Magnetorheological fluids (MRFs) are smart materials consisting of micro-scale magnetizable particles suspended in a carrier fluid. The rheological properties of a MRF can be changed from a fluid-state to a solid-state upon the application of an external magnetic field. This study reports the development of a particle-level simulation code for magnetic solid spheres moving through an incompressible Newtonian carrier fluid. The numerical algorithm is implemented within an open-source finite-volume solver coupled with an immersed boundary method (FVM-IBM) to perform fully-resolved simulations. The particulate phase of the MRF is modeled using the discrete element method (DEM). The resultant force acting on the particles due to the external magnetic field (i.e., magnetostatic polarization force) is computed based on the Clausius-Mossotti relationship. The fixed and mutual dipole magnetic models are then used to account for the magnetic (MAG) interactions between particles. Several benchmark flows were simulated using the newly-developed FVM-IBM-DEM-MAG algorithm to assess the accuracy and robustness of the calculations. First, the sedimentation of two spheres in a rectangular duct containing a Newtonian fluid is computed without the presence of an external magnetic field, mimicking the so-called drafting-kissing-tumbling (DKT) phenomenon. The numerical results obtained for the DKT case study are verified against published data from the scientific literature. Second, we activate both the magnetostatic polarization and the dipole-dipole forces and resultant torques between the spheres for the DKT case study. Next, we study the robustness of the FVM-IBM-DEM-MAG solver by computing multi-particle chaining (i.e., particle assembly) in a two-dimensional (2D) domain for area volume fractions of 20% (260 particles) and 30% (390 particles) under vertical and horizontal magnetic fields. Finally, the fourth computational experiment describes the multi-particle chaining in a three-dimensional (3D) domain allowing to study fully-resolved MRF simulations of 580 magnetic particles under vertical and horizontal magnetic fields.

Melt mixing is a convenient method to prepare polymer nanocomposites, but the extent of the dispersion of the solid filler reached is often limited, and may compromise the anticipated performance of these materials during service. Since the efficiency of extensional flows on dispersion is now well recognized, several mixers were designed with the aim of inducing both shear and extensional flow components. This work combines experimental and numerical data to better understand the kinetics of the dispersion of graphite nanoplates in a polypropylene melt, using a mixing device that consists of a series of stacked rings with equal outer diameter and alternating larger and smaller inner diameters, thus creating a series of converging/diverging flows. Numerical simulation of the flow using the opensource OpenFOAM software assuming both inelastic and viscoelastic responses predicted the velocity, streamlines, flow type and shear and normal stress fields for the mixer. Experimental and computed data were combined to determine the trade-off between the local degree of dispersion of the PP/GnP nanocomposite, measured as Area ratio, and the absolute average value of the hydrodynamic stresses multiplied by the local cumulative residence time. From considerations based on a theoretical approach to dispersion, the cohesive strength of the GnP agglomerates studied was estimated to be in the range 3 - 10kPa.

This study reports the development of a numerical method to simulate two-phase flows of Newtonian fluids that are incompressible, immiscible, and isothermal. The interface in the simulation was located and reconstructed using the geometric volume of fluid (VOF) method. The implementation of the Piecewise-Linear Interface Calculation (PLIC) scheme of the VOF method was performed to solve the three-dimensional (3D) interface transport during the dynamics of two-phase flows. In this method, the interface is approximated by a line segment in each interfacial cell. The balance of forces at the interface was accounted for using the continuum interfacial force (CSF) model. To solve the Navier-Stokes equations, meshless finite difference schemes from the HiG-Flow computational fluid dynamics software were employed. The 3D PLIC-VOF HiG-Flow algorithm was used to simulate several benchmark two-phase flows for the purpose of validating the numerical implementation. First, the performance of the PLIC implementation was evaluated by conducting two standard advection numerical tests: the 3D shearing flow test and the 3D deforming field test. Good agreement is obtained for the 3D interface shape using both the 3D PLIC-VOF HiG-Flow algorithm and those found on the scientific literature. In addition, the absolute error of the volume tracking advection calculation obtained by our 3D PLIC-VOF HiG-Flow algorithm was found to be smaller than the one found in the scientific literature for both the 3D shearing and 3D deforming flow tests. Lastly, the 3D bubble rising problem was simulated for different fluid densities and viscosity’s ratios. Again, good agreement is obtained for the 3D interface shape using both the newly implemented algorithm and the OpenFOAM, DROPS and NaSt3D software. The bubble’s rise velocity and evolution of the bubble’s center of mass is also computed with the 3D PLIC-VOF HiG-Flow algorithm and found to be in agreement with these software.

In this work, we incorporate a thixotropic-viscoelastic model into the widely used Computational Fluid Dynamics (CFD) software OpenFOAM, along with the rheoTool library. The model we implement is known as the Modified-Bautista-Manero (MBM), and effectively describes the rheological behavior of worm-like micellar solutions in extensional flows. We provide a detailed explanation of the numerical implementation of the model, specifically using the log-conformation tensor approach. Unlike previous works focused on this kind of fluids, we simulate inertial flows while considering convective terms in the governing equations, thus obtaining a more realistic behavior on the calculated results. The MBM model implementation is validated through numerical simulations on two different industrial-relevant geometries: the planar 4:1 contraction and the 4:1:4 contraction-expansion configurations. Furthermore, we investigate the influence of inertial, viscoelastic, and thixotropic effects on various flow field variables. These variables include velocity, viscosity, normal stresses, and corner vortex size. Our analysis encompasses both transient and steady solutions of corner vortexes across a range of Deborah and Reynolds numbers. Our results are also directly compared with simulations obtained using the non-thixotropic rubber network-based exponential Phan-Thien-Tanner (EPTT) model. From our planar 4:1 contraction results, we found that vortex-enhancement is seen when high elasticity is coupled with quick structural reformation and very low inertial effects. From our planar 4:1:4 contraction-expansion simulations, we show that an increase in inertia leads both to vortex-inhibition in the upstream channel and slight vortex-enhancement in the downstream channel. Lastly, we show the strong effect of the convection of fluidity into the fluidity profiles and into the upstream/downstream corner vortex sizes.