Analysis and Optimization of Paper Machine Clothings by ... · Aachen Schmallenberg Euskirchen...
Transcript of Analysis and Optimization of Paper Machine Clothings by ... · Aachen Schmallenberg Euskirchen...
Analysis and Optimization of Paper Machine Clothings by Computer Simulation
Dr. Stefan Rief
Fraunhofer Institute for Industrial Mathematics (ITWM)
Kaiserslautern, Germany
Papermaking Research Symposium 2009Papermaking Research Symposium 2009Papermaking Research Symposium 2009Papermaking Research Symposium 2009
Department of Physics, University of Kuopio
June 2, 2009
Finland
Seite 2
Outline
1.1.1.1. IntroductionIntroductionIntroductionIntroduction
• Fraunhofer Society
• Institute for Industrial Mathematics (ITWM), Kaiserslautern
• GeoDict
2.2.2.2. Virtual Structure GenerationVirtual Structure GenerationVirtual Structure GenerationVirtual Structure Generation
• Nonwoven, Woven, Sintered Materials, Fabrics and Felts
3.3.3.3. Structure CharacterizationStructure CharacterizationStructure CharacterizationStructure Characterization
• Pore Size Distribution, Bubble Points, Permeability by CFD
4.4.4.4. Summary and moreSummary and moreSummary and moreSummary and more
Seite 3
Fraunhofer-Society
13.000 Employees
1,3 Billion €Budget
Hannover
Braunschweig
HalleDortmund
SchmallenbergAachen
Euskirchen
Darmstadt
JenaChemnitz
Dresden
Itzehoe
Bremen
KaiserslauternWürzburg
Holzkirchen
KarlsruheSaarbrücken
Duisburg
Erlangen
Pfinztal
St. Ingbert
MünchenFreising
Oberhausen
Stuttgart
GolmBerlin
St. Augustin
Rostock
Freiburg
MagdeburgApplied Research Institutes
• Mechanical Engineering
• Experimental Physics
• Computer Science
• Life Science
• Applied Mathematics
• …
57 Institutes
Fraunhofer Institute for Industrial MathematicsKaiserslautern
Seite 4
Department Flow and Material Simulation
SubdivisionsSubdivisionsSubdivisionsSubdivisions
• Hydrodynamics and CFD
• Complex Fluids
• Micro-structure simulation and virtual material design
• Structure optimization inmechanics and acoustics
Research TopicsResearch TopicsResearch TopicsResearch Topics
• Efficient numerics for large complex systems
• Multi-scale simulation
Seite 5
Virtual Material Design Cycle
Property Requirements Fulfilled?
Computation of Microscopic Properties of the Filter Medium
Selection of Media Types, Dimensions, etc.
Computation of Macroscopic Properties of the Filter
Virtual Design Virtual Design Virtual Design Virtual Design CycleCycleCycleCycle
Seite 6
Virtual Structure Generation
(Geometry)
Software
Structure Characterization
(Prediction)
Seite 7
Virtual Structure Generation
Multilayer Virtual NonwovenMultilayer Virtual NonwovenMultilayer Virtual NonwovenMultilayer Virtual Nonwoven
• Stochastic generation of the structure with guaranteed adjustable properties, e.g.
• Distribution of fiber diameters and cross
sections
• Fiber orientation
• Porosity
• Layer thickness
• …
• Stacking of layers with different parameters
• Use of highly flexible voxel meshes
Seite 8
Virtual Structure Generation
Virtual Nonwoven with Binder MaterialVirtual Nonwoven with Binder MaterialVirtual Nonwoven with Binder MaterialVirtual Nonwoven with Binder Material
• Randomly generated nonwoven
• Morphological operations create the binder material
• Amount of binder is an input parameter
• Binder appears as new material with individually assignable properties -> important, e.g. for elasticity computations
Seite 9
Virtual Structure Generation
Virtual WovenVirtual WovenVirtual WovenVirtual Woven
Seite 10
Virtual Structure Generation
Virtual Sinter StructureVirtual Sinter StructureVirtual Sinter StructureVirtual Sinter Structure
• Stochastic generation based on
• Packings of spheres
• Morphological operations (to generate sinter necks)
• Packings of spheres selected to match the initial grain size distribution of the sinter process
• Approach was applied in an industrial project when no tomographies were available due to
• Difficult preprocessing of samples
• Too coarse resolution
Seite 11
Virtual Structure Generation
Virtual FabricVirtual FabricVirtual FabricVirtual Fabric Virtual FeltVirtual FeltVirtual FeltVirtual Felt
Seite 12
Virtual Structure Generation
Quality Measures for Virtual Structures
• “The Eye”
• Porosity, specific surface area
• Chord length distribution
• Pore size analysis
• Flow properties, e.g. effective permeability or flow resistivity
• Bubble point, capillary pressure curves
• Filtration properties
• Acoustic properties
Comparison of Effective Flow Properties
0
0,5
1
1,5
2
2,5
200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200
Pressure Drop [Pa]
Ve
loc
ity
[m
/s]
Simulation
Experiment
Seite 13
Structure Characterization
Simulation of Pore Size DistributionsSimulation of Pore Size DistributionsSimulation of Pore Size DistributionsSimulation of Pore Size Distributions
Seite 14
Structure Characterization
Maximum Through PoreMaximum Through PoreMaximum Through PoreMaximum Through Pore
2coscp
r
σβ=
YoungYoungYoungYoung----Laplace EquationLaplace EquationLaplace EquationLaplace Equation Bubble PointBubble PointBubble PointBubble Point
Seite 15
Structure Characterization
Flow Solver is based on NavierFlow Solver is based on NavierFlow Solver is based on NavierFlow Solver is based on Navier----StokesStokesStokesStokes----BrinkmannBrinkmannBrinkmannBrinkmann equationsequationsequationsequations
Henry Darcy (1803-1858)
Seite 16
Structure Characterization
Darcy's law: K p
Qlµ
∆= ⋅
∆
Air / Water PermeabilityAir / Water PermeabilityAir / Water PermeabilityAir / Water Permeability
Seite 17
Structure Characterization
Seite 18
Paper Forming
R. Rundqvist: Microstructure simulations of early paperforming (PRS 2009)
Seite 19
Press Nip Simulation
Paper MachinePaper MachinePaper MachinePaper Machine Press SectionPress SectionPress SectionPress Section
100µm
10m
TomographyTomographyTomographyTomography
30 cm
Seite 20
Press Nip Simulation
Modeling and Simulation of the Pressing Section of a Paper Machine
GeoDict provides input parameters for macro simulations:
• Image processing (filters, cut-outs)
• Analysis of porosity distribution
• Computation of layer wise permeability
• Porosity and permeability variations under virtual compression
• Pressure-saturation curves by pore morphology method
Seite 21
Press Nip Simulation
Seite 22
4. Summary and more
---- FiberFiberFiberFiberGeoGeoGeoGeo,,,, SinterSinterSinterSinterGeoGeoGeoGeo, WeaveWeaveWeaveWeaveGeoGeoGeoGeo, GridGridGridGridGeoGeoGeoGeo, , , , PackPackPackPackGeo Geo Geo Geo (Structure generation)
---- ProcessProcessProcessProcessGeoGeoGeoGeo (3d image processing)
---- LayerLayerLayerLayerGeoGeoGeoGeo (building media stacks)
---- ImportImportImportImportGeoGeoGeoGeo (Tomography, STL, etc.)
---- ExportExportExportExportGeoGeoGeoGeo (Fluent, Abaqus)
---- FlowFlowFlowFlowDictDictDictDict (Flow properties)
---- ElastoElastoElastoElastoDictDictDictDict (Effective elasticity)
---- ThermoThermoThermoThermoDictDictDictDict (Heat conductivity)
---- DiffuDiffuDiffuDiffuDictDictDictDict (Effective diffusion)
---- FilterFilterFilterFilterDictDictDictDict (Filtration)
---- SatuSatuSatuSatuDictDictDictDict (Capillary pressure curves)
---- PoroPoroPoroPoroDictDictDictDict (Pore size analysis)
---- AcoustoAcoustoAcoustoAcoustoDictDictDictDict (acoustic absorption properties)
Seite 23
GeoDict Development Teams
The FiberGeo TeamAndreas Wiegmann
Katja SchladitzJoachim Ohser
Hans-Karl HummelPetra Baumann
WeaveGeo & PleatGeoAndreas Wiegmann
The SinterGeo TeamKilian SchmidtNorman Ettrich
The ElastoDict TeamHeiko Andrä
Dimiter StoyanovAndreas Wiegmann
Vita RutkaDonatas Elvikis
GridGeo & PackGeoAndreas Wiegmann
FlowDict Lattice BoltzmannTeam
Dirk KehrwaldPeter KleinDirk Merten
Konrad SteinerIrina Ginzburg
Doris Reinel-Bitzer
FlowFlowFlowFlowDictDictDictDict EJ Solver TeamAndreas Wiegmann
Liping ChengAivars ZemitisDonatas Elvikis
Vita RutkaQing Zhang
The FilterDict TeamStefan Rief
Kilian SchmidtArnulf Latz
Andreas WiegmannChristian WagnerRolf Westerteiger
The SatuDict TeamJürgen BeckerVolker Schulz
Andreas WiegmannRolf Westerteiger
The RenderGeo TeamsCarsten LojewskiRolf WesterteigerMatthias Groß
The GeoDict TeamAndreas Wiegmann
Jürgen BeckerKilian SchmidtHeiko Andrä
Ashok Kumar VaikuntamRolf WesterteigerChristian WagnerMohammed Alam
Jianping Shen
The PoroDict TeamAndreas Wiegmann
Jürgen BeckerRolf Westerteiger
The PleatDict TeamAndreas Wiegmann
Oleg IlievStefan Rief
Seite 24
Software for Generation, Simulation, Visualization:
www.geodict.comThank You Very Much for Your Attention !