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5.1 Introduction
The ANSYS CFX (fluid flow) software is fully integrated into the ANSYS
Workbench environment, the framework for the entire suite of engineering simulation
solutions. Its adaptive architecture enables users to easily set up anything from standard
fluid flow analyses of complex interacting systems with simple drag-and-drop operations.
Fig 5.1 shows project schematic with ANSYS system of fluid flow CFX. Users can easily
assess performance at multiple design points or compare several alternative designs.
Within the ANSYS Workbench environment, applications from multiple simulation
disciplines can access tools common to all, such as geometry and meshing tools.
Most important physical models available in ANSYS CFX software useful to us are:
Heat Transfer and Radiation: Beyond solving the convective transport of energy by
fluid flow, ANSYS CFX software includes a conjugate heat transfer (CHT) capability to
solve the thermal conduction in solids. It also incorporates a wealth of models to capture
all types of radiative heat exchange in and between fluids and solids, whether these are
fully or semitransparent to radiation or opaque.
Fig 5.1 ANSYS workbench project schematic with fluid flow (CFX)
Turbulence: The vast majority of industrial flows are turbulent. Therefore, ANSYS CFX
software has always placed special emphasis on providing and developing state-of-the-art
turbulence models to capture the effects of turbulence efficiently and accurately. In
addition to all common RANS models — such as k-ε, k-ω, SST and Reynolds-Stress
models — and scale resolving LES and DES models, ANSYS CFX software delivers
numerous significant turbulence modeling innovations. These innovations include SST
model extensions to capture effects like streamline curvature, a predictive laminar-to-
turbulent transition model (the Menter-Langtry γ−θ model) and the novel scale-resolving
Scale-Adaptive Simulation (SAS) model for flows in which steady-state turbulence
models are insufficient.
In CFD simulation, the fluid-analysis system in the Project Schematic (Workbench) Fig.
5.1 shows the steps in performing a fluid analysis:
1) Create or import a geometry
2) Building a mesh for a geometry
3) Set up the analysis that will be sent to the solver
4) Control and monitor the solver to achieve a solution
5) Visualize the results in a post-processor and create a report.
These steps are briefed below.
Fig 5.2 Outline tree of Design modeler with Computational domains perforated fin with
cross fins in the center and fluid domain (enclosure) around (CFD simulations of
CR12PR 40W)
Named selection i.e. Surfaces having the similar boundary conditions are grouped
together are known as named selection. It becomes easy to use the same boundary
conditions at a time to the many similar surfaces.
Total Five named selection groups were created, 1) Group of Fluid domain faces
named as ‘5 faces of encl side and Upper’ 2) Group of Bottom of fluid domain named as
‘1Encl bottom face’ 3) Base of fin bottom named as ‘1Fin base bottom heat input’ 4)
Group of Fin base vertical faces is named as ‘4 faces base side’ 5) Group of Actual heat
convective surface of base and fins is named as ‘161 faces convective surfaces’ 6) group
of convective heat transfer area of fin only is named as ‘159 faces only fin surface’ 7)
Upper surface of the base is named as ‘upper surface of base’.
Fig 5.3 Solid and fluid domains labeled with the boundary conditions applied
One of the tedious and time taking event of the CFD simulation is the
discretization of the computational domain. It is also famous as Mesh generation.
Analytical solutions to the Navier-Stokes equations exist for only the simplest of flows
under ideal conditions. To obtain solutions for real flows, a numerical approach must be
adopted whereby the equations are replaced by algebraic approximations which may be
solved using a numerical method, by using the approach of ‘Discretization of the
Governing Equations’ involves fragmenting the spatial domain into small finite control
volumes using a mesh. The governing equations are integrated over each control volume,
such that the relevant quantity (mass, momentum, energy, etc.) is conserved in a discrete
sense for each control volume.
The mesh in finite volume method considers points that form a set of volumes
which are called cells. The finite element methods use sub-volumes called elements
which have nodes where the variables are defined. The values of the dependent variables,
such as temperature, pressure, velocity etc. will be described for each element. The
quality of the CFD result is strongly dependent on the mesh quality. Too many cells may
result in long solver runs and too few may result in inaccurate results. ANSYS Meshing
[46] allows the user to find the balance and get the right mesh for their simulation in the
most automated way possible. The standard volume mesher in CFX-Mesh is the
Advancing Front Volume Mesher. It enables an automatic tetrahedral mesh generation
using efficient mesh generation techniques, meshes were created with high contact sizing
relevance (dense meshing near fin surface), inflation growth rate 1.2 and total no. of
tetrahedral elements between 2.8 to 3.5 million. Fig 5.4 shows the outer look of the
meshed domain enclosure, it can be seen that at the bottom there is a denser mesh due to
contact size meshing option is used.
Fig. 5.4 Meshing of Fluid domain (enclosure), CFD simulations of CR12PR 40W
Fig. 5.5 Meshing of domain fin and base, CFD simulations of CR12PR 40W
Fig 5.5 shows the separate view of the meshed solid domain (fin and base) Fig 5.6
wireframed model of the meshed domains, Fig 5.7 shows the details of the mesh like
physics preference, solver preference, relevance, sizing, inflation, advanced options,
pinch details, statistics showing the no. of nodes and elements.
Under fluid flow analysis 1 need to select the analysis type and as natural
convection heat transfer is a steady state analysis, took all experimental reading after
achieving the steady state, therefore it is required to choose ‘steady state’ under analysis
type.
5.5.2 Creation of Domains
Basic three domains were created i) Fluid Domain ii) Domain Fin and base (solid
domain) iii) Domain interface.
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Buoy reference temp- 32oC,
Turbulence option – None (Laminar)
Thermal Radiation – None
Domain Initialization – Automatic
Setting under fluid model as Heat transfer model – Thermal Energy,
The mixed and natural convection flows and flows in which gravity is important
can be modeled by CFX by the inclusion of ‘Buoyancy’ source terms. Natural convection
refers to the case where convection of the fluid movement is due to local density
variations, for example, in a closed box with a heat source. Mixed convection is nothing
but a case where convection of the fluid is driven by both a buoyancy force and pressure
gradient. Variations in density that can occur from sources like local temperature, and
variations in the mass fraction cause density variations.
Boussinesq Model has many applications involving buoyancy; it is assumed that a
constant fluid density when the change in density over the expected range of conditions is
relatively small. The Boussinesq model is a constant density fluid model, applies a local
gravitational body force throughout the fluid which is a linear function of fluid thermal
expansivity (β) and the local temperature difference with reference to a datum is called
the Buoyancy Reference Temperature.
Fig 5.9 Basic setting Fluid Domain, CFD simulations of CR12PR 40W
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Fig.5.10 Settings (Basic setting, Fluid model, instillation) under fluid domain, CFD
simulations of CR12PR 40W
Basic setting of surface side and top under Boundary conditions of domain
enclosure, refer Fig 5.11 Through the use of boundary condition of ‘opening’ to all sides
of enclosure faces except the bottom face (set to adiabatic) the size of the fluid domain
can be reduced to a great extent and can be assumed to as atmospheric conditions.
Boundary Type – opening
Locations – n5 Faces encl side and upper
Under Boundary details; Flow Regime- subsonic
Mass and momentum – opening pressure and direction;
Relative pressure - 0 Pa
Flow direction – Normal to Boundary condition
Heat transfer – Opening temperature
Opening temperature- 305K
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Fig 5.11 Bo undary conditions to side and top surfaces of fluid domain, CFD simulations
of CR12PR 40)
The boundar y conditions bottom face of enclosure refer Fig.5.12
Basic setting Boundary Type – Wall, Location – boundary fluid domain bottom
Under boundary details, Heat transfer – Adiabatic
Boundary conditions around the fin base bottom under Fluid domain refer Fig.5.13
Basic setting Boundary Type – Wall, Location –n1 Face encl bottom
Under boundary details, Heat transfer – Adiabatic
Fig 5.12 Boundary conditions bottom of Fluid domain, CFD simulations of CR12PR
40W
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Fig 5.13 Boundary conditions to surfaces around base under Fluid domain
CFD simulations of CR12PR 40W
From outline tree select the domain fin and base which is already created refer Fig 5.14,
under the Basic setting set the material and other parameters.
Location- B163
Domain Type – Solid Domain
Solid Definition- Solid 1,
Option – Material library,
Material – Aluminum
Material Morphology – Continuous solid
Under the Solid models chosen
Thermal Radiation – None
Heat Transfer – Thermal energy
Initialization – Automatic
Boundary Conditions applied to the various surfaces are
Bottom surface of the fin base
Boundary Type – Wall, Location – Fin base bottom heat input surface.
Under Boundary details, Heat Transfer, Heat Flux – (Value) W/m2
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The values of heat flux entered here are assumed equal to the electrical input to the
heating coil applied actually while in the experiment.
Fig 5.14 Settings of the domain fin and base, CFD simulations of CR12PR 40W
Fig. 5.15 Boundary condition heat Flux to bottom of base under domain fin and base
(CFD simulations of CR12PR 40W)
The interface between solid fin surface and enclosure fluid was created by using ‘domain
interface’ option available in the selection box.
Interface Type –Fluid Solid
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Interface side 1 Domain Filter – Domain 1 Fluid Domain, List of surfaces under Fluid
domain
Interface side 2 Domain Filter – Domain Fin and base, Heat convection surfaces
Interface Model – General connection
Mesh connection Method – Automatic
Refer Fig.5.16 for Basic setting of Interface heat flow side 1
Boundary Type – Interface,
Under boundary details, refer Fig 5.17
Mass and momentum – No slip wall
Heat transfer – Conservative interface flux (Default Option)
Also under the boundary details of Interface heat flow side 2,
Heat transfer – Conservative interface flux (Default Option)
Fig 5.17 Boundary details settings of interface heat flow side 1 (fluid domain), CFD
simulations of CR12PR 40W
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5.6 Control and Monitor the Solver to Achieve a Solution (Convergence)
The CFD code used in this work uses ANSYS CFX 12.0. which is based on a
finite volume method, uses tetrahedral unstructured mesh and prism elements. This has
the advantage that local numerical diffusion is reduced and is therefore suitable for
complex flows with e.g. flow reversal. The code is based on a coupled solver for solving
the differential equations using the fully implicit discretization method and treating the
hydrodynamic equations as one single system. To decrease the number of required
iterations for convergence, a false-time stepping method is imposed which guides the
approximate solutions in a physically based manner to a steady-state solution. Buoyancy
is modeled using the Boussinesq approximation in which the forces are modeled as
source terms in the momentum equations. For buoyant flows where the density variation
is driven only by small temperature variations, the Boussinesq model is used. In this
model, a constant reference density is used for all terms other than the buoyancy source
term.
ρ –ρrefer = – ρrefer β (T –Trefer) (5.1)
In this β is the thermal expansivity:
and Trefer = is the buoyancy reference temperature, ρrefer – Reference density.
ANSYS CFX allows to create solid regions in which the equations for heat
transfer are solved, but no flow which is named as conjugate heat transfer (natural
convection) in the solid regions (solid domain) the equation of conservation of energy is
simplified, as no flow inside a solid, so conduction is the only heat transfer mode causing.
The transport equation for the heat conduction through the solid is given below
±
(³7´ µ = ¶ • ¶¸ + ˜
¹ (5.2)
±²
Where in this ρ- density, Cp specific heat capacity, k -the thermal conductivity and SE -
energy source term.
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The governing equation for the heat transfer and the fluid flow are the following
form of the incompressible continuity equation, Navier-Stoke equations, energy
equations and X- Y and Z direction momentum together with the equation of the state.
Where u, v and w are components of velocity »¼ is the Velocity vector, B terms are the
body forces, È terms for components of the viscous stress and h total enthalpy.
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Fig 5.18 Basic setting under solver control, CFD simulation s of CR12PR 40W
Fig 5.19 Residuals of momentum and mass equations, CFD simulations of CR12PR 40W
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Fig 5.20 Residuals of Heat transfer Equations, CFD simulations of CR12PR 40W
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5.7 ANSYS Reports
The report generated through the ANSYS Repot option it gives the details of
meshing, boundary conditions applied, solution reports and output generated etc. Such
file created is given below.
Report
Date
2013/11/16 11:36:10
5.7.1 File Report (for cross fin arrays with 12mm size of the perforation)
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5.7.3 Physics Report
Type Fluid
Location B1437
Materials
Air at 25 C
Settings
Type Solid
Location B163
102
102
102
Settings
Settings
Domain Boundaries
103
F1360.1437, F1361.1437, F1362.1437, F1363.1437,
F1364.1437, F1365.1437, F1366.1437, F1367.1437,
F1368.1437, F1369.1437, F1370.1437, F1371.1437,
F1372.1437, F1373.1437, F1374.1437, F1375.1437,
F1376.1437, F1377.1437, F1378.1437, F1379.1437,
F1380.1437, F1381.1437, F1382.1437, F1383.1437,
F1384.1437, F1385.1437, F1386.1437, F1387.1437,
F1388.1437, F1389.1437, F1390.1437, F1391.1437,
F1392.1437, F1393.1437, F1394.1437, F1395.1437,
F1396.1437, F1397.1437, F1398.1437, F1399.1437,
F1400.1437, F1401.1437, F1402.1437, F1403.1437,
F1404.1437, F1405.1437, F1406.1437, F1407.1437,
F1408.1437, F1409.1437, F1410.1437, F1411.1437,
F1412.1437, F1413.1437, F1414.1437, F1415.1437,
F1416.1437, F1417.1437, F1418.1437, F1419.1437,
F1420.1437, F1421.1437, F1422.1437, F1423.1437,
F1425.1437, F1426.1437, F1427.1437, F1428.1437,
F1429.1437, F1430.1437, F1431.1437, F1433.1437,
F1434.1437, F1435.1437, F1436.1437, F1444.1437,
F1445.1437, F1446.1437, F1447.1437, F1448.1437,
F1449.1437, F1450.1437, F1451.1437, F1452.1437,
F1453.1437, F1454.1437, F1455.1437, F1456.1437,
F1457.1437, F1458.1437, F1463.1437, F1464.1437,
F1465.1437, F1466.1437, F1467.1437, F1468.1437,
F1469.1437, F1470.1437, F1471.1437, F1472.1437,
F1473.1437, F1474.1437, F1475.1437, F1476.1437,
F1477.1437, F1478.1437, F1479.1437, F1480.1437,
F1481.1437, F1482.1437, F1483.1437, F1484.1437,
F1485.1437, F1486.1437, F1487.1437, F1488.1437,
F1489.1437, F1490.1437, F1491.1437
104
Settings
Type OPENING
Settings
Flow Subsonic
Regime
Type WALL
Settings
105
Heat Adiabatic
Transfer
Type WALL
Settings
Heat Adiabatic
Transfer
Settings
Type WALL
Settings
Heat Adiabatic
Transfer
106
Boundary - Boundary heat input base
Type WALL
Settings
X Y Z
Domain Interface 1
Side 1 ( Domain 1 Boundary 0.0000e+00 -7.0980e-08 -3.2183e-04 -2.2047e-09
Fluid Domain )
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107
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Table 5.6 Generated Simulation Results
5.8 Closure
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