G. Raush

Influence of the interteeth clearances on the flow ripple in a gerotor pump for engine lubrication

A gerotor pump, which is widely used in the automotive industry for engine oil lubrication, produces an instantaneous flow fluctuation and the estimation of this is fundamental in order to evaluate the pump quality for silent and smooth operation. The intricate aspects of the pumping process of a gerotor pump make computational fluid dynamics the appropriate tool for modelling and simulation to provide insights into its flow characteristics. Because the instantaneous flow is rather dependent on the teeth contact, a new boundary condition of a virtual wall was developed, which allows simulation of the teeth contact in the interteeth radial clearances. This new boundary condition is utilized in a three-dimensional model of the gerotor pump with mesh deformation and remeshing at every time step by means of a home-made ad-hoc code programmed by the present authors and named viscous wall cell. The code has been integrated into the computational fluid dynamics solver. The interteeth clearances are studied under the following different operating conditions (working pressures and rotational velocities): first, no contact points (no teeth contact is studied in order to prove that, even if the interteeth radial clearance is sufficiently small, the leakage cannot be negligible); second, all contact points (the ideal approach is considered with zero interteeth radial clearances used to model zero manufacturing tolerances); third, one contact point at different locations (the existence of manufacturing tolerances and the teeth contact approach make the pump’s operation and its pumping mechanism more realistic in the simulation). The numerical instantaneous flow is compared with the analytical instantaneous flow, with the instantaneous flow modelled by using the bond graph technique, and with the experimental determination of the flow ripple for a specific unit. The results obtained show the importance of simulating the teeth contact and prove to be an excellent estimation of the instantaneous flow behaviour to obtain the dynamic properties of a gerotor pump under more realistic conditions than its design.

Detailed Experimental Validation of the Thermal and Fluid Dynamic Behavior of Hermetic Reciprocating Compressors

A detailed experimental analysis of the thermal and fluid dynamic behavior of hermetic reciprocating compressors is presented. A hermetic compressor for household appliances has been experimentally tested. The fluid and solid thermal map evolution has been logged in several strategic points. The absolute instantaneous pressure has been determined in three specific zones: suction muffler, compression chamber, and cylinder head. The pV diagram inside the compressor chamber has also been experimentally obtained for the different working conditions studied without any previous hypothesis to determine the absolute pressure level. A complete description of the experimental equipment and its instrumentation is included. This experimental approach has allowed validating a mathematical model developed for the numerical simulation of the thermal and fluid dynamic behavior of hermetic reciprocating compressors. Good agreement between the detailed numerical results and the experimental data has been obtained, allowing a better understanding of the thermal and fluid dynamic behavior of these compressors.

Computational fluid dynamics and particle image velocimetry assisted design tools for a new generation of trochoidal gear pumps

Trochoidal gear pumps produce significant flow pulsations that result in pressure pulsations, which interact with the system where they are connected, shortening the life of both the pump and circuit components. The complicated aspects of the operation of a gerotor pump make computational fluid dynamics the proper tool for modelling and simulating its flow characteristics. A three-dimensional model with deforming mesh computational fluid dynamics is presented, including the effects of the manufacturing tolerance and the leakage inside the pump. A new boundary condition is created for the simulation of the solid contact in the interteeth radial clearance. The experimental study of the pump is carried out by means of time-resolved particle image velocimetry, and results are qualitatively evaluated, thanks to the numerical simulation results. Time-resolved particle image velocimetry is developed in order to adapt it to the gerotor pump, and it is proved to be a feasible alternative to obtain the instantaneous flow of the pump in a direct mode, which would allow the determination of geometries that minimize the non-desired flow pulsations. Thus, a new methodology involving computational fluid dynamics and time-resolved particle image velocimetry is presented, which allows the obtaining of the instantaneous flow of the pump in a direct mode without altering its behaviour significantly.

Pressure effects on the performance of external gear pumps under cavitation

The numerical analysis of an external gear pump with cavitation effects has been validated with experimental data obtained by applying Time-Resolved Particle Image Velocimetry. The effect of inlet and outlet pressure on volumetric efficiency has been studied numerically. First, the Particle Image Velocimetry method was used to analyze the two-dimensional velocity field in the middle plane of the suction chamber of the gear pump. The main improvement, with respect to previous similar analysis is the use of alginate micro particles as tracers. It is seen that the two-dimensional model is able to characterize the flow field of the real pump in the region of the inlet chamber in which cavitation is expected. In a previous study, it was seen that a cavitation cloud acted as a virtual contact point at low pressure, being responsible for an increase on the volumetric efficiency. The first set of simulations represents the pump working with high outlet pressure. Now, the cavitation cloud is not present and cavitation no longer helps to improve the efficiency of the pump. The second set of simulations represents the pump with an inlet loss factor, which implies a mean inlet pressure below atmospheric conditions. This allows cavitation clouds to propagate upstream. Despite the larger cavitation clouds, volumetric efficiency only drops at high operating velocities, when some clouds become trapped between gears and casing and are transported to the pressure side.

A novel Sigma–Delta ADC application oriented to test hermetic reciprocating compressors

A novel data acquisition approach to test hermetic reciprocating compressors is presented. A non-uniformly sampled application of a ΣΔ analogue-to-digital converter was used to investigate the compressor pV diagram, together with accurate spectral analysis of pressure readings. Several previous approaches are presented and compared with the one proposed here. Different statistical comparisons have been carried out with the main objective of demonstrating the good performance of the proposal.

Method for Fluid Flow Simulation of a Gerotor Pump using OpenFOAM

A new approach based on the open source tool OpenFOAM is presented for the numerical simulation of a mini gerotor pump working at low pressure. The work is principally focused on the estimation of leakage flow in the clearance disk between pump case and gears. Two main contributions are presented for the performance of the numerical simulation. On one hand, a contact point viscosity model is used for the simulation of solid–solid contact between gears in order to avoid the teeth tip leakage. On the other hand, a new boundary condition has been implemented for the gear mesh points motion in order to keep the mesh quality while moving gears with relative velocity. Arbitrary coupled mesh interface (ACMI) has been used both in the interface between clearance disk in inlet/outlet ports and between clearance disk and interteeth fluid domain. Although the main goal of the work is the development of the numerical method rather than the study of the physical analysis of the pump, results have been compared with experimental measurement and a good agreement in volumetric efficiency and pressure fluctuations has been found. Finally, the leakage flow in the clearance disk has been analyzed.

ESTIMATION OF WALL SHEAR STRESS USING 4D FLOW CARDIOVASCULAR MRI AND COMPUTATIONAL FLUID DYNAMICS

In the last few years, wall shear stress (WSS) has arisen as a new diagnostic indicator in patients with arterial disease. There is a substantial evidence that the WSS plays a significant role, together with hemodynamic indicators, in initiation and progression of the vascular diseases. Estimation of WSS values, therefore, may be of clinical significance and the methods employed for its measurement are crucial for clinical community. Recently, four-dimensional (4D) flow cardiovascular magnetic resonance (CMR) has been widely used in a number of applications for visualization and quantification of blood flow, and although the sensitivity to blood flow measurement has increased, it is not yet able to provide an accurate three-dimensional (3D) WSS distribution. The aim of this work is to evaluate the aortic blood flow features and the associated WSS by the combination of 4D flow cardiovascular magnetic resonance (4D CMR) and computational fluid dynamics technique. In particular, in this work, we used the 4D CMR to obtain the spatial domain and the boundary conditions needed to estimate the WSS within the entire thoracic aorta using computational fluid dynamics. Similar WSS distributions were found for cases simulated. A sensitivity analysis was done to check the accuracy of the method. 4D CMR begins to be a reliable tool to estimate the WSS within the entire thoracic aorta using computational fluid dynamics. The combination of both techniques may provide the ideal tool to help tackle these and other problems related to wall shear estimation.

Feasibility of CO2 Compressors for Light Commercial Appliances

Commercial refrigerating systems are mostly based on hydrochlorofluorocarbon (HCFC) fluids. The Kyoto Protocol requirements encouraged the promotion of policies for sustainable development and reduction of global warming potential, including the regulation of HCFCs. In that sense, R-744 is the only natural refrigerant replacement known to be nontoxic, nonflammable, and not harmful to the environment. The aim of this work is to aid in the development of new reciprocating compressors for light commercial applications that use CO2 as the fluid refrigerant. First, a numerical analysis and experimental validation were developed and carried out, not only for laboratory compressor prototypes, but also for the whole transcritical CO2 cycle. The numerical comparative results present a reasonably good agreement and successfully allow the use of these numerical tools to improve the successive designs. Consequently, several compressor pre-industrial prototypes have been designed, validated, and improved. The experimental results against standard compressors show the possibilities that CO2 compressors offer in terms of efficiency and COP. Finally, an appliance test is presented to check the performance of the overall system and confirm the preliminary results obtained in the calorimeter tests. The appliance platform results prove the feasibility of these light commercial applications using R-744 as the fluid refrigerant.

Numerical study of impingement location of liquid jet poured from a tilting ladle with lip spout

A new approach for simulating liquid poured from a tilting lip spout is presented, using neither a dynamic mesh nor the moving solid solution method. In this case only the tilting ladle is moving, so we propose to rotate the gravitational acceleration at an angular velocity prescribed by a geometrical and dynamical calculation to keep the poured flow rate constant. This angular velocity is applied to modify the orientation of the gravity vector in computational fluid dynamics (CFD) simulations using the OpenFOAM® toolbox. Also, fictitious forces are considered. The modified solver is used to calculate the impingement location for six spout geometries and compare the jet dispersion there. This method could offer an inexpensive tool to calculate optimal spout geometries to reduce sprue size in the metal casting industry.

Flexible Rod Design for Educational Wind Balance

This article provides a technical description of a flexible hinge for wind tunnel rigs. For academic purposes, the device was integrated into several rod flexures to build a home-made external wind balance system. The cylindrical elastic element incorporates several notches, and the flexure linkage is able to transmit force in the main axial direction without hindering perpendicular movement. The flexural element described here is simple and easily manufactured, and can also be used with other types of wind balance. The flexure described in this article has similar functionality to those mentioned in the reference section, but has a more compact element. The project’s effectiveness was demonstrated in a series of experimental comparisons of forces and moments measured on a wing using the N.A.C.A. Clark-Y airfoil profile.