The purpose of this thesis for Sapa Heat Transfer is to examine a furnace in which aluminium is pre-heated before hot rolling. The project is modeled in a computer environment in which the air flow in the furnace and the heat transfer to the aluminium solids are included. The computer environment and its governing equations, as well as boundary conditions and generalizations, are presented and explained. The simulations are based on two models. The first model has an asymmetric solid placement, which is how it looks in today's ovens. It is validated against collected data. The second model has a symmetric solid placement, in which improvements are introduced and evaluated. The results indicate that a symmetric positioning of metal solids in the oven is preferable in order to achieve a good airflow distribution. The use of plates has been proven useful for steering the air to critial areas and to get an even distribution of the airflow. Lastly the simulations indicate that an increased airflow can compensate the less optimal flow distribution that arises with asymmetric solid placements.

A first part of a ”Heat Transfer Handbook” about correlations for internal cooling of gas turbine vanes and blades has been created. The work is based on the cooling of vanes and blades 1 and 2 on different Siemens Gas Turbines. The cooling methods increase the heat transfer in the cooling channels by increasing the heat transfer coefficient and/or increasing the heat transfer surface area. The penalty paid for the increased heat transfer is higher pressure losses. Three cooling methods, called rib turbulated cooling, matrix cooling and impingement cooling were investigated. Rib turbulated cooling and impingement cooling are typically used in the leading edge or mid region of the airfoil and matrix cooling is mostly applied in the trailing edge region. Literature studies for each cooling method, covering both open literature and internal reports, were carried out in order to find correlations developed from tests. The correlations were compared and analyzed with focus on suitability for use in turbine conditions. The analysis resulted in recommendations about what correlations to use for each cooling method. For rib turbulated cooling in square or rectangular ducts, four correlations developed by Han and his co-workers [3.5], [3.8], [3.9] and [3.6] are recommended, each valid for different channel and rib geometries. For U-shaped channels, correlations of Nagoga [3.4] are recommended. Matrix cooling is relatively unknown in west, but has been used for many years in the former Soviet Union. Therefore available information in open literature is limited. Only one source of correlations was found. The correlations were developed by Nagoga [4.2] and are valid for closed matrixes. Siemens Gas Turbines are cooled with open matrixes, why further work with developing correlations is needed. For impingement cooling on a flat target plate, a correlation of Florschuetz et al. [5.7] is recommended for inline impingement arrays. For staggered arrays, both the correlations of Florschuetz et al. [5.7] and Höglund [5.8] are suitable. The correlations for impingement on curved target plate gave very different results. The correlation of Nagoga is recommended, but it is also advised to consult the other correlations when calculating heat transfer for a specific case. Another part of the work has been to investigate the codes of two heat transfer programs named Q3D and Multipass, used in the Siemens offices in Finspång and Lincoln, respectively. Certain changes in the code are recommended.

The thesis investigates if it is possible to replace several pumpimpellers with one controllable pumpimpeller, with a economical and a manufacturing analisys aspect. The studied pumpimpeller is mounted on a midrange wastewaterpump, N3127MT. In the thesis a contemplated manufacturing process is evaluated for a concept that are supposed to act as a controllable pumpimpeller. The pumpimpeller are studied in a manufacturing and flow matter and are presented in the thesis. The manufacturing cost is also estimated, and this has been compared to the storage cost and other costs that the existing pumpimpeller generates. The thesis also shows that the concept has minor losses in cutting quality aswell as the effiency comparing to the existing pumpimpeller. The concept also raises the manufacturing cost and this increasing cost makes the presented concept to expensive to carry through. An investigation of the costs that the existing pumpimpeller produces has also been done, and this shows that there is not that much expenses to earn regarding to for example the storage cost. The storage cost includes information from Flygt’s central storagecenter in Lindas, Sweden and Metz, France, and also an inventory about the pumpimpellers located at Flygt’s different distributors worldwide. The thesis shows that a controllable pumpimpeller will generally increase the cost for the pumpimpeller and the performance of the pumpimpeller will decrease.

When designing a new fuel management system for a spark ignition engine the amount of air that is fed to the cylinders is highly important. A tool that is being used to improve the performance and reduce emission levels is engine modeling were a fuel management system can be tested and designed in a computer environment thus saving valuable setup time in an engine test cell. One important part of the modeling is the throttle which regulates the air. The current isentropic model has been investigated in this report. A throttle body and intake manifold has been simulated using Computational Fluid Dynamics (CFD) and the influence of surface heating and surface wall roughness has been calculated. A method to calculate the effective flow area has been constructed and tested by simulating at two different throttle plate angles and several pressure ratios across the throttle plate. The results show that both surface wall roughness and wall heating will reduce the mass flow rate compared to a smooth and adiabatic wall respectively. The reduction is both dependent on pressure ratio and throttle plate angle. The effective area has showed to follow the same behaviour as the mass flow rate for the larger simulated throttle plate angle 31 degrees, i.e. an increase as the pressure drop over the throttle plate becomes larger. At the smaller throttle plate angle 21 degrees, the behaviour is completely different and a reduction of the effective area can be seen for the highest pressure drop where a increase is expected. / När ett nytt bränslesystem ska designas till en bensinmotor är det viktigt att veta hur stor mängd luft som hamnar i cylindrarna. Ett verktyg som är på frammarsch för att förbättra prestanda och minska emissioner är modellbaserad simulering. Med hjälp av detta kan ett bränslesystem designas och testas i datormiljö och därigenom spara dyrbar tid som annars måste tillbringas i en motortestcell. En viktig del av denna modellering är spjället eller trotteln vilken reglerar luften. I denna rapport har studier gjort på den nuvarande isentropiska modellen. Ett spjällhus och insugsgrenrör har simulerats med hjälp av Computational Fluid Dynamics (CFD) och påverkan av värme samt ytjämnhet på väggen har beräknats. En metod att beräkna den effektiva genomströmmade arean har konstruerats och testats vid två olika spjällvinklar samt flertalet tryckkvoter över spjället. Resultaten visar att både en uppvärmd vägg och en vägg med skrovlighet kommer att minska massflödet jämfört med en adiabatisk respektive en slät vägg. Minskningen har både spjällvinkel samt tryckkvots beroende. Den effektiva genomströmmade arean har visats sig följa samma beteende som massflödet vid den större simulerade spjällvinkeln 31 grader, det vill säga öka med ökat tryckfall över spjället. Vid den mindre vinkeln 21 grader, är beteendet helt annorlunda jämfört med massflödet och en minskning av den effektiva arean kan ses vid det största tryckfallet där en ökning förväntades.

<p>Despite its importance in various industrial applications there is still a lack of experimental studies on the dynamic and thermal field of swirling jets in the near-field region. The present study is an attempt to close this lack and provide new insights on the effect of rotation on the turbulent mixing of a <i>passive scalar</i>, on turbulence (joint) statistics as well as the turbulence structure.</p><p>Swirl is known to increase the spreading of free turbulent jets and hence to entrain more ambient fluid. Contrary to previous experiments, which leave traces of the swirl generating method especially in the near-field, the swirl was imparted by discharging a slightly heated air flow from an axially rotating and thermally insulated pipe (6 m long, diameter 60 mm). This gives well-defined axisymmetric streamwise and azimuthal velocity distributions as well as a well-defined temperature profile at the jet outlet. The experiments were performed at a <i>Reynolds</i> number of 24000 and a swirl number (ratio between the angular velocity of the pipe wall and the bulk velocity in the pipe) of 0.5.</p><p>By means of a specially designed combined X-wire and cold-wire probe it was possible to simultaneously acquire the instantaneous axial and azimuthal velocity components as well as the temperature and compensate the former against temperature variations. The comparison of the swirling and non-swirling cases clearly indicates a modification of the turbulence structure to that effect that the swirling jet spreads and mixes faster than its non-swirling counterpart. It is also shown that the streamwise velocity and temperature fluctuations are highly correlated and that the addition of swirl drastically increases the streamwise<i> passive scalar</i> flux in the near field.</p>

<p>Boundary layer separation is usually an unwanted phenomenon in most technical applications as for instance on airplane wings, on ground vehicles and in internal flows such as diffusers. If separation occurs it leads to loss of lift, higher drag and results in energy losses. It is therefore important to be able to find methods to control and if possible avoid separation altogether without introducing a too heavy penalty such as increased drag, energy consuming suction etc.</p><p>In the present work we study one such control method, namely the use of vortex generators (VGs), which are known to be able to hinder turbulent boundary layer separation. We first study the downstream development of streamwise vortices behind pairs and arrays of vortex generators and how the strength of the vortices is coupled to the relative size of the vortex generators in comparison to the boundary layer size. Both the amplitude and the trajectory of the vortices are tracked in the downstream direction. Also the influences of yaw and free stream turbulence on the vortices are investigated. This part of the study is made with hot-wire anemometry where all three velocity components of the vortex structure are measured. The generation of circulation by the VGs scales excellently with the VG blade height and the velocity at the blade edge. The magnitude of circulation was found to be independent of yaw angle.</p><p>The second part of the study deals with the control effect of vortex generators on three different cases where the strength of the adverse pressure gradient (APG) in a turbulent boundary layer has been varied. In this case the measurements have been made with particle image velocimetry. It was found that the streamwise position where the VGs are placed is not critical for the control effect. For the three different APG cases approximately the same level of circulation was needed to inhibit separation. In contrast to some previous studies we find no evidence of a universal detachment shape factor<i> H</i>_12,that is independent of pressure gradient.</p>

<p>The orientation of fibres suspended in a viscous fluid, flowing over a solid surface, has been studied experimentally. A shear layer was generated, by letting the suspension flow down an inclined plate. Far upstream from the measuring section the suspension was accelerated to obtain an initial orientation of the fibres aligned with the flow direction. A CCD-camera was used to visualise the fibres. The velocity profile of the fibres coincided with the theoretical expression for fully developed flow of Newtonian liquid down an inclined wall.</p><p>The orientation of the fibres was analysed in planes parallel to the solid surface. At distances from the wall larger than one fibre length the fibres performed a tumbling motion in the flow-gradient plane in what appeared to be Jeffery-like orbits. Closer to the wall a difference was found between fibres of aspect ratio <i>r</i><i>p </i>= 10 and 40. The longer fibres of <i>r</i><i>p </i>= 40 kept their orientation, aligned with the flow, also in the near wall region. For the shorter fibres the orientation shifted gradually, to orientations closer to the vorticity axis, when the distance from the wall was decreased. In the very proximity to the wall the fibres were aligned with the vorticity, perpendicular to the direction of the flow. Another distinction, most likely related to the fibre orientation, was seen in the wall normal concentration profile. Due to sedimentation effects fibres accumulated in the near wall region. For fibres of <i>r</i><i>p </i>= 10 a peak in concentration was found at the wall, while for r=40 the maximum concentration was found approximately half a fibre length from the wall. It is previously known that a fibre can interact with the wall in what is referred to as a "pole vaulting" motion away from the wall. It is suggested, as a likely explanation to the location of the maximum concentration, that fibres of <i>r</i><i>p </i>= 40 perform this motion, while fibres of <i>rp</i>=10 do not.</p><p>In another experiment the surface of the wall was modified with ridges. For fibres of <i>r</i><i>p </i>= 10 there were no longer any fibres oriented perpendicular to the flow direction in the near wall region.</p><p>The main application in mind throughout this work is papermaking. The study is considered to be of fundamental character and is not applicable in a direct sense. The difference between the flow situation in the experiments and the paper machine is discussed further.</p>

<p>In this thesis we apply linear feedback control to spatially evolving flows in order to minimize disturbance growth. The dynamics is assumed to be described by the linearized Navier--Stokes equations. Actuators and sensor are designed and a Kalman filtering technique is used to reconstruct the unknown flow state from noisy measurements. This reconstructed flow state is used to determine the control feedback which is applied to the Navier--Stokes equations through properly designed actuators. Since the control and estimation gains are obtained through an optimization process, and the Navier--Stokes equations typically forms a very high-dimensional system when discretized there is an interest in reducing the complexity of the equations. One possible approach is to perform Fourier decomposition along (almost) homogeneous spatial directions and another is by constructing a reduced order model by Galerkin projection on a suitable set of vectors. The first strategy is used to control the evolution of a range of instabilities in the classical family of Falkner--Skan--Cooke flows whereas the second is applied to a more complex cavity type of geometry.</p>

<p>An Eulerian-Eulerian model for dilute gas-particle turbulent flows is</p><p>developed for engineering applications. The aim is to understand the effect of particles on turbulent flows. The model is implemented in a finite element code which is used to perform numerical simulations. The feedback from the particles on the turbulence and the mean flow of the gas in a vertical channel flow is studied. In particular, the influence of the particle response time and particle volume fraction on the preferential concentration of the particles near the walls, caused by the turbophoretic effect is explored. The study shows that the particle feedback decreases the accumulation of particles on the walls. It is also found that even a low particle volume fraction can have a significant impact on the turbulence and the mean flow of the gas. A model for the particle fluctuating velocity in turbulent gas-particle flow is derived using a set of stochastic differential</p><p>equations. Particle-particle collisions were taken into account. The model shows that the particle fluctuating velocity increases with increasing particle-particle collisions and that increasing particle response times decrease the fluctuating velocity.</p>

<p>Non-pulsatile and pulsatile flow in bent pipes and radial turbine has been assessed with numerical simulations. The flow field in a single bent pipe has been computed with different turbulence modelling approaches. A comparison with measured data shows that Implicit Large Eddy Simulation (ILES) gives the best agreement in terms of mean flow quantities. All computations with the different turbulence models qualitatively capture the so called Dean vortices. The Dean vortices are a pair of counter-rotating vortices that are created in the bend, due to inertial effects in combination with a radial pressure gradient. The pulsatile flow in a double bent pipe has also been considered. In the first bend, the Dean vortices are formed and in the second bend a swirling motion is created, which will together with the Dean vortices create a complex flow field downstream of the second bend. The strength of these structures will vary with the amplitude of the axial flow. For pulsatile flow, a phase shift between the velocity and the pressure occurs and the phase shift is not constant during the pulse depending on the balance between the different terms in the Navier- Stokes equations.</p><p>The performance of a radial turbocharger turbine working under both non-pulsatile and pulsatile flow conditions has also been investigated by using ILES. To assess the effect of pulsatile inflow conditions on the turbine performance, three different cases have been considered with different frequencies and amplitude of the mass flow pulse and different rotational speeds of the turbine wheel. The results show that the turbine cannot be treated as being quasi-stationary; for example, the shaft power varies with varying frequency of the pulses for the same amplitude of mass flow. The pulsatile flow also implies that the incidence angle of the flow into the turbine wheel varies during the pulse. For the worst case, the relative incidence angle varies from approximately −80° to +60°. A phase shift between the pressure and the mass flow at the inlet and the shaft torque also occurs. This phase shift increases with increasing frequency, which affects the accuracy of the results from 1-D models based on turbine maps measured under non-pulsatile conditions.</p><p>For a turbocharger working under internal combustion engine conditions, the flow into the turbine is pulsatile and there are also unsteady secondary flow components, depending on the geometry of the exhaust manifold situated upstream of the turbine. Therefore, the effects of different perturbations at the inflow conditions on the turbine performance have been assessed. For the different cases both turbulent fluctuations and different secondary flow structures are added to the inlet velocity. The results show that a non-disturbed inlet flow gives the best performance, while an inflow condition with a certain large scale eddy in combination with turbulence has the largest negative effect on the shaft power output.</p>