Le conditionnement, opération unitaire clé du processus industriel de fabrication des produits fromagers, consiste à remplir par un jet de façon homogène des emballages de formes variées par des produits à propriétés rhéologiques complexes tout en assurant des cadences optimisées. L’objectif de cette étude est de prédire le remplissage d’un emballage, à partir de la connaissance de la rhéologie des produits et des paramètres opératoires pour le dimensionnement de nouveaux procédés de conditionnement ou l’optimisation de procédés existants.Nécessaire à la poursuite de l’étude, le comportement rhéologique des produits fromagers dans les domaines de sollicitation du procédé à 80°C a été caractérisé comme rhéofluidifiant, à seuil de contrainte, élastique en-dessous et au-dessus du seuil d’écoulement.L’hydrodynamique des jets et du remplissage lors du conditionnement a été étudiée avec trois types de produits grâce au pilote à l’échelle laboratoire du procédé, dimensionné pour reproduire les conditions opératoires industrielles. Après avoir vérifié la cohérence des résultats obtenus avec le dispositif expérimental avec ceux de la littérature pour un fluide newtonien, l’étude s’est portée sur des fluides modèles viscoplastiques, gels de Carbopol®, et sur des produits fromagers.Cinq régimes d’écoulement ont été observés et caractérisés à partir des évolutions du diamètre de jet et de la vitesse d’atteinte des bords pendant le remplissage et de la hauteur de motte finale du dépôt après le remplissage, paramètre décisif de la qualité du conditionnement. Des diagrammes de fonctionnement adimensionnels d’observation des régimes ont été déterminés à partir des forces en jeu dans le système. Ainsi, le régime d’écoulement peut être prédit par ces diagrammes à partir des propriétés rhéologiques du produit et des paramètres géométriques et opératoires du procédé. / Packaging is a key step of cheese products industrial manufacturing process. It consists in filling containers of various shapes with non-Newtonian products while ensuring optimized rates. The aim of the present work is to describe the influence of cheese rheological properties as well as process parameters onto packaging, thereby contributing towards its optimization.Necessary for the study, the rheological behavior of cheese products on the process stress range at 80°C has been identified as shear-thinning with a yield stress, with elasticity both below and above the yield stress.Jets and filling hydrodynamics during packaging have been studied with three types of products by the means of the laboratory-scale process pilot, which is able to reproduce the industrial process conditions. After checking for consistency between experimental and litterature results for Newtonian products, the study focused on viscoplastic model fluids, Carbopol® hydrogels, and on cheeses.Five flow patterns have been observed and characterized through jet diameter, spread velocity during filling and final mound height after filling, which is a key factor of the packaging quality. Flow patterns dimensionless distributions have been determined from the forces involved in the system. Thus, the flow pattern can be predicted thanks to theses distributions from product rheological properties and geometrical and process parameters.

Neste trabalho é apresentado a modelagem mecânica e numérica de um escoamento elastoviscoplástico tixotrópico, em termos dos campos de velocidade, pressão, tensão e parâmetro de estrutura. A discretização numérica é feita pelo Método de Elementos Finitos Estabilizado, também conhecido como Galerkin Mínimos Quadrados (GMQ), através de elementos quadrangulares bilineares. O clássico problema da cavidade é utilizado nas simulações, a fim de comparar a formulação e o código utilizados com os resultados conhecidos na literatura. Além disso, apresenta-se o estudo de materiais elasto-viscoplástico tixotrópico em uma contração abrupta na escala 4:1, utilizando a formulação descrita e uma nova função viscosidade para fluidos viscoplásticos, denominada função Viscoplástica Harmônica (VPH). Resultados envolvendo a função VPH são introduzidos e discutidos pela primeira vez nesta tese e apresenta um ótimo ajuste de curva, quando comparada com outras funções disponíveis na literatura. Além da fácil implementação, essa função também apresenta um platô para as altas e baixas viscosidades que são fisicamente realistas, visto que não é possível uma viscosidade infinita ou nula. O menor tempo computacional é também uma característica perceptível nas simulações usando a nova função viscoplástica, isso é um atributo do seu equacionamento que não depende de um termo exponencial, como outros modelos. O estudo de qualidade de malha também é apresentado a fim de garantir a escolha do domínio discreto adequado. Apesar do uso de elementos de ordem inferior, o método GMQ mostrou-se estável na aproximação numérica de todos os problemas dispostos, garantindo até mesmo a análise sobre os efeitos da cinemática, da elasticidade e da tixotropia no escoamento dos fluidos dentro da contração abrupta. / In this work the mechanical and numerical modeling of a thixotropic elasto-viscoplastic flow in terms of the velocity, pressure, stress and structure parameter is presented. Numerical discretization is done by the Stabilized Finite Element Method, also known as Galerkin Least Squares (GLS), through bilinear quadrangular elements. The classical liddriven cavity problem is used in the simulations in order to compare the formulation and code used with the results in the literature. In addition, the study of elasto-viscoplastic thixotropic materials in a 4:1 abrupt contraction using the described formulation and a new viscosity function for viscoplastic fluids, called the Harmonic Viscoplastic Function (HVP), is presented. Results involving the HVP function are introduced and discussed for the first time in this thesis and present a better curve fit when compared to other functions available in the literature. Besides to easy implementation, this function also features a plateau for high and low viscosities that are physically realistic, since infinite or zero viscosity is not possible. The shortest computational time is also a perceptible feature in the simulations using the new viscoplastic function, this is an attribute of its equation that does not depend on an exponential term like other models. The mesh quality study is also presented in order to ensure the choice of the appropriate discrete domain. Despite the use of lower-order elements, the GLS method proved to be stable in the numerical approximation of all the problems, guaranteeing even the analysis of the effects of kinematics, elasticity and thixotropy on fluid flow within the abrupt contraction.

Neste trabalho é apresentado a modelagem mecânica e numérica de um escoamento elastoviscoplástico tixotrópico, em termos dos campos de velocidade, pressão, tensão e parâmetro de estrutura. A discretização numérica é feita pelo Método de Elementos Finitos Estabilizado, também conhecido como Galerkin Mínimos Quadrados (GMQ), através de elementos quadrangulares bilineares. O clássico problema da cavidade é utilizado nas simulações, a fim de comparar a formulação e o código utilizados com os resultados conhecidos na literatura. Além disso, apresenta-se o estudo de materiais elasto-viscoplástico tixotrópico em uma contração abrupta na escala 4:1, utilizando a formulação descrita e uma nova função viscosidade para fluidos viscoplásticos, denominada função Viscoplástica Harmônica (VPH). Resultados envolvendo a função VPH são introduzidos e discutidos pela primeira vez nesta tese e apresenta um ótimo ajuste de curva, quando comparada com outras funções disponíveis na literatura. Além da fácil implementação, essa função também apresenta um platô para as altas e baixas viscosidades que são fisicamente realistas, visto que não é possível uma viscosidade infinita ou nula. O menor tempo computacional é também uma característica perceptível nas simulações usando a nova função viscoplástica, isso é um atributo do seu equacionamento que não depende de um termo exponencial, como outros modelos. O estudo de qualidade de malha também é apresentado a fim de garantir a escolha do domínio discreto adequado. Apesar do uso de elementos de ordem inferior, o método GMQ mostrou-se estável na aproximação numérica de todos os problemas dispostos, garantindo até mesmo a análise sobre os efeitos da cinemática, da elasticidade e da tixotropia no escoamento dos fluidos dentro da contração abrupta. / In this work the mechanical and numerical modeling of a thixotropic elasto-viscoplastic flow in terms of the velocity, pressure, stress and structure parameter is presented. Numerical discretization is done by the Stabilized Finite Element Method, also known as Galerkin Least Squares (GLS), through bilinear quadrangular elements. The classical liddriven cavity problem is used in the simulations in order to compare the formulation and code used with the results in the literature. In addition, the study of elasto-viscoplastic thixotropic materials in a 4:1 abrupt contraction using the described formulation and a new viscosity function for viscoplastic fluids, called the Harmonic Viscoplastic Function (HVP), is presented. Results involving the HVP function are introduced and discussed for the first time in this thesis and present a better curve fit when compared to other functions available in the literature. Besides to easy implementation, this function also features a plateau for high and low viscosities that are physically realistic, since infinite or zero viscosity is not possible. The shortest computational time is also a perceptible feature in the simulations using the new viscoplastic function, this is an attribute of its equation that does not depend on an exponential term like other models. The mesh quality study is also presented in order to ensure the choice of the appropriate discrete domain. Despite the use of lower-order elements, the GLS method proved to be stable in the numerical approximation of all the problems, guaranteeing even the analysis of the effects of kinematics, elasticity and thixotropy on fluid flow within the abrupt contraction.

Le travail de thèse s'inscrit dans la modélisation numérique de l'écoulement des matériaux cimentaires à l'état frais couplée à un outil d'identification des paramètres. Il traite en particulier l'étape de mise en place de l'identification par analyse inverse. D'abord, une analyse de la littérature fait ressortir l'existence d'outils rhéométriques dédiés aux suspensions cimentaires ; le passage des grandeurs macroscopiques à celles locales est faite, soit par le biais de l'utilisation de géométries conventionnelles, soit au moyen de méthodes de calibration. Néanmoins, ces outils ne permettent pas de trouver une signature rhéologique unique pour une même suspension. De plus, les stratégies d'identification des paramètres relatifs aux matériaux cimentaires frais sont peu nombreuses et limitées aux données locales. Ensuite, une stratégie qui consiste à identifier les paramètres d'une loi supposée, directement à partir des mesures macroscopiques simulées (couples, vitesses de rotation imposées au mobile de cisaillement) a été développée et validée en 2D, en discutant notamment de l'efficacité des algorithmes d'optimisation testés (méthode du simplexe et algorithmes génétiques), en fonction du degré de connaissances que l'utilisateur a du matériau. Enfin, la méthode a été appliquée en 3D sur des fluides modèles supposés homogènes. Elle apparaît efficace en fluide pseudo-plastique, notamment par combinaison des algorithmes d'optimisation. Mais il reste des obstacles à lever en fluide visco-plastique, vraisemblablement liés aux outils expérimentaux plutôt qu'à la procédure d'identification elle-même. / The thesis work is part of the numerical modeling of the flow of cementitious materials in the fresh state coupled with an identification procedure of the parameters. It deals in particular with the step of the development of the identification by inverse analysis. First,the literature review reveals the existence of rheometric tools dedicated to cementitious suspensions; The passage from the macroscopic quantities to the local ones is made either by the use of conventional geometries or by means of calibration methods. Nevertheless, these tools do not make it possible to find the expected single rheological signature for a given suspension. In addition, there are few studies reporting strategies for identifying constitutive parameters in the case of fresh cement-based materials and they are limited to local data. Then, a strategy consisting in identifying the parameters of a supposed law, directly on the basis of the simulated macroscopic measurements (torques, rotational speeds imposed on the shearing tool) was developed and validated in 2D, discussing in particular the efficiency Of the optimization algorithms tested (simplex method and genetic algorithms), according to the degree of knowledge that the user has of the material. Finally, the method has been applied in 3D on model fluids, assuming that they are homogeneous. The method appears effective in the case of pseudo-plastic fluid, in particular by combining both optimization algorithms used. But there remain obstacles to overcome in the case of visco-plastic fluids, probably related to the experimental tools rather than to the procedure of identification itself.

Αντικείμενο της παρούσας εργασίας είναι η πρόβλεψη τόσο της κίνησης, αλληλεπίδρασης και παραμόρφωσης δύο φυσαλίδων λόγω μεταβολής της πίεσης στο περιβάλλον ιξώδες υγρό, όσο και της ανοδικής κίνησης μιας φυσαλίδας λόγω άνωσης σε ένα Νευτωνικό ή ιξωδοπλαστικό ρευστό. Για τη μοντελοποίηση των αλληλεπιδρώντων φυσαλίδων, αναπτύχθηκε μιας νέα ελλειπτική μεθόδος κατασκευής του υπολογιστικού πλέγματος προκειμένου να αντιμετωπιστούν επιτυχώς τα ιδιάζοντα σημεία (πόλοι) των φυσαλίδων και οι μεγάλες παραμορφώσεις των διεπιφανειών τους. Με τη μέθοδο αυτή η πύκνωση του πλέγματος περιορίζεται μόνο στις περιοχές που είναι αναγκαίο, μειώνοντας έτσι το υπολογιστικό κόστος και αυξάνοντας την ακρίβεια των υπολογισμών. Για την επίλυση των παρακάτω προβλημάτων χρησιμοποιήθηκε η μέθοδος των μικτών πεπερασμένων στοιχείων κατά Galerkin. Στην περίπτωση των αλληλεπιδρώντων φυσαλίδων έχει εξετασθεί η επίδραση του σχετικού μεγέθους τους, της συχνότητας και του εύρους μεταβολής της επιβαλλόμενης πίεσης και πότε οδηγούν σε έλξη ή άπωση των φυσαλίδων. Στην περίπτωση ελκτικής δύναμης, ακολουθείται η κίνηση και η παραμόρφωσή τους μέχρι του σημείου που έρχονται σε επαφή, όπου αυτό είναι εφικτό. Για τη μελέτη του προβλήματος της φυσαλίδας που ανέρχεται λόγω άνωσης, υποθέτουμε αξονική συμμετρία και μόνιμη κατάσταση. Σύγκριση των προβλέψεών μας για το σχήμα των φυσαλίδων και το πεδίο ροής γύρω τους με προηγούμενα θεωρητικά και πειραματικά αποτελέσματα για Νευτωνικά ρευστά έδειξε άριστη συμφωνία. Στην περίπτωση του ιξωδοπλαστικού ρευστού εξετάστηκαν λεπτομερώς οι παραμορφώσεις των φυσαλίδων σαν συνάρτηση των αριθμών Bingham, Bond και Αρχιμήδη και υπολογίσθηκαν οι συνθήκες υπό τις οποίες είναι δυνατή η παγίδευση της φυσαλίδας μέσα σε αυτό. / The present study deals with the numerical simulation of the motion, interaction and deformation of two bubbles due to variation of the pressure of the ambient Newtonian fluid, and the buoyancy-driven rise of a bubble in a Newtonian or a viscoplastic fluid. A new elliptic mesh generation method is developed in order to deal with the singular points (poles) of the bubbles and the large deformations of their surface. This method permits us to increase the mesh resolution only in the regions that is necessary, decreasing thus the computational cost and increasing the precision of our calculations. The following problems are solved using the mixed finite element/Galerkin method. In the case of the interacting bubbles the effect of their relative size, the frequency and the width of the imposed pressure is examined as well as the conditions that lead in attraction or repulsion of the bubbles. In the case that attractive forces exist, the motion and the deformation of the bubbles followed up to the point that they come in contact, whenever this is possible. In order to study the problem of the bubble that rises due to buoyancy, axial symmetry and steady flow is assumed. Our results for the shape of the bubbles and the flow around them are in very good agreement with previous theoretical and experimental results for Newtonian fluids. The deformations of the bubbles rising in a viscoplastic material are also examined for various values of the Bingham, Bond and Archimedes numbers and the conditions under which entrapment of a bubble is possible are determined.

Στόχος της παρούσας διδακτορικής διατριβής είναι η μελέτη χρονικά μεταβαλλόμενων και ασταθών υπό συνθήκες ροών ιξωδοπλαστικών και ιξωδο-ελαστικών ρευστών λόγω της σημασίας που παρουσιάζουν τα υλικά αυτά σε διάφορες βιομηχανικές διεργασίες. Στα πλαίσια της εργασίας αυτής μελετήθηκε αρχικά το πρόβλημα της συμπίεσης ιξωδοπλαστικού ρευστού μεταξύ δύο δίσκων το οποίο είναι ένα βασικό πείραμα ρεολογικού χαρακτηρισμού μη Νευτωνικών υλικών. Η χρονικά μεταβαλλόμενη προσομοίωση επέτρεψε τον προσδιορισμό των σημαντικών διαφορών μεταξύ των δύο εκδοχών του συγκεκριμένου ρεολογικού πειράματος (δίσκοι κινούμενοι υπό σταθερή ταχύτητα ή υπό σταθερή δύναμη) που ήταν αδύνατος με τα προηγούμενα μοντέλα, ενώ παρουσιάζεται και πλήρης παραμετρική μελέτη της διεργασίας αυτής. Το υπόλοιπο μέρος της παρούσας εργασίας αφιερώθηκε στη μελέτη της διεργασίας εκβολής ιξωδοελαστικών υλικών η οποία συναντάται ευρέως στη βιομηχανία μορφοποίησης πολυμερών. Παρουσιάζεται μια πλήρης παραμετρική ανάλυση για την εκβολή ενός ιξωδοελαστικού ρευστού Phan-Tien & Tanner (PTT) από ένα δακτυλιοειδή αγωγό προκειμένου να εξετάσουμε την επίδραση της γεωμετρίας του αγωγού, και των ρεολογικών ιδιοτήτων του ρευστού. Επιπλέον ένα σημαντικό πρόβλημα που εμφανίζεται κατά την εκβολή από ένα κυλινδρικό, επίπεδο ή δακτυλιοειδή αγωγό είναι η εμφάνιση ασταθειών οι οποίες επηρεάζουν σημαντικά την ποιότητα του τελικού προϊόντος. Προκειμένου να διερευνηθεί ο μηχανισμός που προκαλεί την εμφάνιση αυτών των ασταθειών πραγματοποιήθηκε γραμμική ανάλυση ευστάθειας για τη αξονοσυμμετρική και καρτεσιανή δισδιάστατη ροή επικόλλησης-ολίσθησης (stick-slip flow) ενός ρευστού PTT. Γύρω από τη λύση μόνιμης κατάστασης πραγματοποιείται γραμμική ανάλυση ευστάθειας, και υπολογίζονται οι ιδιοτιμές του γενικευμένου προβλήματος με τη βοήθεια της μεθόδου Arnoldi. Έτσι προσδιορίζεται η επίδραση των ιδιοτήτων του υλικού στην ευστάθεια ή μη της ροής. / The purpose of this dissertation is to perform a study on time-dependent and conditionally unstable flows of viscoplastic and viscoelastic fluids because of their importance in various industrial processes. A typical experiment which is used widely for the rheological characterization of non-Newtonian fluids is squeeze flow which is the subject of the first chapter of this dissertation. The time-dependent simulation permitted the determination of the distinct differences between the two versions of this rheological experiment (disks moving with constant velocity or under constant force) which was impossible with the models used up to now, while a complete parametric analysis of this process is presented. The rest of this work focuses in the important problem of the extrusion process of a viscoelastic fluid, which is frequently encountered in the polymer industry. A complete parametric analysis is presented for the extrusion of a Phan-Thien Tanner (PTT) fluid from an annular die in order to examine the effect of the die geometry and the rheological properties of the fluid on this process. Moreover, it is widely known that during the extrusion from a cylindrical, planar or an annular die various flow instabilities may arise affecting significantly the quality of the final product. In order to investigate the mechanism, which causes the appearance of these instabilities, a linear stability analysis is performed for the cylindrical or planar stick-slip flow of a PTT fluid. The stability analysis is performed around the steady state solution and the eigenvalues of the generalized problem are calculated using the Arnoldi algorithm. With this method the effect of the various rheological properties of the fluid on the stability of the flow is determined.