Thermal fluid-structure-interaction - Experimental and numerical analysis

Tobias Gleim, Philipp Birken, Matthias Weiland, Detlef Kuhl, Andreas Meister, and Olaf Wünsch

Citation: AIP Conference Proceedings 1648, 560003 (2015); doi: 10.1063/1.4912782

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 Thermal Fluid-Structure-Interaction - Experimental and
Numerical Analysis
Tobias Gleim∗ , Philipp Birken†, Matthias Weiland∗ , Detlef Kuhl∗ , Andreas
Meister∗∗ and Olaf Wünsch‡
∗
Institute of Mechanics and Dynamics, University of Kassel, Mönchebergstr. 7, 34109 Kassel, Germany
†
Centre for the Mathematical Sciences, Numerical Analysis, Lunds University, Box 118, 22100 Lund, Sweden
∗∗
Institute of Mathematics, University of Kassel, Heinrich-Plett-Str. 40, 34132 Kassel, Germany
‡
Institute of Fluid Mechanics, University of Kassel, Mönchebergstr. 7, 34109 Kassel, Germany

Abstract. In the present paper the thermal Àuid-structure-interaction is experimentally and numerically investigated. There-
fore, the interaction phenomena is modeled by the Reynolds-averaged Navier-Stokes equations and the nonlinear Fourier heat
conduction equation are used for the Àuid and the solid phase, respectively. The simulation is performed using a partitioned
approach using the ¿nite volume method for the Àuid domain, the ¿nite element method for the solid domain and Runge-Kutta
integration schemes for the time domain. Furthermore, as a basis for the understanding of thermal Àuid-structure-interaction
and also for the veri¿cation and validation of the applied continuum mechanical models and numerical methods, respectively,
a fundamental wind tunnel experiment is presented.
Keywords: Thermal Fluid-Structure-Interaction numerical analysis, Partitioned Coupling, Experimental analysis
PACS: 44.20.+b, 44.40.+a, 45.10.Db, 47.11.Fg

INTRODUCTION
An important concept in metal forming processes, which allows to inÀuence workpiece characteristics such as ductility,
hardness, yield strength, or impact resistance locally, is partial heat treatment and cooling. Due to the resulting
heterogeneous temperature distribution functionally graded materials with precisely de¿ned properties can be created,
see [1, 2]. As an example a cooling strategy using a locally applied higher pressure air stream is considered. The
advantage of such a process is the minimal environmental impact because of the non-toxic quenching media, see
[3]. This technique, based on the thermal interaction between Àuids and structures, plays an important role in many
industrial applications [4, 5]. In order to optimize its application, corresponding validated continuum mechanical
models and reliable numerical simulation tools are needed.
In the present paper, we consider the thermal Àuid-structure-interaction (FSI) of a real and virtual wind tunnel experi-
ment to investigate the heat exchange between a heated structure and the air Àow. The application of computational
Àuid dynamics for the advantage of gas quenching has proved to be essential, see [6, 3, 7]. For the solution of a coupled
problem, we use a partitioned approach [8], where different codes for the sub-problems are applied and the coupling
is done by a master program which calls interface functions of the other codes. This allows to use existing software
for each sub-problem. To satisfy the boundary conditions at the interface, the subsolvers are iterated in a ¿xed point
procedure. For these particular equations, we use a ¿nite volume method (FVM) for the Àuid and a ¿nite element
method (FEM) for the heat equation. Speci¿cally, for the Àuid use is made of the DLR TAU-Code [9] and for the
structure the inhouse FE-program Native is employed.
As basis for the understanding of thermal Àuid-structure-interaction and also for the veri¿cation and validation of the
applied continuum mechanical models and numerical methods, respectively, a fundamental wind tunnel experiment
has been developed. Furthermore, the temperature dependent thermal material and radiation properties have been
measured. Various heated test specimens are subjected to a cooling Àow ¿eld with a wind speed of 0-30m/s. The
solid specimens are heated by electric heating elements from room temperature up to 900 K. The spatial temperature
distribution and temporal temperature evolution is measured inside and on the surface of the specimen by thermo
couples and a thermo camera, respectively. Due to the pronounced nonlinear behavior of the material parameters
and the merging of two subprograms performing the numerical analysis, a series of fundamental experiments with
increasing complexity had to be developed to validate material models as well as to verify the coupling solver. The
comparison of numerical and experimental results demonstrates a good agreement. Nevertheless, the results indicate

Proceedings of the International Conference on Numerical Analysis and Applied Mathematics 2014 (ICNAAM-2014)
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 also the demand of improved models and probably also experimental and numerical methods.

INVESTIGATION OF EXPERIMENTAL HEATING AND COOLING PROCESSES

The main purpose of these experiments is to provide data for the validation of the entire model consisting of material
data, mathematical model, and the veri¿cation of associated numerical solution methods. The variations of the
fundamental experiment from the pure heating plate to the heating plate with a bimetal Àag are depicted in Figure
1. Thus, in the end various experiments in a modular design will be built up to increase the degree of dif¿culty in the
experimental as well as in the numerical part, cf. [10]. Likewise, the various test cases are under different boundary
p
conditions, for example, under free or forced convection or various heating and cooling phases. The experiments are
carried out in a Göttingen-type wind tunnel, which has a closed air gap and an open test section with a grade of
Wind tunnel outÀow
(b)
Plate and monolitic Plate with monolitic quadratic prism with Àag Flow in measuring section
cylinder with Àag p measurement: temperature
Plate and cylinder with bimetal Àag and velocity
- 
D = 22mm
Plate and cylinder Flag of bimetal in caster
p with Àag p measurement temperature
H = 100mm

6 and deformation
? p p p
D= Heated cylinder
p
- 50
0m measurement: temperature
Heated plate p m
- p Heated plate
and heated cylinder H = 185mm measurement: temperature
p 6
Basic heated plate (a) ?p Wind tunnel inÀow
FIGURE 1. Evolution of the fundamental experiment (a) and sketch of the experimental setup in the wind tunnel (b)
turbulence Tu = 1%. A steel plate made of 51CrV4 with a length of 200mm x 200mm x 30mm and four holes with
a diameter of 10mm is heated up with eight heating cartridges (see Figure 2 (c)). In order to carry out thermographic
recordings the heating plate is coated with a thin black layer to resemble a black body. The heating plate is embedded
in a kind of wing pro¿le with insulation (see Figure 2), so that the heat transfer is basically restricted to the top surface.
The wing pro¿le itself is suspended in a wind tunnel (see Figure 1 and 2). The shape of the wing pro¿le (splitter plate)
will allow a uniform inÀow of the structure. The experimental structure has a blockage ratio of 33.6%.

(a) (b) (c)

82 32
125
125
400

650
125

800 100
900

FIGURE 2. Experimental setup of the heated plate: (a) exploded view of the structure, (b) views and dimensions of the composite
construction, (c) heated plate in close-up view

GOVERNING EQUATIONS AND DISCRETIZATION

On a domain Ω1 ⊂ Rd
the physics is described by a Àuid model, whereas on a domain Ω2 ⊂ Rd , a different model
describing a structure is used. The two domains are almost disjoint. The part of the interface where the Àuid and
the structure are supposed to interact is called the coupling interface. On this surface the coupling conditions are the
temperature and the normal component of the heat Àux which are both continuous across the interface.
Fluid
We model the Àuid using the Reynolds-averaged Navier-Stokes equations, which are a second order system of
conservation laws (mass, momentum, energy) modeling viscous compressible Àow. We consider the two dimensional
case, written in conservative variables density ρ , momentum m = ρ v and energy per unit volume E. Herein, T =
η (∇v+∇vT ) represents the viscous shear stress tensor and q = −λ ∇Θ the heat Àux. As the equation are dimensionless,

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 the Reynolds number Re and the Prandtl number Pr appear. The equations are closed by the equation of state for
the pressure p = (γ − 1)(ρ E − 12 |v|2 ). Furthermore, a Spalart-Allmaras one-equation model is used for the existing
turbulence [11]. The spatial discretization is done by a ¿nite volume method whereas a Runge-Kutta method [12] is
used for the time integration.
∂ρ
+ ∇ · (ρ v) =0
∂t
∂ ρv 1
+ ∇ · (ρ v ⊗ v)+ ∇p = ∇·T (1)
∂t Re  
∂ ρE 1 1
+ ∇ · (v (ρ E + p)) = ∇ · (Tv) − ∇ · q .
∂t Re Pr

Solid
The governing equations within the solid domain Ω2 are given by the balance of heat energy and the Fourier law
Ú
ρ cp (Θ)Θ(x,t) = −divq(x,t, Θ) − Q(x,t) q(x,t, Θ) = −λ (Θ)∇Θ(x,t). (2)

Here, q is the heat Àux vector, Θ the temperature, Θ Ú the temperature rate, ρ the density, Q the heating source and
λ (Θ) as well as cp (Θ) are the temperature dependent conductivity and speci¿c heat capacity. The Neumann boundary
conditions are the forced convection q¯ of the Àuid together with the thermal radiation ε (Θ) σ [Θ4 − Θ4∞ ] at the surface
with the Stefan Boltzmann constant σ , the emissivity ε (Θ) and the bulk temperature Θ4∞ .

Thermal Material Characterization

For the numerical validation of the experiments described above, the material parameters of the steel 51CrV4 are
investigated in three different experiments. As part of the collaborative research center Transregio 30, different institu-
tions were commissioned to determine the temperature dependent speci¿c heat capacity cp (Θ), the heat conductivity
λ (Θ) and the emissivity ε (Θ). The speci¿c heat capacity was measured by a differential scanning calorimetry (DSC).
The thermal conductivity was de¿ned with a laser Àash apparatus (LFA). The determination of the emissivity is done
by comparing the emitted radiation to the one of an approximated black body. The speci¿c heat capacity and the emis-
sivity show in Figure 3 a pronounced change with an increasing temperature due to the phase transformation. Here we
use temperature dependent phenomenological constitutive model coef¿cient functions [13, 14].
c p [J/(g K)] (a) λ [W /(m K)] (b) ε [−] (c)
3.0 exponential function 50 potential function exponential function
2.5 0.7
45
2.0
40 0.5
1.5
35
1.0 0.3
0.5 30
0.0 25 0.1
300 500 700 900 1100 1300 300 500 700 900 1100 1300 300 500 700 900 1100 1300
Θ [K] Θ [K] Θ [K]

FIGURE 3. Temperature-dependent material parameters: speci¿c heat capacity, heat conductivity and emissivity [13, 14]. Points
are experimental data and lines are the associated material models as a function.

NUMERICAL VS. EXPERIMENTAL RESULTS

Figure 4 demonstrates the grid of the plate (a) and its symmetric temperature distribution due to the heating elements
under free convection (b). Moreover, experimental and numerical results can be seen in Figure 4 (c) and (d), where
the plate is heated and simultaneously cooled by an inÀow from the wind tunnel with a velocity of 30m/s from the left
side. A good agreement between the thermographic camera (c) and the numerical solution (d) can be detected, when
the upper edge in the cross section of the heating plate Figure 4 (c) is compared to the thermographic image in Figure
4 (d). Furthermore, in Figure 5 (a), the experimental and numerical solutions are given by means of time histories of
the temperature at the position of a selected thermo couple. Also here a good trend of the solution can be recognized,
but further investigations and studies on the material parameters and the boundary conditions needs to be done. Figure

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 5 (b) demonstrates the velocity distribution in the center of the plate over the height. The experimental results were
carried out with a Prandtl’s pitot tube. There signi¿cant differences between experimental and numerical analysis
prevail. Since Prandtl’s pitot tube does not reach the plate’s surface, further investigations, using other methods such
as the hot-wire anemometer, need to be performed. Also, the temperature is plotted over the height in Figure 5 (b).
Furthermore, it can be seen that the thermal boundary layer has the same tendency as the velocity boundary layer.
(a) (c)

(b) Temperature [K] (d)

FIGURE 4. Grid of the heating plate (a): The steel plate is green colored, the heating element is shown in blue and the insulation
of the heating cartridge is red colored, result of the heating plate after 1000 seconds under free convection (b), thermophotographic
recording after 100 seconds of heating (top view of the heating plate) (c), simulation of the heating process after 100 seconds (cross
section of the heating plate) (d). Θ [K]
Θ [K] (a) 370 360 350 340 330 320 310 300 290
(b)
600 3
500 velocity ,experiment
2 velocity, numerics
400 H [cm] temperature, numerics
300
200 1
numerics
100 experiment
0 0
0 500 1000 1500 2000 0 5 10 15 20 25 30 35
T [s] v [m/s]

FIGURE 5. Comparison of numerical and experimental result at the heating cartridge for a wind speed v = 30m/s (a) and
comparison of the velocity distribution and the temperature over the height in the middle of the plate (b).

ACKNOWLEDGMENTS
Financial support was provided by the German National Science Foundation (DFG) in the framework of project C1 of
the collaborative research center (SFB/TR TRR 30). This support is gratefully acknowledged.
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