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Baines, W. D. aud Peterson, E. G., 1951, "An Investigation of Flow Through Screens,"
Manuscript submitted for the SAND--91-142 9C
ASME/AIAA/ASCE/SIAM/AIChE
National Fluid Dynamics Congress DE9 2 00 293 0
June 22-25, 1992
Los Angeles, CA
..
• . ,, ...... . ,,..
ABSTRACT
The laminar flow downstream of fine-mesh sc:'eens is studied experimentally and numeri-
cally. Two different screen types are examined experimentally, both with open areas greater
than 50°_ and wire dimensions less than 100 /_m. Such screens produce flow disturbances
of much smaller scale than those examined in most previous studies of flow-conditioning
screens and grid-generated turbu._ence. Instead of using standard woven-wire screens, high-
uniformity screens are used which are fabricated b- photoetching holes into 50.8 #m thick
Inconel sheets. The holes thus produced are square with rounded corners, arranged to form
a square array, with a minimum wire thickness (located halfway between wire crossings) of
D = 50.8 #m. A flow facility has been constructed for experiments with these screens. Air at
85 kPa e,nd 295 K is passed through each screen at upstream velocities of 1 to 12 m/s, yield-
ing Reynolds numbers ReD -- pUD/# in the range 2 _< ReD (_ 35. Pressure drops across the
screens are measured at the_c conditions using pressure transducers and manometers. From
these data, the Reynolds number dependence of the drag coefficient CD is determined. Three-
dimensional flow simulations are performed over the Reynolds number range 2.5 < ReD <: 15 ;
using the spectral-element code NEKTON (Nektonics/creare.x). The geometry of the pho-
toetched screens is simulated by a similar geometry with the same open area and minimum
!
¢ W
wire thickness. The drag coefficients are determined from the computed press,:rc differences
across the screens and are in reasonable agreement with the experimental values, although
the agreement degrades slightly with increasing Reynolds number. Comparison with stan-
dard semi-empirical correlations for the drag on screens shows that such correlations are
applicable for the present screens so long as the correct choices for screen open area fraction
0 and minimum wire thickness D are used in the correlation.
From the simulations, the length of the recirculating region downstream of the screen
is found to grow roughly linearly with increasing ReD. Also, the downstream extent of
the recirculating region is different behind different screen locations: it is longest behind
a wire crossing and shortest behind a wire waist. Photorefractive schlieren photographs of
the flow structure immediately downstream of the screen have been recorded. The screen
is electrically heated, and the thermal wake clearly indicates the variation in fluid density
(refractive index) between the heated screen wire wakes and the cold jet flows through the
screen openings. Such schlieren photographs show long, narrow flow structures downstream
DISCLAIMER
This report was prepared as an account of work sponsored by an agency of the Uniled States
Government. Neither the United States Government nor any agency thereof, nor any of their
employees, makes any warranty, express or implied, or assumes any legal liability or responsi- I_"
bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or ._
process disclosed, or represents that its use would not infringe privately owned rights. Refer-
ence herein to any specific commercial product, process, or service by trade name, trademark,
manufacturer, or otherwise dees not necessarily constitute or imply its endorsement, recom-
mendation, or favoring by the United States Government or any agency thereof. The views
and opinions of authors expressed herein do not necessarily state or reflect those of the
United States Government or any agency thereof.
t
J
NOMENCLATURE
x spati_l coordinates
p fluid density
# fluid viscosity
(') nondimensional ()
¢ (
f
:1
r • ! 0
INTRODUCTION
The downstream evolution of flow through screens is a fundamental fluid mechanics prob-
lem that is important in a variety of engineering situations. Screens are commonly used for
flow conditioning in wind and water tunnels due to their effect of reducing turbulent length
scales and intensity. As discussed by Roach (1987), several methods for computing the tur-
bulent intensity downstream of a screen require an estimate of the pressure drop across the
screen. The flow through screens is also commonly used to generate quasi-homogeneous grid
turbulence. For these reasons, a large body of published literature (discussed below) is avail-
able on screen flows, and a number of important findings have been made concerning the
behavior of this flow. For example, the flow can be categorized depending on the value of the
screen wire Reynolds number, with the flow laminar for Reynolds number less than 40 and
has been shown by a number of investigators to lead to jet coalescence and subsequent for-
mation of larger-scale flow structures (e.g., Bbttcher and Wedemeyer, 1988). However, most
of this work has focused on screens with characteristic wire dimensions several times larger
and with slightly different geometries than those of interest here. For example, Bbttcher and
Wedemeyer (1989) examined flows through screens composed of 0.300 mm diameter wires,
Roach (1987) used wire diameters of 0.914 mm, and Pinker and Herbert (1967) used wire
diameters ranging from 1.22 to 0.376 mm. Notable exceptions are Groth and Johansson
(1988), who examined screens of seven different wire diameters ranging from 2.5 mm down
to 40 #m, and Bernardi et al. (1976) who examined screens with wire diameters as small as
25 #m.
The present study is unique in combining experimental and numerical examination of the
steady laminar flow through highly-uniform fine-mesh photoetched screens. The experimen-
tal and numerical results are also compared with the results of Groth and Johansson (1988)..
The Reynolds numbers of interest are maintained below 40 in order to avoid initiation of
vortex shedding in the wire wakes. The objective of the present experiments and simulations
4
ii
r • ! t
Ap
½pu (1)
i on the wire thickness Reynolds number
t pUD
:, Reo = (2)
,' /Z
:1
1
for fixed value= of the screen aspect ratios
H D
J A1 = A2 = (3)
with the quantities p, U, and /Z measured upstream of the screen (see Fig. 1). Roach
(1987) points out that the wire diameter or width D is the appropriate length scale for
consideration of the downstream flow. Therefore, D was chosen as the characteristic length
in the definitions used here.
EXPERIMENTS
The pressure drop is measured for the flow through two different screen geometries (80-
and 100-mesh), with open area fractions O of 0.66 and 0.55, respectively, and minimum wire
thickness D = 50.8/zm. Such screens produce flow disturbances of much smaller scale than
those examined in most previous studies of flow-conditioning screens and grid-generated tur-
bulence reported in the literature. Screen nonuniformity has been shown by a number of
investigators to lead to jet coalescence and subsequent formation of larger-scale flow struc-
tures (e.g., BSttcher and Wedemeyer, 1988). For this reason, high-uniformity photoetched
screens are used in this work instead of standard woven-wire screens. High-uniformity screens
are fabricated by photoetching holes into Inconel (76% Ni, 16% Cr, 8% Fe) sheets of thick-
between wire crossings, and its value is measured for each screen using an optical microscope.
The screen open area is also determined by direct optical microscopic examination. Table 1
lists the pertinent parameters of the two screens examined in this work.
f i
An open-loop wind tunnel has been constructed for experiments with these screens.
Screens are mounted to span the 50 by 5 cm rectangular test section, and are held in such
a way that no screen supports protrude into the flow. A steady flow of filtered room air at
85 kPa and 295 K is passed through each screen. Under these conditions, air has a density
of p = 1.01 kg/m 3 and a viscosity of # = 1.82 x 10-5 kg/m.s. Upstream velocities U range
from 1 to 12 m/s, which yield Reynolds numbers ReD = pUD/# in the range 2 _<ReD _ 35.
Static pressure ports are located 2 cm upstream and downstream of each screen. Pres-
sure drops are measured using a MKS Baratron Type 223B differential pressure transducer
(0 to 1 torr), with MKS Model PD_-C-2C power supply and digital readout unit, and an
inclined oil manometer. The pressure transducers used for recording the data have a factory-
supplied accuracy of 0.01% of reading il digit (0.13 Pa). The velocity values are determined
using a calibrated in-line turbine flowmeter (EG&G Flow Technology Model FT-64C1NA-
GEA-2), providing a mean velocity with an uncertainty of approximately -}-0.02 m/s. The
mean velocities are also periodically checked using a hot wire anemometer.
These measured pressure-drop values have not been corrected to account for pressure loss
due to friction in the duct. As shown by Pinker and Herbert (1967), such losses are typically
(cf. Eq. 1). Figures 3 and 4 show experimentally determined drag coefficients as functions
of the wire thickness Reynolds numbers for the 80-mesh and 100-mesh screens, respectively.
The screen wakes are visualized using a photorefract;_ve schlieren technique (Robey ct
6
al., 1990; O'Hern et al., 1991). In this technique, a crystal of the photorefractive material
barium titanate (BaTiO3) is used as an optical temporal and intensity filter, deflecting the
steady portion of the illuminating beam and transmitting the fluctuating portion containing
phase and intensity perturbations introduced by the flow. Schlieren photographs of the
flow structure immediately downstream of the screen have been recorded. The screen is
electrically heated, and the thermal wake clearly indicates the variation in fluid density
(refractive index) between the heated screen wire wakes and the cold jet flows through the
Three-dimensional flow simulations are performed using the spectral-element code NEK-
where x represents position. Thus, these simulations correspond to the experimental results
for 100-mesh screens discussed in the previous section (/) = All). The nondimensional
viscosity is scaled by the desired wire thickness Reynolds number ReD according to the
relation
1
[z- 5ReD ' (4)
ZXp (5)
An- pU2 •
CD = 2A/5. (6)
Schematic and perspective views of the computational domain and the spectral-element
mesh are shown in Figs. 6 and 7, respectively. The rounded-corner geometry of tl_ pho- :
toetched screens is modeled by a similar geometry with the same open area and minimum
wire thickness. Symmetry is assumed about planes passing parallel to the inflow direction
through each wire midplane and hole midplane but is not assumed along diagonal planes (see
7
Fig. 6). Although this latter symmetry assumption would permit additional computational
savings, it is not made due to the inability of NEKTON to impose a symmetry boundary
condition on a surface that is not normal to one of the coordinate axes. The computational
= 0 and _ = 0 passes through the center of a hole, and the line defined by _ = _I and_= i
passes through the center of a wire crossing (see Fig. 6). The screen itself is centered at the
streamwise position $ = 1, with leading face at 2 = 0.9 and with trailing face at _, = 1.1.
Thus, the computational domain extends one screen-mesh spacing upstream of the screen
Table 2 shows the results of simulations for several different Reynolds numbers in the
range 2.5 < ReD <_ 15 (these results are also included in Fig. 4). Simulations at higher
Reynolds numbers are not performed because the thinness of the boundary layers at the
screen surface requires greater resolution than permitted by the spectral-element mesh shown
in Fig. 7, which in turn significantly increases the required computational effort. The pressure
drop is determined by taking the difference in pressure between the inflow plane (_ = 0) and
the outflow plane (_, = 3). In ali cases, the spatial variation of the pressure within each of
these planes is about 1%. The effect of grid refinement is examined by using successively
higher-order polynomials (5th, 7th, and 9th) to represent the flow within each element. Since
kNektonics, 1991), an extrapolation is made to infinite order to indicate the accuracy of the
results. This is accomplished by fitting the pressure drop at a given Reynolds number to
this relation to infinite order are typically within 1% of the values determined using 9th-
order elements, which are themselves typically within 1% of the values from the 7th-order
solutions. ¢
Ii _ tl .......
Table 2. Computational results for aspect ratio A1 -- 5.
i
Order 5 Order 7 Order 9 Extrapol.
ReD Ap CD Ap CD Ap CD Ap CD
! From the computational flow solutions, the shape and extent of the recirculating region
I immediately downstream of the screen can be examined. The flow in this region has a
I complex vortical structure: streamlines originating near the point (0.5,0.5,0) enter the recir-
culating region, swirl around one or more times in this region, and finally exit this region
near the side walls defined by the planes _ = 0.5 or 9 = 0.5. Figure 8 shows a streamline
originating at the point (0.475, 0.485, 0) that exhibits this phenomenon for the simulation
The maximum extent of the recirculating region can be determined in the following
' manner. The streamline that exits the computational domain at the point (0.5,0.5,3) can be
_: traced backward through the domain. For each of the four Reynolds numbers, this streamline
I is shown in Fig. 9. Note that this streamline does not enter the computational domain at
the point (0.5,0.5,0), as discussed above. The point at which the streamline reattaches to
the line defined by _ = _ = 0.5 indicates the maximum extent of the recirculating region.
A plot of the nondimensional distance Ln between the downstream screen face (4 = 1.1)
and this reattachment point as a function of Reynolds number ReD is given in Fig. 10.
From Figs. 9 and 10, the length of the recirculating region is seen to grow almost linearly
with Reynolds number for ReD > 5 . Recalling that the screen mesh H is five times the
nfinimum wire thickness D, it is seen that the length of the recirculating region is nearly 7D
for ReD --- 15, which is much longer than the recirculating region behind a cylinder of the
The shape of the recirculating region is difficult to depict in two dimensions but can be
characterized by its "footprint" on the 9 = 0.5 plane (or, equivalently, on the _ = 0.5 plane).
9
This footprint is given approximately by the curve in this plane for which the streamwise
velocity component vanishes. The footprint of the recirculating region is shown in Fig. 11 for
the simulation with ReD = 2.5. It is seen that the recirculating region is of greatest extent
downstream of a wire crossing (k = 9 = 0.5) but becomes much shorter downstream of a wire
waist (:_ = 0_ 9 = 0.5). The footprints have the same bell-shaped curve for tile other three
simulations but grow increasingly long with increasing Reynolds number. Extrapolation of
these results and the results of Figs. 9 and 10 to larger Reynolds numbers suggests that the
recirculating regions downstream of the wire crossings are related to the long, narrow flow
Figure 4 shows the experimentally and computationally determined values of the screen
drag coefficient CD. Direct comparison of the two data sets can be made only for the 100-mesh
screens over the Reynolds number range 2.5 < ReD < 15. The computational values agree
reasonably well with the experimental values (to within about 20%) at lower values of the
Reynolds number but increasingly overpredict the drag coefficient as the Reynolds number
becomes large. This is probably due to two aspects of the simulation. First, the computa-
tional domain is probably not long enough in the upstream direction. As a result, the flow is
turned more sharply by the screen in the simulations than occurs in the experiments, which
causes larger pressure drops. Second, the model of the screen used in the computations has
sharp corners, at which separation is forced to occur, whereas the real screens have beveled
edges (see Fig. 2). The sharpness of the screen edges is an important parameter in deter-
mining the pressure drop, oince the precise shape of each individual surface will control the
location of separation. As a result, the flow in the experiments probably remains attached
further along the screen surface, and the delayed separation (compared to the simulations)
Groth and Johansson (1988) have proposed a correlation relating the drag coefficient cD
to the wire diameter Reynolds number Red and the open area fraction O of the form
10
!1
This correlation was developed for woven-wire meshes constructed from wires of round cross-
section, with various wire diameters and screen open areas. The values of the function f(Red)
used below are read directly from Fig. 1 of Groth and Johansson (1988), with an approximate
error of +0.01.
, ,
It is of interest to apply this correlation to flow through photoetched screens with the
parameters discussed above. However, due to the obvious differences in wire cross-section and
screen geometry from the Groth-Johansson screens, it is not entirely clear how the Reynolds
number based on minimum wire thickness D, used in the previous sections, compares to the
Reynolds number based on screen wire diameter d used by Groth and Johansson. Three
possibilities for calculation of the Reynolds number are outlined below. First, an effective
(1 - D/H) 2. Second, an effective wire diameter den can be calculated assuming the prescribed
open area O as den = H(1 - v/-O). Third, the actual measured values of D and O for each
screen can be used. Tables 3 and 4 show the Groth-Johansson drag coefficients for 80-mesh
and 100-mesh photoetched screens, determined from their correlation using the three different
methods discussed above. In these tables, the Reynolds number Red is equal to ReD except
ReD Using Oe_ and D Using O and de_ = 59.7 izm Using O and D
_0_0 _, 0_1_
10.c _00_ 0_1
_ . _, __0.000
11_ 0_0_,
_, _0 _ 0_0_1
_00_ 00_
_
_ _0 1_00_11_1_0,_00_0_0_1_0_0 000_
_, _0 0900_10_0_1_0_00_0
.... _0__0 0_00__
t,.a'
Figures 3 and 4 compare these correlations to the experimental and computational results '
discussed in the previous sections. Figure 3 shows that use of D and Oe_ produces drag
coefficients that are in agreement with the 80-mesh screen experiments, whereas use of den
and O or use of D and O results in a significant overprediction of the drag coefficient. Figure
11
Table 4. Correlation results for aspect ratio A1 = 5 (100-mesh screen).
ReD U_ing Oen and D Using O and deft = 63.9 #m Using O and D
Red f Red') O_fr CD Red f.(Red) 0 CD Rea f!Red) 0 ......
CD
2:5 2.5 4.46 0.64 6.43 3.1 3.67 0.56 8.03 2.5 4.46 0.56 9.76
5.0 5.0 2.71 0.64 3.91 6.2 2.34 0.56 5.12 5.0 2.71 0.56 5.93
10.0 10.0 1.78 0.64 2.57 12.6 1.51 0.56 3.31 10.0 1.78 0.56 3.90
15.0 15.0 1.36 0.64 1.96 18.9 1.16 0.56 2.54 15.0 1.36 0.56 2.98
35.0 35.0 0.90 0.64 1.30 44.1 0.80
....
0.56 1.75 35.0 0.90 0.56 1.97
4 shows that use of D and O produces drag coefficients that are in agreement with the 100-
mesh screen experiments and simulations, whereas use of d_fr and O or use of D and Oefr
results in a significant underprediction of the drag coefficient. The cause of the different
behavior for the two meshes is not known at present. The spread of the values predicted by
the three correlation methods is lower for the 80-mesh than for the 100-mesh screens, one
J
reason being that each wire in a photoetched screen decreases the actual open area from the
t effective value based on wires of diameter d D. For the 100-mesh screens there are 20_
more wires than for the 80-mesh screens, so the deviation from the effective value is larger.
These observations are valid only over the limited Reynolds number range examined here.
f
For example, Roach (1987) states that for a square mesh array of square rods, the same
as the computational geometry considered here and similar to the experimental geometry,
the geometric term in Eq. 7 should be raised to the power 1.09 to achieve the best fit of
available experimental data over the Reynolds number range 102 < ReD < 104. Applying
such a correction to the correlations shown in Figs. 3 and 4 does not lead to a noticeable
improvement in their agreement with the experimental data, indicating that such a power
relationship may not be needed in the low Reynolds number regime considered in the present
study.
¢
,'
12
n lr
CONCLUSIONS
Experiments and three-dimensional computations ha.ve been performed to study the flow
through and downstream of screens. A comparison has been made between experimental and
computational determinations of the drag coefficient for flow through screens at a variety
of Reynolds numbers. Iu the cases examined to date, the experimental and computational
w'aes of the drag coefficient are in reasonably good agreement over Reynoids numbers in
the range 2.5 < ReD < 15. The extent of the recircu]ating region behind the screen wires
is found to grow almost linearly with Reynolds number but to vary significantly in length
behind different spanwise locations along a wire. The maximum extent occurs downstream
of wire crossings and is found to be unusually long when compared to the rech culating region
downstream of a circular cylinder at the same Reynolds number. These long, narrow recir-
culating regions are hypothesized to be related to the long, narrow flow structures observed
with reasonable accuracy so long as the correct values of screen open area fraction 0 and
minimum wire thickness D are used in the correlation.
ACKNOWLEDGMENTS
The authors wish to thank John Lewin and Bob Meyer for their assistance in design
and fabrication of the screen test facility, and to Tom Grasser for his help in performing the
experiments. This work was performed at Sandia National Laboratories, supported by the
U. S. Department of Energy under contract number DE-AC04-76DP00789.
¢
REFERENCES
Bernardi, R. T., Linehan, J. H., and Hamilton, L. H., (1976), "Low Reynolds Number Loss
BSttcher, J. and Wedemeyer, E., 1989, "The Flow Downstream of Screens and its Influence
on the Flow in the Stagnation Region of Cylindrical Bodies," J. Fluid Mech., Vol. 204,
pp. 501-522.
Groth, J. and Johansson, A. V., 1988, "Turbulence Reduction by Screens," d. Fluid Mech.,
Laws, E. M., and Livesey, J. L., 1978, "Flow Through Screens," Ann. Rev. Fluid Mech.,
Nektonics, NEKTON User's Guide: Version 2.7fl, 1991, Nektonics, Cambridge MA.
O'Hern, T. J., Robey, H. F., Torczynski, J. R., Neal, D. R., and Shagam, R. N., 1991,
Jones, H. Hayami, and M. Nishi, eds., American Society of Mechanical Engineers, New York,
pp. 29-33.
Pinker, R. A., and Herbert, M. V., 1967, "Pressure Loss Associated with Compressible Flow
Through Square-Mesh Wire Gauzes," J. Mech. Engr. Sci., Vol. 9, pp. 11-23.
Roach, P. E., (1987), "The Generation of Nearly Isotropic Turbulence by Means of Grids,"
Robey, H. F., Albrecht, G., and Moore, T., 1990, "An Optical Technique for the_])irect •
Measurement of the 2-D Spectral Density of a Passive Scalar in a Turbulent Flow," AIAA
Paper 90-1667, American In, titute of Aeronautics and Astronautics, Washington DC.
Van Dyke, M., 1982, An Album of Fluid Motion, Parabolic Press, Stanford CA, p. 28.
lA
._ p, T, p, I.'_,U _ p-,_p
!t .....
screen screen
side view front view
15
6 .... I .... I .... I .... I .... 1 .... I ....
4>
;. --"-- Measured
_ --A--. Corr (Oeff, D)
t
0
Q,) '_ . ".',":.::,
(..) =., ...:,
'% "8"-..
(0
o') 2 "_ii _ "'"'.'.".,.
L _"_ li ..,.,,,...... _ .....
a --._._;;.._.;._..
" ........ .....-.:.-.:...
m.-- ......
= :::'" :.;..:.'.:......... .
........ ... ,,._'_...,,._...._;,: :.-.
:;
0 5 10 15 20 25 30 35
of the screen drag coefficient ep on the wire thickness Reynolds number ReD for the 80-mesh
10 ' ',.,' ' i .... i .... I .... i .... , .... I ....
screen. •
=_ i"_
| Measured
le----
I Simulation
0\_ iA ..... Corr (Oeff. D)
" Io.........
o,rlO,
(,.} lo...... Corr 10, DI
" _\\
-!
.__ 6 ,, _,_-..
_,_
o
0 5 10 15 20 25 30 35
of the screen drag coefficient CDon the wire thickness Reynolds number ReD for the 100-mesh
screen.
16
|
. °
symmetry assumed
y=O 7 °
x=O x=1/2
Fig. 6. Schematic of screen plane used for computations (tildes are suppressed in the
figure).
17
l1
I
= ,,_
/_ /
/ t
I ]
, IS Z=O
screen
, location
: / Z=l
y=O _z- =3
X=O X= 112
Fig. 7. Perspective view of the computational domain. (tildes are suppressed in the
figure).
18
|
° .....
t •
x=y=O
x+y=l/2 ....
x=y=l/2 ---_
z-O_ z-3-
x=y - _""_-----
x = 1/2, y = 0
z=O Z-3
x= 1/2
y_O .....
z=O z=3
Fig. 8. Several views of the streamline entering the computational domain at the point
(0.475, 0.485, 0) for ReD = 2.5. It enters the domain, swirls around immediately behind the
screen, and exits the domain near the plane _7= 0.5 (tildes are suppressed in the figure).
!9
1
X= 1/2
x=O
z=O z=3
X= 1/2
x= 1/2
x=O
z=O z=3
X=x=O
1/2 J-_ ,, I_ -"'_ ReD=
], 15
Fig. 9. Views of the streamlines that indicate the maximum extent of the recirculating
region (tildes are suppressed in the figure): (a) Re = 2.5; (b) Re = 5; (c) Re = 10;
(d)R_= zs.
2O
,|
m i, •
Re D
Fig. 10. Plot of the nondimensional maximum length of the recirculating region against
Reynolds number.
• Z
_t
footprint of the recirculating region. The case ReD = 2.5 is shown here (tildes are suppressed
in the figure).
21