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Tutorial 5.

Modeling Mixing Tanks Using Multiple Rotating


Reference Frame (MRF) Model
Introduction
Many engineering problems involve rotating flow domains. One example is mixing tank
that is typically used in chemical industry. For problems, where all the moving parts
(fan/rotor blades, hub and shaft surfaces, etc.) are rotating at a prescribed angular
velocity, and the stationary walls (e.g., tank outer wall, duct walls) are surfaces of revolution with respect to the axis of rotation, the entire domain can be referred to as a
single rotating frame of reference.
However, when each of several parts is rotating about a different axis of rotation or
about the same axis at different speeds, or when the stationary walls are not surfaces
of revolution (such as the volute around a centrifugal blower wheel), a single rotating
coordinate system is not sufficient to immobilize the computational domain so as to
predict a steady-state flow field. This scenario can be taken care of using Multiple
Rotating Reference Frame (MRF) model available in FfC. This tutorial illustrates the
procedure for setting up and solving a problem using the MRF capability.
This tutorial demonstrates how to do the following:
Identify and separate fluid zone around the rotating part.
Change group types.
Specify rotation to the fluid zone around the rotating part.
Set rotation to rotating parts (wall zones).
Using force monitor to determine momentum force.

Prerequisites
This tutorial assumes that you are familiar with the menu structure in FfC. It also assumes
that you have read the Getting Started section in the Tutorial Guide and completed
Tutorial 1. Some of the steps in setup and solution procedure will not be shown explicitly.
Note: It is assumed that you have FMD and FMS licenses. Without these licenses
you will not be able to generate the mesh as explained in the tutorial. For more
information see the FLUENT for CATIA V5 FAQ page at
http://www.fluentusers.com/ffc/faqs/mesh.htm.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

Problem Description
This problem considers a generic mixing tank with only one rotor. The rotor is fitted
at the bottom end of a shaft entering the tank from the top. A domain is shown in
Figure 5.1. The rotor consists of 4 blades and is rotating with an angular velocity of 500
rpm. The flow is assumed to be turbulent.

Figure 5.1: Mixing Tank Schematic

Preparation
1. Copy the CATIA V5 file (mixer inclined shaft-new.CATPart) to your working folder.
2. Start FfC.

Step 1: Setting the Options


Tools Options... Analysis & Simulation Fluent Options
1. Click the General tab in the Options dialog box.
(a) Enter the path for ANSYS FLUENT solver in the text entry box next to Folder
for solver.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

Figure 5.2: Options Dialog BoxGeneral

Note: ANSYS FLUENT solver is provided with the installed FfC package. You
can use the Browse button to specify the path for solver:
For 32 bit the path is:
FfC Installation/FfC-R18/R19-5.X.XX/solver/Fluent.Inc/ntbin/ntx86
For 64 bit the path is:
FfC Installation/FfC-R18/R19-5.X.XX/solver/Fluent.Inc/ntbin/win64
(b) Similarly, specify the path for the external postprocessor, CFD-Post (or FloWizard) executable.
(c) Set the remaining parameters as shown in Figure 5.2.
Note: You can specify the Maximum number of iterations. For this tutorial
the recommended value is 2500 iterations.
2. Click the Data Management tab in the Options dialog box.
(a) Enter the path for Temporary files, FLUAnalysisComputations file and FLUAnalysisResults file in the External Storage folder groupbox.
You can use the Browse button to specify the path. The analysis files will be
saved in the temporary folders while FfC computes the solution. The analysis
will be saved to its permanent location when the computation is complete.

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Figure 5.3: Options Dialog BoxData Management

(b) Set the remaining parameters as shown in Figure 5.3.


3. Click the Advanced Parameters tab in the Options dialog box.
(a) Set the parameters as shown in Figure 5.4.
4. Click the Customization tab in the Options dialog box.
(a) Enable Advanced Turbulence Models.
Note: If the Advanced Turbulence Models option is deactivated, then the default turbulence model (k-epsilon, Realizable) for turbulent flows and Reynolds
Stress Model for turbulence with strong swirl will be selected without any
further access to more turbulence models.
(b) Enable Advanced Boundary Condition Parameters.
Note: The Advanced Boundary Condition Parameters option allows specification of heat generation rate for wall boundary.
(c) Enable Use solution steering by default.
Note: The Use solution steering by default option enables solution steering
mechanism to control the solution convergence automatically.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

Figure 5.4: Options Dialog BoxAdvanced Parameters

Figure 5.5: Options Dialog BoxCustomization

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

(d) Enable Control Solver Accuracy Settings based on slider position of Mesh
Definition.
Note: The Control Solver Accuracy Settings based on slider position of Mesh
Definition option uses second order solutions after 75% accuracy settings
during mesh definition. If this option is disabled, then first order solution
is computed for all slider positions.
(e) Select Residuals from the Convergence Criterion drop-down list.

Step 2: Reading the File


Read in the CATIA V5 file (mixer inclined shaft-new.CATPart) in CATIA V5.
File Open...
The File Selection dialog box opens, in which you can select the required file. When you
read the file, it will be opened in the Assembly Design workbench of CATIA V5.

Step 3: Starting FfC


1. Launch FfC workbench.
Start Analysis & Simulation FLUENT for CATIA V5
The graphics display is updated. The specification tree on the left-hand side will
also be updated to display the analysis related parameters.
2. Specify a path to the directory where you want to store the solver files in the Options
dialog box.

Step 4: Defining and Extracting a Flow Volume


Click the
icon or double-click Geometry Definition.1 located below the Environment.1
feature in the specification tree to open the Geometry Definition dialog box.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

1. Select flow volume from the Geometry definition drop-down list.


2. Retain No selection for Inlet.
3. Click in the text entry field next to Outlet, zoom in the top side of the tank and
select the tank top surface as the outlet.
4. Make sure that Merge all Fluids is deactivated.
5. Click OK to validate and close the Geometry Definition dialog box.
This extracts the flow volume and the graphics window gets updated to show the
extracted flow volume.

Figure 5.6: Flow Volume

6. Once the flow volume is extracted as shown above, FfC will create group of publications located below Groups.1.

Figure 5.7: Groups

(a) Double click on Outlet Boundary.1 to open the Group of Boundaries dialog box.

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(b) Select Symmetry from the Type drop-down list.

(c) When the Type is changed to Symmetry the name of the boundary group will
be modified and the color of the group will also be changed.

Step 5: Defining Physics


Click the
icon OR double-click Physics Definition.1 located below Environment.1 in
the FfC specification tree to open the Physical Model Definitions dialog box.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

1. Disable Accounting for Temperature Effect.


2. Select Turbulent from the Flow Type drop-down list.
3. Select k-epsilon, Realizable model in the Turbulence Model scrolling list.
4. Select steady from the Time drop-down list.
5. Click OK to validate and close the Physical Model Definitions dialog box.

Step 6: Defining Meshing Parameters


Click the
icon or double-click Mesh Definition.1 located below Environment.1 in the
FfC specification tree to open the Mesh Definition dialog box.

1. Click

icon to select the optimized surface mesh.

2. Move the slide bar towards Accuracy till the number above it shows a value of 75.
As you move the slide bar, other parameters will change accordingly. Use the Reset
All button to set all the field values to their default values. Please note that, if you
dont use the Reset All button, the values from the previous session will be taken by
FfC for meshing.

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3. Click the Global tab and enter 4.4mm for Critical Length.
4. Retain the default values for other parameters.

5. Click OK to close the Mesh Definition dialog box.

Step 7: Apply Material to the Outer Fluid Zone


In this step, apply material to the outer fuid zone using the drag and drop method.
1. Click the

icon to open the Library dialog box.

2. Select the FLUENT for CATIA V5 fluid materials library.


To open the materials library, you have to specify the path where it is stored.
For 32 bit the path is:
C:\Program Files\x.y.z\FfC-Rx-x.y.z\intel a\startup\materials\Fluids and Mixtures.CATmaterial
For 64 bit the path is:
C:\Program Files\x.y.z\FfC-Rx-x.y.z\win b64\startup\materials\Fluids and Mixtures.CATmaterial
where x.y.z represents the version used.
3. Click and hold the mouse button on water-liquid material icon.
4. Drag and drop the material on the outer fluid zone displayed in the graphics window.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

Step 8: Naming the Fluid Zones


1. Click the

icon.

2. Select any zone in the specification tree under Properties.1.


Make the outer tank wall transparent. The selected zone gets highlighted. Identify
the fluid zone around the rotor blades.

3. Rename the smaller zone around the rotor-blades as rotating-zone and rename
the other fluid zone representing tank volume as outer-fluid-zone.

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Step 9: Create a Seperate Group for Faces of the Shaft


1. Set the view from rendering style to perspective.
View Render Style Perspective
2. Click the

icon to open the Group of Boundaries dialog box.

Figure 5.8: Shaft-Rotating-Zone

3. Now zoom in the model around impeller to select the faces of the shaft lying in the
rotating zone in the Support text entry (Figure 5.8).
4. Select wall as the Type.
5. Specify shaft-rotating-zone as the Name.
6. Select Wall (FluidtoSolid.3.0 1).3 under Groups.1 in the specification tree as shown
in Figure 5.9 and rename it as rotor-blades.
7. Similarly, rename a group for shaft-not-rotating-zone as shown in Figure 5.10.

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Figure 5.9: Rotor-Blades

Figure 5.10: Shaft-Not-Rotating-Zone

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8. Similarly, rename a group for tank-outer-wall as shown in Figure 5.11.

Figure 5.11: Tank-Outer-Wall

Step 10: Specify MRF Zone


Note: The mixing tank is divided into two fluid zones, due to which the MRF model is
applied here. A rotation speed is specified for the impeller blades, which is bounded
by surfaces of revolution. The other fluid zone is specified as stationary. The flow
volume is divided into two fluid zones as mixing tanks typically have baffles on the
outside walls, which are not surfaces of revolution.
1. Under Properties.1 in the specification tree, double click on the Property corresponding to the inner fluid zone Flow Property Definition dialog box.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

2. Select Moving Reference Frame in the Motion Type drop-down list.


3. Click the

icon to open the Motion of Rotating Machinery dialog box.

(a) Select one vertical face of the shaft as Surface for direction calculation.
(b) Select Clockwise for rotation direction and click OK.
The direction of rotation should be clockwise with reference to the top of the
tank. Use Clockwise or Counter Clockwise options to get the desired rotational
direction.

Figure 5.12: Motion Direction


4. Click OK in the Flow Property Definition dialog box.
5. Click the

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icon.

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(a) Click the text entry next to the Supports and select rotor-blades in specification
tree under the Groups.1.
(b) Change the Name to rotor-blades.
(c) Select Rotating in the Motion Type scrolling list.
(d) Select Relative to adjacent fluid region in the Reference Frame scrolling list.
(e) Enable Clockwise and click OK.
6. Similarly define new wall boundary conditions using the same parameters as mentioned above.
(a) Select the group shaft-rotating-zone as support.
(b) Rename this wall boundary as shaft-rotating-zone.
7. Click the

icon.

(a) Click the text entry next to the Supports and select shaft-not-rotating-zone in
specification tree under the Groups.1.
(b) Change the Name to shaft-not-rotating-zone.
(c) Select Rotating in the Motion Type scrolling list.
(d) Select Absolute in the Reference frame scrolling list.
(e) Enter 500turn mn for Rotational Speed.
(f) Select shaft outer wall for Support for direction calculation.
(g) Enable Clockwise and click OK.

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Step 11: Solver Settings


1. Double-click on Initialzation Values.1 below the Fluent Problem Setup.1 feature in
the specification tree to open the Initialization Values dialog box.
(a) Click Reset All and OK to validate.
2. Double-click on Fluent Solution.1 in the specification tree to open the Fluent Solution
dialog box.
(a) Click Reset All.
(b) Ensure that Use solution steering is enabled.
(c) Ensure that Max number of iterations is enabled and set to 2500.
(d) Click OK to validate.

Step 12: Perform Computation


1. Click the

icon to open the Compute dialog box.

2. Select All and Default Solution Option in the two drop-down lists.
3. Click OK to validate and start the computations.
Note: Solution converges after around 2000 iterations. It will take a few hours
to complete the soluion. You can postprocess the results by interrupting the
computations. Use Stop Computation button to stop the calculations.

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Step 13: Save Management


Save the analysis files as mix tank Analysis1.CATAnalysis file and propogate directory.
File Save Management...

Step 14: Show Residuals and Monitor Plots


Click the

icon to open the Residual Images dialog box.

Figure 5.13: Residual Plot

Step 15: Show Velocity Vectors on a Cut Plane


1. Click

icon.

Velocity contours are displayed and this is listed under Fluent Solution.1 as Velocity.1.

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2. Double click on Velocity.1 to open the Image Edition dialog box.

3. In the Image Edition box under Visu tab select Symbol as Type.
Note: Velocity vectors will be displayed on boundaries. Click the Options... tab to
manipulate arrows.

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4. Click OK to verify.
To include parts of the mixing tank in this image right click on the Link Manager.1
and in the contextual menu, click Hide/Show. For a better view you may have to
make some parts transparent or hide them.
5. Click the

icon to open the Cut Plane Analysis dialog box.

Please keep the settings as shown in Figure 9.16.

Figure 5.14: Cut Plane Dialog Box

6. Adjust the position of the plane using the compass, so that the plane cuts the tank
vertically into two equal parts.
Note: You can also double-click on the compass to adjust the cutting plane. This
opens the Parameters for Compass Manipulation dialog box.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

7. Similarly we can show velocity vectors on a horizontal cutting plane passing from
the blades. See Figure 5.15.

Figure 5.15: Velocity Vectors

Step 16: Show static Pressure Contours on a Cut Plane


1. Click the

icon.

Static pressure contours are displayed and is listed under Fluent Solution.1 as Pressure(nodal values).1. You can include parts of the mixing tank in this image as you
did in Step 17.
2. The procedure to show the pressure contour on a cut plane is same as you performed
in the previous step.

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Step 17: Show Turbulence Kinetic Energy Contours on the Blades


1. Click the

icon.

Contour of turbulent kinetic energy will be displayed and this will be listed under
Fluent Solution.1 as Turbulence Kinetic Energy (average iso).1.
2. Double click Turbulence Kinetic Energy (average iso).1 to open the Image Edition
dialog box.

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Modeling Mixing Tanks Using Multiple Rotating Reference Frame (MRF) Model

3. Click the Selection tab and select rotor-blades under Availabel Groups and click the
down arrow.
rotor-blades is available under Activated Groups and the contours are shown on the
rotor-blades.

Summary
In this tutorial you learned how to setup the case for rotating impellers, blowers using
Multiple Reference Frame (MRF) approach embedded in FfC R18/R19 V5.1. This approach can also be used for turbomachinery applications in which rotor-stator interaction
is relatively weak, and the flow is relatively uncomplicated at the interface between the
moving and stationary zones.
You may want to generate the report of your simulation. For details on report generation,
refer to Tutorial 7.

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