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Chapter 2

ANSYS Polyflow - Part A

Introduction to
ANSYS Polyflow

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Introduction to ANSYS POLYFLOW

Basic equations

Graphical interface : WORKBENCH

DATA file construction : POLYDATA

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Basic equations

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Incompressible Fluid Flow

The following are the field equations governing


incompressible fluid flow.
Mass conservation
v = 0
where v is the velocity
Momentum conservation
p + T + f = a
where p is
i the
th pressure
T is the extra-stress tensor
f is the volume force given by f = g
v
a is the acceleration term given by a = + v v
t
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Incompressible Fluid Flow

nergy conservation
D
c p ( ) = r + T : v q
Dt
where q is the heat flux defined as q = k
D
=
and + v
D
Dt t
: refers to the scalar product of two tensors
Constitutive equation : closure of the system

NB : Definition of Cauchy Stress Tensor

= pI + T
where p is the pressure and T is the extra-stress tensor
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Generalized Newtonian Fluid or


Non-Newtonian Inelastic Fluid

The constitutive equation governing a generalized


N t i fl
Newtonian fluid
id iis:
T = 2 (& , )D

where is the viscosity which can be dependent on shear


rate, &, and temperature, . D is the rate-of-deformation
t
tensor d
defined
1
2
(
fi d as D = v + v T . )
& is the local shear rate defined as & = 2tr ( D 2 ).

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Viscosity Laws
The following viscosity models are available in
ANSYS POLYFLOW.
In general, the viscosity law can be written as:

(&, T ) = F (& ) H (T )
The following laws are available for shear-rate dependence of
viscosity:
Constant
F (& ) = o
where o is the viscosity at zero shear rate.

Power law
F (& ) = K ( & )
n 1

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Viscosity Laws

Bird-Carreau
Bird Carreau

( )
n 1
F (& ) = + ( o ) 1 + & 2 2 2

for shear thinning fluids

Bingham

0
F (& ) = 0 + & & c
&
&
0 2
&c
F (& ) = 0 + & < &c
&c

for yield stress materials (mud, dough, etc.)


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Viscosity Laws Viscosity Laws

Cross

(& ) = 0
1 + (& ) m

Carreau-Yasuda
C Y d

[
(& ) = + ( 0 ) 1 + (& ) b
]
n 1
b

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Viscosity Laws
The following laws are available for temperature dependence of
viscosity H( ).
Constant viscosity

H (T ) = 1
Arrhenius law
1 1
H (T ) = exp
T T0 T T 0
Where is a material coefficient (linked to the activation
energy)
is a reference temperature
0 is a scaling temperature (absolute temperature)
Approximate Arrhenius law
H (T ) = exp[ (T T )]
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Simplified Viscoelastic Model (ScafTen)


Motivation :
Decrease the CPU time for viscoelastic simulation
Application to the swelling effect for extrusion process with free surface
Add a first normal stress difference on top of a generalised Newtonian
model
d l
extra-stress tensor T in shear flow
(& )& (& )& .

T = (& )& . .
. . .
exhibiting:
first normal stress difference (& )&
relaxation mechanism via (& )
Shear stress component (& )&
The viscoelastic variable & obeys a transport equation
D&
(& ) + & = &
Dt
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Simplified Viscoelastic Model (ScaFTen)


Features
Different possible equations for the first normal viscosity (& )

For facilitate the setup


setup, consider:
(& ) = (& ) & = &

identify the other parameters from extrudate swelling :


the shear rate dependence of relaxation time (& )
development of the free
surface
the weighting coefficient amplitude of the swelling

For non-isothermal flows :


Temperature dependence for shear and normal viscosities

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Simplified Viscoelastic Model (ScaFTen)


Example
p of result obtained for a technical profile:
p

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Differential Viscoelastic Constitutive


Equations
T = T1 + T2
Equations for T1 and T2
T1 is the viscoelastic component of the extra-stress tensor

T1
g ( T1 ) T1 + = 21D
t
where 1 is the partial viscosity, and is the relaxation time.

T2 is the Newtonian component of the extra


extra-stress
stress tensor
T2 = 2 2 D
where 2 is the partial viscosity.

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Integration in Workbench

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Training Manual

Main entry

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Symbols in Workbench
Unfulfilled
U f lfill d
Refresh required
Attention required
Update required
Up-to-date
Interrupted
Input changes pending
Pending
R f h failed,
Refresh f il d refresh
f h required
i d
Update failed, update required
Update failed, attention required

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Fluid flow system, and first actions

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POLYFLOW system, Extrusion Blow moulding

and warning if violation

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Fluid flow system, Geometry / Mesh, Mesh import


(Right-click)

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Fluid flow system,

Setup, preferences
(Right-click) Solution, preferences
(Right click)
(Right-click)

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Fluid flow system,


Import any file,
file e.g.
e g for using POLYMAT

and browse
browse

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Run POLYMAT
(Right-click)

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Solution (i.e. calculation), inspection of progresses.

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Upon completion, Results update


(analysis with CFD-Post)

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POLYFLOW system, analysis of results


Create
C t a results
lt system,
t
drag/drop Solution onto results

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POLYFLOW system, analysis of results

If a change occurs upstream

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2D or 3D?
Tools
T l -> Options
O ti
Select Geometry Import
Choose 2D or 3D (Analysis type)

And then create a new project!


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Import a GAMBIT mesh file? (i)


Create
C t a POLYFLOW neutralt l fil
file with
ith GAMBIT
GAMBIT, as
usual
In WB analysis system, mesher:
Import mesh file, .neu is accepted

Conversion is done at the refresh of the setup cell


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Import a GAMBIT mesh file? (ii)


Create
C t a POLYFLOW neutral
t l fil
file with
ith GAMBIT
GAMBIT, as
usual
In a WB component system, setup:
Import mesh, select file type .neu ; conversion is then done

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Assigning input variables as parameters

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UDT (user-defined template)


Create
C t a UDT in
i POLYDATA
POLYDATA, e.g. on a h heatt fl
flux
Click on UPDT, select the variable, and flag it

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UDT
A parameter
t sett iis created
t d

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UDT
Update
U d t POLYFLOW (run),( )
Display the results in CFD-Post

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UDT
Define
D fi a point
i t

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UDT
a new expression: probe(TEMPERATURE)@point 1

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UDT
And assign it as Workbench output parameter
[Right-click on the expression]

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UDT
Exit CFD-Post,
CFD Post and the loop is closed

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UDT
Click on Parameter
Parameter, enter a value and update
update

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UDT
Click on Parameter
Parameter, enter a value and update
update

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UDT
Repeat
Repeat

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Files and directory structure in WB (hidden)

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POLYDATA
O

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Graphical User Interface

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POLYDATA has a tree architecture

Task

Sub-task
Domain of the sub-task
Material data
Flow
Fl boundary
b d conditions
diti

Save and exit

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POLYDATA architecture

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Global remeshing
Local remeshing
Save and exit

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Task Options
A task is an entity
y in POLYDATA where y
you define the
following:

The nature of the task:


task

F.E.M. task

POLYFLOW uses a finite element method ((F.E.M.)) to solve


the partial differential equations for the flow problem.

MIXING task

The main goal of this task is the creation of trajectories


needed for statistical analysis of flows with Polystat (very
y g mixing).
useful for studying g)

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Task Options
The type of geometry:
2D planar geometry
A 2D velocity field (u,v) is described in a 2D Cartesian reference
frame.
2D axisymmetric
y geometry
g y
A 2D velocity field (u,v) is described in a 2D cylindrical reference
frame.
2D 1/2 planar geometry
A 3D velocity field (u,v,w) is described in a 2D Cartesian reference
frame.
2D 1/2 axisymmetric geometry
A 3D velocity field (u,v,w) is described in a 2D cylindrical reference
frame.
3D geometry
Full 3D calculations are performed assuming a Cartesian (x,y,z)
reference frame.
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Task Options
The type of simulation:

Steady
Steady--state
Identify a flow regime. The flow parameters (material parameters or boundary
condition parameters) will not change with time.

Time
Time--dependent
Use if you want to study the evolution of the flow with time. The flow
parameters (boundary condition parameters) can be a function of time.

Evolution
A continuation scheme applied on flow parameters causing non-linearity
(hence posing convergence problems); the parameters (material parameters
or boundary condition parameters) are progressively increased (or
decreased) from an initial value to the desired nominal value.
value

Optimization
It allows the definition of flags in POLYDATA and an optimization of the
shape
p of the flow domain ((internally
y or by
y coupling
p g with external optimizer
p
software)

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Multiple Tasks
A task usually corresponds to one simulation. However, you can also
create several tasks that will be solved sequentially, each task being an
independent problem.

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POLYDATA architecture

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Thermal boundary conditions ( for non
non-isothermal)
isothermal)
Global remeshing
Local remeshing
Save and exit

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Sub-Task Options
The models available in POLYDATA are:
Preprocessor
Postprocessor
Heat conduction problem
Generalized Newtonian flow problems
Generalized Newtonian isothermal flow problem
Generalized Newtonian non-isothermal flow problem
Differential Viscoelastic flow problems
Differential viscoelastic isothermal flow problem
Differential viscoelastic non-isothermal flow problem
Integral Viscoelastic flow problems
Integral viscoelastic isothermal flow problem
Integral viscoelastic non-isothermal flow problem
Simplified viscoelastic flow problem (ScaFten)
Simplified viscoelastic isothermal flow problem
Simplified viscoelastic non-isothermal flow problem

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Sub-Task Options
Darcy flow problems
Darcy isothermal flow problem
Darcy non-isothermal flow problem
Mass transfer problem
Transport of species
Closure
Potential problem
Film model
Generalized Newtonian isothermal
Generalized Newtonian non-isothermal
Viscoelastic isothermal
Viscoelastic non-isothermal
Shell model
Generalized Newtonian isothermal
Generalized Newtonian non-isothermal
Viscoelastic isothermal
Viscoelastic non-isothermal

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Sub-Task Options

Crystallization
isothermal crystallization
non-isothermal crystallization
Elasticity
Elasticity isothermal
Elasticity non-isothermal
Post-processor of isothermal elasticity
Post-processor of non-isothermal elasticity
Linear Thermo-Elastic stresses and deformations
Residual stresses and deformations ( Narayanaswamy)

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Multiple Sub-Tasks

Multiple sub-tasks can be defined in a


single task in order to cover the
different aspects of the simulation
(e.g., co
co-extrusion
extrusion of two or more
fluids)
Usually, one sub-task is attached to
one material.

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Features of POLYDATA

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Global remeshing
Local remeshing
Save and exit

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Domain of the Sub-task

This is the portion of the mesh in which the sub-task


problem is defined.
defined

By default, the sub-task covers the entire mesh.

Sub-domains are necessary in simulations when


multiple sub-tasks are defined (with each sub-task
defined on non-overlapping
non overlapping sub-domains).
sub domains)

Sub-domains are useful when moving boundaries are


defined
defined.

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Features of POLYDATA

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Global remeshing
Local remeshing
Save and exit

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Material Data
System of units in Polydata:
The length unit is given by the dimension of the
imported meshed geometry ( m, cm, mm)
Choose your own systems of units, keeping in mind
that the numerical values in Polydata should not be too
(& ) = f (& )
large or too low
Example :
Consider that the geometry is in mm
Then the unit of length is mm for all the data
In
I MKS viscosity
i it unit
it is
i Pa.s
P or kg/m.s
k / 2, then
th ini mm.g.s,
the numerical value of the viscosity is the same.
But for flow boundary conditions expressed by
velocity, V in m/s have to be multiplied by 1000 to be in
mm/s.
mm/s
For all the (thermal) material data, boundary conditions,
the conversion from MKS to mm.g.s should be also
done.
The Change
Change System of Units
Units option is applied only
on the material data, not on the geometry and on the
boundary conditions!!!
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Material Data

The viscosity expression is:

(&, T ) = f (& )* h(T )


Shear-rate dependence of viscosity (& ) = f (& ) (& ) = f (& )
D
Defined
fi d forf generalized
li d N t i
Newtonian fl
flow
problems.

Temperature dependence of viscosity (T ) = h(T )


Defined for generalized Newtonian non-
isothermal flow problems.

For simplified viscoelastic model :

First normal viscosity (& )


Viscosity & ( )
Relaxation time & ( )
Weighting coefficient

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Differential
ff viscoelastic models and Integral
Viscoelastic models
Defined for viscoelastic flow problems only.
Densityy
Defined for simulations where inertia, heat
convection, or natural convection is taken into
account.
Inertia terms
Defined when the effects of inertia are taken into
account in the simulation.
In polymer processing applications, the viscous
forces are dominant over the inertial forces, hence
the effects of inertia are generally neglected unless
for time dependent problem.
Coefficient of thermal expansion
Defined for natural convection problems.

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Material Data

Thermal conductivity
Defined for non-isothermal flow problems and
heat conduction problems.
Heat capacity per unit mass
Defined for non-isothermal flow problems and
transient heat conduction problems.
Viscous heating
Defined for non-isothermal flow problems and
heat conduction problems.
problems
Gravity
Defined in simulations where the effects of
gravity are taken into account.
Average temperature
Defined for non-isothermal problems.
Initialization of the temperature field.
Heat source per unit of volume
Allows to define a heat source term in the heat
transfer equation

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Features of POLYDATA

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Global remeshing
Local remeshing
Save and exit

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Flow Boundary Conditions

Boundary conditions are defined along the borders of the


domain of the sub-task (intersections with a boundary set or a
sub-domain). )
The boundary conditions are usually specified with respect to a
local reference frame n-s where:
n is the vector specifying the direction normal to the boundary
surface.
s is the vector specifying the direction along the boundary surface.

Boundary 2

Boundary 1 Domain of definition


s

n
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Flow Boundary Conditions

Types of flow boundary conditions


z Interface
Only defined for simulations involving

multiple
lti l sub-tasks.
bt k
Defined along the border between adjacent
sub-tasks, also establishing continuity of the
flow variables between the two sides of the
interface in different sub-tasks.
Interfaces can be fixed or moving.

This boundary condition in one sub-task


requires a similar condition on the other side
of the boundary in the adjacent sub-task.

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Flow Boundary Conditions

Normal and tangential velocities imposed (vn,vs)

vn normal velocityy component


p
vs tangential velocity component

The default condition in POLYDATA is vn = vs =0,


this corresponds to the full
full stick along the wall
wall
condition

You can override the default values by assigning


non-zero values
l for
f vn andd vs.

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Flow Boundary Conditions

Normal and tangential forces imposed (fn,fs)


fn normal force, fs tangential force
The default condition in POLYDATA is fn= fs = 0.
This condition is typically imposed along the outlet
section of extrudate.

Normal velocity and tangential force imposed (vn,fs)


The default condition is vn= fs = 0
Typical example: imposing a uniform value for vn at
the inlet of the computational domain.

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Flow Boundary Conditions

Normal force and tangential velocity imposed (fn,vs)


The default condition is fn= vs = 0
Typical example: Outlet pressure

Plane of symmetry
Specify zero normal velocity and zero surface force
fs= vn = 0
Applicable for 2D planar or 3D flows.
For 2D axisymmetric flows,
flows the Axis of symmetry is
automatically identified by POLYDATA as Y axis.

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Flow Boundary Conditions


Inflow
Defined along the inlet section of the flow.
The volumetric flow rate Q is specified.
The three types
y of Inflow calculation in POLYDATA are:
Fully developed
Based on the flow rate, POLYFLOW calculates a fully
developed velocity profile and imposes the
computed velocity profile as the prescribed velocity.
Constant normal force
POLYFLOW calculates the value of the normal force
that will induce the desired flow rate.
Automatic
Based on the simulation definition,
f POLYFLOW
automatically identifies the best inflow calculation
for the simulation.

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Flow Boundary Conditions

Slip Conditions
The normal velocity component is zero, i.e., v n = 0.
The surface force fs is assigned according to the
slip model defined for the simulation.
simulation
For the Navier law, expression is :

Outflow
Defined along the outlet section of the flow.
Specify zero normal force and zero tangential
velocity.
For
F viscoelastic
i l ti simulations,
i l ti you mustt specify
if the
th
flow rate in order to allow for the calculation of the
stresses corresponding to a fully developed profile.
If the flow rate is unknown, the f n= 0 = vs boundary
condition should be selected
selected.

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Flow Boundary Conditions

Free Surface
This refers to a boundary whose position is unknown
and is calculated as part of the solution for the
problem.
This boundary condition obeys a first-order differential
equation in the absence of surface tension.
The calculation of the location of the free surface in this
case requires an initial condition at the starting point of
the free surface.
Thi
This boundary
b d condition
di i obeys
b a second-order
d d
differential equation in the presence of surface tension.
The calculation of the location of the free surface in this
case requires two initial boundary conditions; usually
the position at the starting point of the free surface and
an angle at its extremity.
extremity
Global force imposed
Specify the contact force (or the drawing force) along a
boundary.
Typical example would be a fiber spinning process
where
h a drawing
d i force
f is
i imposed
i d along
l a specific
ifi
boundary.

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Flow Boundary Conditions

Cartesian velocities imposed


Specify
p y the rigid-body
g y velocity
y ((combination of a
translational velocity and an angular velocity
around an axis of rotation) on a boundary.
The velocity is described in a Cartesian reference
frame instead of a normal/tangential one.

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Features of POLYDATA

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Thermal boundary conditions
Global remeshing
Local remeshing
Save and exit

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Thermal Boundary Conditions


For non-isothermal sub-task,, thermal boundary y conditions
are defined along the borders of the domain of the sub-task
(intersections with a boundary set or a sub-domain).

Interface
I t f
Only defined for simulations involving multiple sub-
tasks
Defined
e ed aalong
o g tthe
e bo
border
de bet
between
ee adjace
adjacentt sub-tasks
sub tas s
Continuity of the temperature field along the interface
With possibility of jump of the heat flux
Temperature imposed
By default, temperature vanishes
Temperature could be defined as constant, function
of coordinates, mapped from CSV file, or via an user
defined function ( UDF)

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Thermal Boundary Conditions

Flux density imposed


Defined as the sum of a constant flux, a convective
fl and
flux d a radiative
di i flux
fl :

Insulated boundary/symmetry
Vanishing heat flux
Inflow
If an inflow boundary condition has been defined
Calculation of a fully developed temperature profile
Outflow
Vanishing heat flux

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Thermal Boundary Conditions

Rosseland correction
Boundary condition specially designed for glass
furnace, where the radiation inside the molten glass
mustt b
be taken
t k iinto
t accountt
The formulation of the heat flux is :

with =
q1 = Ck
q4 =
and

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Features of POLYDATA

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Global remeshing
Local remeshing
Save and exit

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Local Remeshing

Applied in problems in which free surfaces or moving


interfaces are present.
p

In free surface and moving interface problems, a portion


of the mesh will be affected by the relocalization of the
free surface boundary or the moving interface boundary.

The purpose of this technique is to relocate the internal


nodes according to the displacement of the boundary (free
surface or moving interface) nodes.

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Local Remeshing

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Local Remeshing
Thompson
p Transformation
For 2D and 3D flows, steady or transient
Accept any type of elements for the mesh
Used when the mesh can not be mapped
Elliptic method, obeys a second order differential
equation
a mapping is defined by the equation 2 G ( x ) = 0 with

1 : G2 = 1 , n G1 = 0
2 : G1 = 1 , n G2 = 0
3 : G2 = 1 , n G1 = 0
4 : G1 = 1 , n G2 = 0

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Local Remeshing

Method of Spines
The simplest of 2D remeshing techniques.
Appropriate for extrusion, co-extrusion and
coating problems.
problems
Robust for moderate displacements of the free
surface or moving interface.

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Local Remeshing
Optimesh (2D or 3D)
Similar to Thompson transformation method in
2D (more robust).
2D problem and 3D extrusion problems.

Streamwise
Applicable only for 3D extrusion and co-
extrusion problems.
Well adapted for large isotropic deformation as
in 3D fiber spinning
Firs recommended in 3D extrusion

Improved Elasticity based remeshing


For 2D and 3D extrusion, and 3D extrusion
parison extrusion.
No geometric or topological constraints to the
remeshing domain.

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Local Remeshing
Thin Shell Method
Applicable for 2D and 3D blow molding
and thermoforming applications.

Thin Shell Method + Lagrangian master


Applicable for 2D blow molding simulations.
Recommended for thin 2D fluid domain

Lagrangian
L i
Transient flows
2D or 3D.
Shell domains, especially when the
deformation is elongational

Lagrangian on the border only


Applicable for 2D contact problems.
For thick fluid domain

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L
Local/Global
l/Gl b l Remeshing
R hi

For inverse extrusion or when several moving


boundaries are defined, several local remeshing
can be
b defined
d fi d in
i order
d t apply
to l the
th best
b t
technique on each sub-domain of the part of the
mesh that must be deformed.

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Introduction to POLYFLOW training

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Features of POLYDATA

Input
I t
Task
Nature of the task
Type of geometry
Type of simulation
Sub-task
Domain of the sub-task
Material data
Flow boundary conditions
Global remeshing
Local remeshing
Save and exit

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Save and Exit

In this step, you save the data (problem definition, material


properties, boundary conditions, and other parameters
d fi d in
defined i POLYDATA) using i a suitable
it bl filename
fil with
ith .dat
d t
extension to be used by POLYFLOW.

You can enable or disable the output of some fields in the


Field Management menu.

In the File Management menu,


menu you can change the names of
the various files the solver will create: POLYFLOW format
results res file that can be used as a starting point for another
simulation, and post-processing files cfx.res for CFX-Post.

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Appendix Training Manual

POLYMAN

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The ANSYS POLYFLOW Package


POLYMAN GUI

GAMBIT

POLYSTAT
Statistical
analysis
POLYFUSE POLYFLOW
POLYDATA
Modification of Solver
mesh files Set up
CFX-Post
Visualization
post-processing
POLYMAT POLYDIAG
Fitting of Convergence of
experimental the calculation
curves

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Polyman project

Project creation

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Polyman simulation

Simulation creation

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Polyman import mesh

Mesh importation

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Mesh export from Gambit

Solver : Polyflow or
Generic
Definition of Boundaries
and sub-domains in
Gambit
Names with index
number.
For example :
z sd1, sd2
sd1 sd2 for the
continuum types
z bs1,bs2 bs7 for the
Boundary types

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Mesh export from Gambit

Export
Mesh

Neutral file :

ident neu
ident.neu

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Mesh conversion in Polyman

Select the gambit


neutral file

Tools :
Convert a gambit
C
neutral file
Create Polydata mesh
file : ident.msh for the
simulation

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Polyman open Polydata

Open polydata :
double clicking
on Mesh file

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