etc., were determined from fitting a roughness
length scales best typify a surface hydraulically? Researchers have
height to match a measured pressure drop from an experiment, or
been working on this problem since the early experimental work
in other words, determining ks. The question then is how the
of Nikuradse 关1兴 and Colebrook 关2兴. However, most previously
height listed on the diagram relates to a physical roughness length
proposed roughness scales, discussed in detail later in this paper,
scale measured from surface topography. This is especially perti-
are not sufficiently robust and are valid only for regular roughness
nent since many of the manufactured surfaces listed on the Moody
or for a limited range of roughness types. What is needed in en-
diagram do not have a consistent roughness. For example, some
gineering practice is some means of relating the rough surface
surfaces are listed with a roughness height that spans an order of
waveform to its frictional drag. In recent years, direct numerical
magnitude. Additionally, the equivalent sandgrain roughness
simulations 共DNS兲 have further elucidated the understanding of
height is unknown for numerous other surfaces of engineering
the underlying flow physics on rough walls 共e.g., Refs. 关3–5兴兲. To
interest. As a result, one can only expect to obtain accurate results
date, however, DNS computations have been limited to idealized
using the Moody diagram if ks is known for the surface of interest
roughness types at a limited Reynolds number range, making
and the flow is fully rough.
them incapable of resolving issues regarding appropriate scaling
The naval architecture community includes the effects of sur-
for irregular three-dimensional roughness. Therefore, the need for
face roughness 共e.g., paint, corrosion, and fouling兲 in an allow-
accurate predictive correlations in engineering practice remains.
ance coefficient, which is added to the smooth surface friction and
One of the most commonly employed fluids engineering tools
residual 共wave making兲 resistance coefficients when determining
is the Moody 关6兴 diagram. This useful diagram relates the pressure
the overall drag of a full scale ship 关9兴. The International Towing
drop in a pipe to the relative roughness 共i.e., the ratio of the
Tank Committee 关10兴 adopted the allowance coefficient of
roughness height to the pipe diameter兲 and the Reynolds number.
Bowden and Davison 关11兴 to be used with the 1978 ITTC perfor-
Moody developed the diagram to be used for naturally occurring
mance prediction line for ship resistance. This coefficient is a
roughness based on the results of Colebrook 关2兴 for smooth and
function of the mean hull roughness, the average peak-to-trough
rough pipe flow. However, recent results by Allen et al. 关7兴 and
roughness height measured over 50 mm sampling lengths on the
Langelandsvik et al. 关8兴 show that the Moody diagram signifi-
hull surface, as compared with the ship length. This equation,
cantly overestimates the pressure drop in the transitionally rough
however, is not an accurate hull roughness penalty predictor since
flow regime for honed and commercial steel pipes, respectively.
it includes additional residual components of resistance predic-
This clearly indicates that the Colebrook roughness function used
tion, including model scale effects 关12兴. Townsin et al. 关13兴 pro-
in the formulation of the Moody diagram may not be applicable to
vided a formula for predicting the roughness penalty based on the
a wide range of roughness of engineering interest. Fortunately,
mean hull roughness and the Reynolds number. While the inclu-
from an engineering standpoint, the Moody diagram likely gives a
sion of a Reynolds number dependence allows for calculations in
conservative estimate of pressure drop for a given roughness in the transitionally rough regime, the roughness parameter is still
the transitionally rough regime. only based on a simple measure of the roughness height and does
A more important issue regarding the Moody diagram is defin- not account for other roughness texture characteristics. These con-
siderations, along with a lack of accurate hull roughness measure-
Contributed by the Fluids Engineering Division of ASME for publication in the ments, led the ITTC Specialist Committee on Powering Perfor-
JOURNAL OF FLUIDS ENGINEERING. Manuscript received July 3, 2009; final manuscript mance Prediction 关12兴 to conclude in 2005 that the methods used
received March 12, 2010; published online April 20, 2010. Assoc. Editor: James A. to correct for hull roughness and fouling are of doubtful accuracy.
Liburdy.
This material is declared a work of the US government and is not subject to
Computational fluid dynamics 共CFD兲 has generally represented
copyright protection in the United States. Approved for public release; distribution is rough surfaces by a smooth surface with modified boundary con-
unlimited. ditions or near wall equations. Discrete roughness models include

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roughness as an additional drag term in the near wall momentum
equations. Using this approach, the effect of roughness is confined
to the near wall mean flow, not influencing the outer layer turbu-
lence. Alternately, roughness can be accounted for in the turbu-
lence by modifying the eddy viscosity models 关14兴. In this ap-
proach, a wall offset is included in the mixing length model that
produces a nonzero eddy viscosity at the wall. The mean flow log
region extends to this new origin. The amount of wall offset is a
function of an empirically determined hydraulic roughness length.
For the two layer approach, the wall layer model is patched to the
outer layer model by modifying the k boundary condition in the
k − ␧ model, and the ␻ boundary condition in the k − ␻ model 关15兴.
In the fully rough regime, the proposed k − ␧ 关16兴 and k − ␻ 关17兴
models do not require a wall function since the log layer extends
all the way to the wall. The common feature of all the models is
an empirically determined term to accurately account for the
roughness. Predictive correlations for a wide range of rough sur-
faces would provide computational models the necessary rough- Fig. 1 Mean velocity profiles for mesh and sandpaper sur-
ness length scale. faces from Ref. †18‡
The development of more accurate predictive correlations relies
on a robust database of experimental results that have accurate
frictional loss data and detailed surface topography information. the roughness function can also be expressed as the difference in
The approach taken in the present research is to expand on previ- skin friction for the smooth wall C fS and the rough wall C fR, at the
ous work that uses statistical moments of the surface profile, in- same displacement thickness Reynolds number 共Re␦ⴱ兲 as proposed
cluding a wider range of three-dimensional roughness. Successful by Hama 关19兴 and shown in

冉冑 冊 冉冑 冊
correlation of the momentum deficit due to roughness with surface
statistics will provide a method of drag prediction based solely on 2 2
⌬U+ = − = U+eS − U+eR 共4兲
the surface roughness topography. Cf S Cf R
This allows roughness function results from rough surfaces ob-
2 Background tained in the laboratory to be scaled up to full scale using the same
The velocity deficit due to roughness has been represented in a outer layer similarity arguments. Mean flow similarity can be
variety of ways, based on the smooth wall log-law profile. Equa- demonstrated through collapse of smooth and rough wall data
tion 共1兲 represents the effect of roughness by the roughness func- when plotted in a velocity-defect form. Similarity has been experi-
tion ⌬U+ or the downward shift in the log-law profile mentally verified by a number of researchers 共e.g., Refs. 关20–23兴兲
including the present authors for a wide range of roughness types
1 关18,24–28兴. A representative velocity-defect plot from Flack et al.
U+ = ln y + + B − ⌬U+ 共1兲
␬ 关18兴 for mesh and sandgrain roughness is shown in Fig. 2.
Ideally, the roughness function could be determined using a
where ␬ is the von Kármán constant and B is the intercept for a correlation based on a physical measure of the surface roughness
smooth wall. This can also be recast into a relative roughness instead of having to rely on laboratory hydrodynamic tests. The
form, Eq. 共2兲, where k is a measure of the roughness height. challenge is to determine the proper scales obtained from surface
1 y 1 measurements that effectively correlate with the roughness func-
U+ = ln + B − ⌬U+ + ln k+ 共2兲 tion for a wide range of roughness types. Figure 3 shows the
␬ k ␬
relationship between the roughness function and the roughness
Atmospheric boundary layer analyses generally represent rough- height for a variety of surfaces. For comparison, the uniform
ness by a roughness length scale y 0, which matches the smooth sandgrain roughness results of Nikuradse 关1兴 are also presented.
wall log-law profile, as shown in Eq. 共3兲. In this equation, d is the Three flow regimes are observed in Fig. 3. When the roughness
zero-plane displacement, or the distance below the top of the Reynolds number k+ is small, the flow is hydraulically smooth
roughness where the mean flow is zero. 共i.e., ⌬U+ = 0兲. In this case the perturbations generated by the
1
U+ = ln

冉 冊
y−d
y0
共3兲
roughness elements are completely damped out by the fluid vis-

Equation 共3兲 is only valid in the fully rough regime; thus y 0 is an


alternate scale that is similar to the equivalent sandgrain rough-
ness height ks, forcing collapse to a single profile in the fully
rough regime.
Figure 1 shows typical rough wall boundary layer profiles and
the corresponding roughness functions. The results presented are
from Flack et al. 关18兴 for flows over sandgrain and mesh rough-
ness. The roughness heights for these surfaces are a significant
fraction of the boundary layer thickness, resulting in large rough-
ness functions. Similar roughness functions are obtained for the
mesh and sandgrain surfaces at approximately the same unit Rey-
nolds number even though the roughness heights differ substan-
tially. This indicates that the roughness height alone is not ad-
equate to scale the momentum deficit resulting from surface
roughness.
If the shapes of the mean profile in the overlap and outer region Fig. 2 Mean velocity profiles in velocity-defect form from Ref.
of the boundary layer are similar for smooth and rough walls, then †18‡

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Fig. 3 Roughness function results for a variety of rough surfaces

cosity, creating no additional drag. As k+ increases, the flow be- in relative roughness form ⬇8.5 共Eq. 共2兲兲, ks can be determined
comes transitionally rough. In the transitionally rough regime, vis- for a given roughness from its roughness function ⌬U+ in the fully
cosity is no longer able to damp out the turbulent eddies created rough regime using the following relationship:
by the roughness elements and form drag on the elements, as well
as the viscous drag, contributes to the overall skin friction. As k+ 1
B − ⌬U+ + ln ks+ = 8.5 共5兲
increases further, the roughness function reaches a linear asymp- ␬
tote. This asymptotic region at large values of k+ is the fully rough
regime. In this regime, the skin friction coefficient is independent The equivalent sandgrain roughness height is then used as the
of Reynolds number, and form drag on the roughness elements is scale in Fig. 4. As expected, all surfaces asymptote to the same
the dominant mechanism responsible for the momentum deficit. line in the fully rough regime. It should be noted, however, that
In Fig. 3, the peak-to-trough roughness height is used as the ks+ is unable to collapse the surfaces in the transitionally rough
roughness scale. A common roughness scale in literature is the regime. Figures 3 and 4 highlight the fact that a single measure of
equivalent sandgrain roughness height ks. This is the roughness the roughness height, i.e., k, ks, and krms, is not able to collapse the
height that produces the same roughness function as the uniform roughness function results in all regimes for a range of surfaces.
sandgrain of Nikuradse in the fully rough regime. Using the A number of questions remain regarding the relationship be-
equivalent sandgrain roughness height as the roughness height in tween the roughness Reynolds number and the roughness function
Eq. 共2兲, and the log-law intercept for a uniform sandgrain surface for a generic roughness. The value of k+ 共or ks+兲 when the surface

Fig. 4 Roughness function results for a variety of rough surfaces using ks

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roughness ceases to be hydraulically smooth has been shown to be
a function of the roughness type. Second, the shape of the rough-
ness function in the transitionally rough regime varies depending
⌳= 冉 冊冉 冊
d
k
Af
As
−4/3
共8兲

on the roughness type and is not known for most surfaces. Addi- Dirling provided correlations for the ratio of the equivalent
tionally, the value of k+ that defines the onset of the fully rough sandgrain roughness height ks, to roughness height k, for two-
regime is unknown for most roughness types. The transitionally dimensional square rods, hemispheres, spheres, cones, right
rough regime has previously been defined as 5 ⬍ ks+ ⬍ 70, based angles, as well as Nikuradse sand.
on the uniform sandgrain results of Nikuradse 关1兴. However, a ks
wide range of values has been reported in literature for other = 0.0164⌳3.78, ⌳ ⱕ 4.93
roughness types. Ligrani and Moffat 关29兴 reported that the transi- k
tionally rough regime spans 15⬍ ks+ ⬍ 50 for a packed sphere bed.
ks
This range is reported as 3.5⬍ ks+ ⬍ 30 for honed pipe roughness = 139⌳−1.90, ⌳ ⬎ 4.93 共9兲
by Shockling et al. 关30兴 and is given by the present authors 关26兴 as k
2.5⬍ ks+ ⬍ 25 for a similar surface created by surface scratches. Sigal and Danberg 关43兴 introduced the effect of roughness density
Langelandsvik et al. 关8兴 indicated that the range of the transition- in a different manner, including S, the reference surface area be-
ally rough regime is 1.4⬍ ks+ ⬍ 18 for a commercial steel pipe. fore adding roughness, and S f , the total frontal area of the rough-
Lewkowicz and Musker 关31兴 found that the onset of the fully ness.
rough regime ranged from krms+ = 17 to 40 for ship-hull roughness.
These disparate results for various roughness types clearly illus-
trate the difficulty of identifying scaling parameters that are appli-
⌳s = 冉 冊冉 冊
S
Sf
Af
As
−1.6
共10兲

cable in both the transitionally and fully rough regimes. As illus- The following correlations were provided for two-dimensional
trated in Fig. 4, collapse in the fully rough regime at high transverse roughness including bars, rods, and ribs.
Reynolds numbers does not ensure that the transitionally rough
regime has been properly captured. In fact, Clauser 关32兴 discussed ks
= 0.00321⌳s4.925, 1.400 ⱕ ⌳s ⱕ 4.890
the difficulty of finding a roughness scale in the transitionally k
rough regime stating that some roughness types produce rough-
ness functions with a monotonically changing slope while others ks
have inflection points. = 8, 4.890 ⱕ ⌳s ⱕ 13.25
k

ks
= 151.711⌳s−1.1379, 13.25 ⱕ ⌳s ⱕ 100 共11兲
3 Previously Proposed Roughness Function k
Correlations van Rij et al. 关44兴 expanded the use of this parameter to three-
The development of correlations for the roughness function has dimensional regular roughness, using the results of Schlichting
been an area of active research for many years. Correlations range 关39兴 for staggered patterns of spheres, spherical segments, and
from simple models based on roughness height and pitch to more cones. The data used incorporated the corrections given in Ref.
complicated relationships that include density and shape param- 关45兴. The correlations for three-dimensional roughness are listed
eters, as detailed below. as follows:
Bettermann 关33兴 proposed a functional relationship between the ks
rough wall log-law intercept and a roughness spacing parameter = 1.583 ⫻ 10−5⌳s5.683, ⌳s ⬍ 7.842
k
␭, where ␭ = pitch/ height of 2D transverse bars, as shown in Eq.
共6兲, for the range of ␭ listed.
ks
= 1.802⌳s0.03038, 7.842 ⱕ ⌳s ⱕ 28.12
1 k
f共␭兲 = B − ⌬U+ + ln k+ = 17.35共1.165 log10 ␭ − 1兲, 1ⱕ␭ⱕ5

ks
共6兲 = 255.5⌳s−1.454, ⌳s ⬎ 28.12 共12兲
k
Dvorak 关34兴 modified this relationship, using a density parameter, van Rij et al. 关44兴 also tested irregular, three-dimensional rough-
␭ = total surface area/total roughness area, which is equivalent to ness and applied a modified version of the roughness parameter,
the spacing parameter of Bettermann for square bars. Dvorak defined as

冉 冊冉 冊
added another relationship, which extends the range of applicabil-
−1.6
ity for more sparse roughness as follows: S Sf
⌳s = 共13兲
Sf Ss
f共␭兲 = 17.35共1.165 log10 ␭ − 1兲 1 ⱕ ␭ ⱕ 4.68
where S, S f 共as defined by Sigal and Danberg 关43兴兲, and Ss, the
f共␭兲 = − 5.95共1.103 log10 ␭ − 1兲 ␭ ⬎ 4.68 共7兲 total windward wetted surface area, are calculated numerically
based on detailed surface profiles. The equivalent sandgrain
These correlations were developed using sandgrain surfaces roughness is determined from the correlations developed for
关1,35,36兴, mesh screens 关19兴, staggered rows of spheres 关37兴, and three-dimensional regular roughness, Eq. 共12兲, using this modified
square bars 关33兴. Simpson 关38兴 modified the parameter further roughness parameter and kavg, the average roughness height. Ex-
using ␭k = total surface area/total roughness frontal area normal to perimental results for two rough surfaces were used to test the
the flow, showing reasonable agreement for spheres and cones correlation: one completely covered by the roughness and one
关39兴, staggered hemispheres 关40兴, and machined groves 关41兴. where rough regions of the surface alternate with smooth regions.
Dirling 关42兴 introduced a combined density and shape param- The predicted skin friction, using the calculated values of ks, com-
eter ⌳. Roughness density is included as the ratio of the average pared well to experimentally results obtained from the pressure
element spacing d to roughness height k, whereas shape is ac- drop in a channel.
counted for in the frontal area of a single roughness element A f Additional three-dimensional roughness predictive correlations
and the windward wetted surface area of a single roughness ele- were presented by Waigh and Kind 关46兴. Their relationships were
ment As. based on the results for a variety of roughness element shapes

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including cubes, blocks, flat plates, cylinders, rods, cones, tive replicas of ship-hull roughness. Musker cautioned that the
spheres, and hemispheres. They expressed the effect of roughness cut-off wavelength used to characterize the surface should depend
as a log-law shift C 共Eq. 共14兲兲, using a similar form of the law of on the size of the roughness elements since the sizes of the turbu-
the wall as Eq. 共2兲. lent eddies near the surface are a function of the longest surface
wavelength. He proposed the use of the Taylor integral micro-
1 y 1 1 y scale 关49兴 as the cut-off for the longest wavelength and two orders
U+ = ln + B − ⌬U+ + ln k+ = ln + B − C 共14兲
␬ k ␬ ␬ k of magnitude lower for the smallest wavelengths.
The element distribution is characterized by a density parameter Medhurst 关50,51兴 reported correlations for painted ship rough-
⌳k, which modifies the density parameter of Simpson 关38兴 ␭k, ness based on a parameter C1h, which he called the hydrodynamic
with the streamwise aspect ratio k / sm, where k is the roughness roughness number, having units of roughness height. Medhurst
used the following form of the roughness function:

冋 册
height and sm is the streamwise roughness length.
1 C1 hU␶
k ⌬U+ = ln + C2 共19兲
⌳k = ␭k 共15兲 ␬ B1 ␯
sm
The following relationships were presented for two density re- where B1 is found using an alternate form of the smooth wall
gimes: log-law intercept

C = 10.56 log10 ␭k 冋冉 冊 冉 冊 册
k
bm
0.87
Aw
Af
0.44
− 7.59, ⌳k ⬍ 6
1
B = ln关B1兴

共20兲

Utilizing the linearized form of Eq. 共20兲 along with experimental


C = − 5.75 log10 冋冉 冊 冉 冊 册
␭k
k
bm
0.55
Aw
Af
1.38
+ 5.78, ⌳k ⬎ 6
data, a regression analysis can be performed to determine C1h and
C 2.

where Aw is the roughness wetted area, A f is the projected frontal


共16兲 +
B1e␬⌬U = 共C1h兲 冉 冊
U␶

+ B 1C 2 共21兲

area, and bm is the spanwise roughness length. Waigh and Kind If the surface is assumed to follow a Colebrook form of the rough-
discussed the fact that the relationships were obtained for simple ness function 共i.e., monotonic兲, then C2 = 1.0 and ⌬U+ is only a
roughness element shapes in regular patterns and stressed the need function of C1h. Medhurst presented different values of the hy-
to find ways to parametrize the geometry of natural roughness. drodynamic roughness number for three types of ablative paints.
Turbine blade roughness that included surfaces with pitting, Medhurst also cautioned on the use of cut-off wavelengths and
erosion, and deposits was studied by Bons 关47兴. Bons also adapted other filtering techniques, as well as spatial resolution issues that
the Sigal and Danberg parameter for irregular roughness to calcu- can bias results and reject important surface information.
late the equivalent sandgrain roughness for the surfaces as fol- Townsin and Dey 关52兴 utilized the moments of the roughness
lows: amplitude energy spectral density, incorporating a variable long

log 冉冊
ks
k
= − 1.31 log共⌳s兲 + 2.15 共17兲
wavelength cut-off, to determine the roughness function for
painted ship surfaces. The height of the roughness is represented
by the spectral area m0, the slope by the second moment m2, and
The surface parameters were determined numerically from de- the range of frequencies composing the roughness profile by a
tailed surface profiles, with the roughness height k, taken as the bandwidth parameter ␣ = m0m4 / m22. Based on the results for 26
average of the local peak-to-trough roughness height for smaller ship paint surfaces, the best correlation between the roughness
subregions. The skin friction correlation using ks proposed by function ⌬U+ and the roughness height k is shown in
Schlichting 关39兴 fits the experimental data best.
Many of the proposed correlations are valid for two- and three-
dimensional regular roughnesses, including bars, blocks, cones,
k ⬀ 冑␣m0m2 = 冑 m 02m 4
m2
共22兲
hemispheres, etc. Determining the required shape and density pa- While this technique shows promise, significant scatter was
rameters for an idealized roughness is a relatively straightforward present using this correlation in the fully rough regime while the
procedure. Extending this work to naturally occurring, irregular correlation did not collapse the data in the transitionally rough
roughness is more challenging due to potentially complex surface regime.
features. While it is possible to determine the required shape and The correlations presented have demonstrated some utility in
density parameters for irregular, three-dimensional roughness collapsing experimental data for a subset of rough surfaces, but
关44,47兴, complex numerical fitting procedures are needed. A sim- they yield a high degree of variance when applied to a larger
pler method of utilizing the surface topography map would be range of three-dimensional roughness types. Furthermore, many
useful for predicting frictional drag due to roughness in a wider of the correlations are difficult to apply to irregular, three-
range of engineering applications. dimensional roughness. The approach taken in the present re-
Correlations that relate the statistical moments of the surface search has been to expand on the previous work using statistical
profile with the frictional drag or roughness function have been moments of the surface profile, including a wider range of three-
offered by various investigators. Musker 关48兴 proposed an effec- dimensional roughness. Successful correlation of the roughness
tive roughness height to correlate the roughness function ⌬U+ function with surface statistics will provide a method of drag pre-
= f共k+兲, as shown in diction based solely on the surface roughness.
kU␶ krmsU␶
k+ = = 共1 + as p兲共1 + bskku兲 共18兲
␯ ␯ 4 Full Scale Prediction Methods
where krms is the standard deviation, sk is the skewness, ku is the Roughness function results for rough surfaces obtained in the
kurtosis of the surface elevation distribution, and s p is the average laboratory can be scaled up to full scale using outer layer similar-
slope of the roughness elements. The constants a and b were ity arguments. Thus, knowing ⌬U+ = f共k+兲 allows for the frictional
empirically chosen to collapse the data of naturally occurring sur- drag of a full scale rough surface to be determined. If the equiva-
faces. This effective roughness height was reasonably successful lent sandgrain roughness ks is taken as the roughness scale, then
in collapsing the roughness function for pipes covered with posi- this functional relationship is valid for all roughness in the fully

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L+

冑 冉 冑 冊
ReL = 共24兲
CF 1 CF
1−
2 ␬ 2
The intersection of this line and the rough surface line identifies
CF for the rough plate at a single value of ReL for a given ⌬U+.
If this process is repeated for a range of ⌬U+ and L, the overall
frictional resistance coefficient can be mapped out. If the relation-
ship ⌬U+ = f共ks+兲 is used to account for the roughness, then this
diagram is valid for all roughness in the fully rough regime pro-
vided ks is known. This is shown in Fig. 6, as a “Moody” type
diagram, where the overall frictional drag coefficient is presented
as function of the ratio of ks to the overall length of the plate L. In
the fully rough regime the relationship can be expressed as the
following formula:

Fig. 5 Scaled-up procedure from CF smooth to CF rough


冑 2
CF
= − 2.186 ln 冉冊
ks
L
+ 0.495 共25兲

With an estimated 10% uncertainty in ⌬U+ at 95% confidence, the


resulting uncertainty in the overall frictional drag coefficient CF is
2% for ks / L = 0.001, decreasing to less than 1% for ks / L
= 0.00001.
rough regime provided ks is properly specified. Schultz 关53兴 de- On the diagram, it is assumed that the onset of the fully rough
tailed the similarity methods used to determine the overall fric- regime occurs at ks+ = 70, based on the uniform sandgrain results
tional resistance coefficient CF for rough wall boundary layer flow of Nikuradse. As noted previously, the onset of the fully rough
over a flat plate of length L if the roughness function ⌬U+ is regime is highly dependent on the specific roughness and likely
known. The methodology incorporates the analysis of Granville occurs at lower values of ks+ for many types engineering rough-
关54,55兴 and relies on outer layer similarity in the mean flow for ness. Additional measurements that span the transitionally rough
smooth and rough walls, as demonstrated in the velocity-defect regime are needed to determine the important scales for predicting
profiles shown in Fig. 2. A graphical representation of the scaling when a surface becomes fully rough. With the relationship given
procedure is shown in Fig. 5. Here, the smooth wall overall fric- in Eq. 共25兲, the frictional drag on a planar surface can be deter-
tional drag coefficient CF is plotted as a function of log10共ReL兲 mined by identifying roughness scales that accurately predict ks. It
using the Karman–Schoenherr 关56兴 friction line as follows: should also be noted that the roughness function could also be


incorporated in CFD models and used to calculate the frictional
2 1 drag of an arbitrary body covered with the given roughness.
= ln共ReL CF兲 共23兲
CF ␬
5 Development of a New Roughness Correlation
The rough surface overall frictional resistance coefficient for a The development of a roughness function correlation is re-
known roughness function is determined by displacing the smooth stricted here to flows in the fully rough regime. In this regime, a
friction line by a distance ⌬U+␬关ln共10兲兴−1 in the positive larger number of experimental results are available, and it is pos-
log10共ReL兲 direction. For a given plate length L, a line of constant sible to collapse all roughness functions to a single line if the
L+ = LU␶␯−1, which satisfies the following relationship, is plotted: equivalent sandgrain roughness height ks is used as the roughness

Fig. 6 Overall frictional drag coefficient in the fully rough regime

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Table 1 Surfaces used in predictive correlation for ks

kt krms ks actual ks predicted


Surface Ref. 共␮m兲 共␮m兲 sk ku 共␮m兲 共␮m兲 % diff

Sandpaper—80 grit 关18兴 546 67.9 0.497 4.49 529 522 1.3
Sandpaper—24 grit 关18兴 1291 167 0.719 4.06 2626 1954 25.6
Sandpaper—12 grit 关18兴 2466 320 1.51 6.17 6354 6512 2.5
Packed spheres 关28兴 824 199 0.212 1.90 876 1146 30.8
Packed spheres with grit 关28兴 738 158 0.315 2.22 1097 1018 7.2
Honed 共scratch兲 关26兴 193 26.4 ⫺0.455 3.63 71.0 51.0 28.2
Honed pipe 关30兴 15.96 2.5 0.31 4.05 7.5 16.0 113
Commercial pipe 关8兴 27.27 5.0 ⫺0.19 2.53 8.0 16.5 106
Gravel—medium 关23兴 3079 605 0.618 3.43 5383 5167 4.0
Gravel—coarse 关23兴 7350 1490 0.0305 2.46 6785 6875 1.3
Pyramid—A1 关27兴 304.8 72.1 0.566 2.40 510 589 15.5
Pyramid—A2 关27兴 457.2 108 0.566 2.40 706 883 25.1
Pyramid—A3 关27兴 609.6 144 0.566 2.40 1301 1177 9.5
Pyramid—B1 关27兴 304.8 72.1 0.566 2.40 540 589 9.1
Pyramid—B2 关27兴 457.2 108 0.566 2.40 577 883 53.0
Pyramid—B3 关27兴 609.6 144 0.566 2.40 1012 1177 16.3

scale. This scale understandably has its limitations since it is not as the mean value from the replicate profiles. The data were not
intrinsically related to roughness topography. The advantage of ks filtered to remove short or long wavelength roughness compo-
is that it provides a “common currency” among different rough- nents. However, long wavelength or “wavy” roughness has not
ness types as pointed out by Bradshaw 关57兴. Here an investigation been included in this study. Expanding on the work of Napoli et
is made into which physical roughness scales, if any, effectively al. 关58兴, Schultz and Flack 关27兴 determined that roughness with an
correlate with ks. This study was conducted using the results from effective slope ES less than approximately 0.35 does not scale on
a variety of three-dimensional rough surfaces, listed in Table 1. the roughness height. The relationship for the effective slope is
Numerous other researchers have measured the roughness func- shown in
tion in the fully rough regime for other surfaces. However, only
results that also report detailed surface topographical measure-
ments have been included.
A sample three-dimensional topographical map for the honed
ES =
1
Ls
冕冏 冏
Ls
⳵r
⳵x
dx 共26兲

surface of Schultz and Flack 关26兴 is shown in Fig. 7. This surface


was profiled using a CyberOptics laser diode point range sensor Filtering, sampling interval, and sampling length can all have a
laser profilometer system. The vertical accuracy of the sensor is significant effect on roughness statistics as pointed out by
1 ␮m with a laser spot diameter of 10 ␮m. The data were digi- Medhurst 关51兴 and Howell and Behrends 关59兴. This was not a
tized at increments of 25 ␮m in the lateral directions, and the primary focus in the present study. The practical difficulty in ad-
sampling area was 5 ⫻ 5 mm2. The other surfaces of the present dressing the effect of these parameters is that not all surfaces were
authors 关18,24,27兴, as well as the surfaces of Castro 关23兴, were profiled using the same sampling interval and length. Specifying
profiled using the MicroPhotonics Nanavea ST300 white light the most appropriate sampling interval, sampling length, and fil-
chromatic aberration surface profilometer. The vertical accuracy tering length is quite complex and can be expected to depend at
of this system is 0.3 ␮m with a lateral resolution of 6 ␮m. Five least to some extent on the inner and outer length scales of the
replicate surface profiles were gathered on each of these surfaces flow in question. This point underlines the need for the adoption
as well as the surface shown in Fig. 7. The sampling interval was of a consistent method of measuring hydraulic surface roughness,
25 ␮m, and the sampling length was 50 mm. The surface statis- as was highlighted by Howell and Behrends 关59兴.
tics and roughness parameters, listed in Table 1, were calculated Common surface statistical parameters, as well as the wide

Fig. 7 Surface topography map and pdf of r, distance above the mean roughness elevation, for a honed surface

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Fig. 8 Predicted ks versus actual ks using Eq. „27…

range of other roughness scaling parameters reviewed previously 共ks ⬎ 500 ␮m兲 naturally occurring type roughness. The only ex-
in this paper, were investigated as candidate hydraulic scales. This ception is the 24 grit sandpaper surface. However, even with a
was done using a series of statistical correlations between the 26% difference in the predicted ks from the measured value for the
candidate hydraulic scales and the measured equivalent sandgrain 24 grit sandpaper, the predicted overall drag coefficient CF
roughness height ks for the surface. This analysis indicated that = 0.00773 is only 6.5% in error from values measured in tow tank
the root-mean-square roughness height scale 共krms兲 and the skew- tests CF = 0.00826 关60兴.
ness of the roughness surface elevation probability density func- Considering the percent error from the expected value, the cor-
tion 共pdf兲 共sk兲 had the strongest correlations with ks. Based on this relation does not adequately predict the small values of ks for the
observation, it was decided to develop a single length-scale cor- honed and commercial steel pipes. This is not surprising due to
relation using both of these parameters. A number of different the nature of the fitting where the sum of the square of the residual
functional forms were considered. The function that best corre- is being minimized. This will bias the best fit toward the larger
lates the present data 共Table 1兲 is given in Eq. 共27兲 and graphically roughness where the absolute value of the difference is larger even
represented in Fig. 8. though the relative difference is smaller. Using the results of
Shockling et al. 关30兴, a 113% difference in the predicted value of
ks = f共krms,sk兲 ⬇ 4.43krms共1 + sk兲1.37 共27兲
ks yields an error in friction factor of approximately 30%. There-
In Fig. 8, ks actual was determined using Eq. 共8兲 for an experi- fore, the correlation presented may not be adequate for all the
mentally determined value of ⌬U+ with B = 5.0 and ␬ = 0.41 in the roughness considered. However, it appears that the important
fully rough regime. The surfaces used in this correlation along scales for better predictive correlations are the root-mean-square
with some of their roughness statistics are shown in Table 1. The roughness height and the skewness of the surface elevation pdf. It
skewness is a quantitative way of describing whether the rough- should be noted that this is a sparse data set to base a predictive
ness has more peaks or valleys. A roughness with isolated large correlation. Unfortunately, experimentally obtaining the rough-
peaks will have a high positive skewness. Surfaces that have be- ness function for a single roughness requires a large number of
come rough due to deposits of roughness elements 共i.e., exhaust boundary layer profile measurements. While pressure drop data
particulates, biological fouling, etc.兲 will generally have positively are easier to obtain in pipe flow, it is more difficult to coat/
skewed pdf’s. A surface that is pitted 共i.e., corrosion, surface wear, manufacture the pipe surface with a specific roughness. Recent
etc.兲 will have negatively skewed pdf’s. It should be cautioned advances in computing the flow over complicated surfaces, which
that only two surfaces used in the present correlation had a nega- can be easily parametrically changed, may be capable of provid-
tive skewness, and both are relatively mild. The correlation, given ing a larger data set covering more of the sample space. This
in Eq. 共27兲, has an additive constant of 1. This means that the should allow for improvement in predictive capabilities.
present correlation would be undefined for sk ⱕ −1. This constant
was chosen in order to define a predictive correlation that is near 6 Conclusions and Recommendations
the range of the parameter space that was investigated. It should
be noted that using a larger additive constant would change the An investigation has been carried out to identify hydraulically
other constants in Eq. 共27兲 but would not significantly reduce the relevant roughness scales for three-dimensional roughness in the
goodness of fit. However, further data for surfaces with negative fully rough regime. A range of common surface statistical param-
sk are needed to validate and refine this correlation for a larger eters, as well as a host of roughness parameters from literature,
range of the parameter space. Nevertheless, Fig. 8 shows the lin- was considered. The results indicate that the root-mean-square
ear correlation between the predicted value of ks using the corre- roughness height 共krms兲 and the skewness of the surface elevation
lation and the measured ks. The goodness of fit is excellent with pdf 共sk兲 are the most effective parameters in describing a surface
r2 = 0.990. hydraulically. A correlation based on these parameters is offered,
Table 1 also lists the difference between the measured and pre- and it shows promising agreement with the measured equivalent
dicted values of the ks. The correlation works very well for the sandgrain roughness height 共ks兲. However, further data are needed
sandgrain, sanspray 共gravel兲, and packed spheres covered with to validate and refine this correlation. Surfaces with negative sk
grit. This indicates that the correlation would do an excellent job 共i.e., pitted or eroded surfaces兲 would be especially helpful in this
of predicting the equivalent sandgrain roughness height for large regard. Collapse of the roughness function in the fully rough re-

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gime does not ensure collapse in the transitionally rough regime. U ⫽
mean velocity
In fact, the nonuniversal nature of the roughness function in the Ue ⫽
mean freestream velocity
transitionally rough regime makes a universal scaling for this re- U␶ friction velocity= 冑␶o / ␳

gime seem intractable. Therefore, the development of a Moody- y ⫽
normal distance from the wall or virtual origin
type diagram that is applicable to a wide range of surfaces and is y0 ⫽
effective roughness height
accurate in the transitionally rough regime appears highly un- ␣ ⫽
roughness bandwidth parameter= m0m4 / m22
likely. ␦ ⫽
boundary layer thickness
␦ⴱ displacement thickness= 兰␦0共1 − U / Ue兲dy

Acknowledgment ⌬U +

roughness function
The authors would like to thank the Office of Naval Research ␬ ⫽
von Kármán constant ⬇0.41
for financial support of this research. Thanks also go to Professor ␭ ⫽
roughness spacing or density parameter
Ian Castro of the University of Southampton and Professor Lex ␭k ⫽
modified roughness density parameter
Smits of Princeton University for providing surface samples, sur- ⌳ ⫽
roughness density and shape parameter
face profiles, and data used in this research. Finally, the authors ⌳k ⫽
modified roughness density parameter
acknowledge the superior support given to this research by USNA ⌳s ⫽
modified roughness density and shape
Hydromechanics Laboratory and USNA Technical Support parameter
Branch. ␯ ⫽ kinematic viscosity of the fluid
␪ ⫽ momentum thickness= 兰␦0U / Ue共1 − U / Ue兲dy
Nomenclature ␶w ⫽ wall shear stress
a ⫽ roughness function fitting constant Superscript
A f ⫽ frontal area of a single roughness element + ⫽ inner variable 共normalized with U␶ or U␶ / ␯兲
As ⫽ windward wetted area of a single roughness
element Subscript
Aw ⫽ wetted area of a single roughness element min ⫽ minimum value
b ⫽ roughness function fitting constant max ⫽ maximum value
bm ⫽ spanwise roughness length R ⫽ rough surface
B ⫽ smooth wall log-law intercept ⬇5.0 S ⫽ smooth surface
C ⫽ log-law shift in a relative roughness form
C f ⫽ skin friction coefficient= ␶w / 1 ␳Ue2 References
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