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Unresolved and semi-resolved CFD-DEM coupling are frequently used for modeling particulate flows due to their high efficiency and satisfying accuracy. The grid size (in unresolved CFD-DEM) and smoothing distance (in semi-resolved CFD-DEM) are usually around three times of the particle diameter so as to properly reproduce the background flow field. An over-estimation of the grid size or smoothing distance can lead to low-fidelity flow fields, while under-estimations of these parameters can produce an inaccurate drag force. Therefore in practices, the size ratio is usually empirical, and how does it vary with cases remains unclear. In this paper, we provide an approach to identify the most suitable grid size or smoothing distance in coupled CFD-DEM. Firstly, resolved simulations based on immersed boundary method (IBM) are conducted to compute particles' drag forces. The obtained forces are then compared with those calculated by force models with certain smoothing lengths to identify an optimal smoothing length or effective grid size. During this process, integral scale of each case is also computed. Finally, linearity between integral length and the optimal smoothing distance or grid size is found. This correlation can offer guidance to CFD-DEM modeling in future and provide insights for novel drag force models. [Display omitted] • Optimal grid size in un-resolved CFD-DEM coupling is identified. • Optimal smoothing distance in semi-resolved CFD-DEM coupling is identified. • Optimal grid size and smoothing distance are determined by flow's integral scale. • Quantitative relation of the ratio of grid size to particle diameter is found. • Quantitative relation of ratio of smoothing distance to particle diameter is found. [ABSTRACT FROM AUTHOR]

Particulate flows with charged particles under electric flow field exist in many practical applications, including metal particles in Gas Insulated Switchgear (GIS) or manipulation of powders in fluidized bed. The motions of these particles are affected by the electrical field, ambient flow and collisions. This work further develops the four-way coupled CFD-DEM framework under electric field, which not only computes the coupling of flow field, electric field with particle motion and particle charge, the particle-occupied solid fractions on CFD cell, particle-particle interactions and particle-wall interactions, but also considers the dielectrophoretic force, particle-particle Coulomb force, virtual mass force and Magnus force. Particle electrification on its contact with electrode is computed as well. Besides, the multi-sphere model is also introduced into the present framework in order to simulate particles of irregular shapes. The model is validated with theoretic solutions and experiments, and is applied to GIS and fluidized bed. Based on the framework, statistic information from the particulate flow in GIS, e.g., time-averaged solid fraction, time-averaged electric field or particles' velocity and charge distribution are analyzed. A dimensionless number is proposed to predict the particle motion in GIS with Alternating Current (AC), which is further conducive to reducing the parameter window in relevant simulations and studies. • The four-way coupled CFD-DEM modeling framework for charged particulate flows is extended with more concerned forces. • Fluid fraction is counted in the standard four-way coupling. • Multi-sphere model is introduced for modeling irregular-shaped particles. • Interesting phenomena of charged particles in GIS are revealed and discussed. • A dimensionless number is proposed to predict the particle motion in GIS. [ABSTRACT FROM AUTHOR]

The rigid motions of powders widely exist in powder-based laser additive manufacturing, like powder deposition, entrainment and spattering. These phenomena simultaneously happen as the laser melts these powders, and can have significant impacts on the quality of the printed products. However, existing models can hardly efficiently reproduce the co-existence of melting and rigid motion which greatly influences the molten pool and molten track evolution. The bottleneck therein lies in the demand that unresolved Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) has on the CFD grid size, that is, larger than 3 times of the particle diameter. However, this large size ratio (CFD grid cell vs particle diameter) handicaps the description of the particle deformation during melting. Hence in this paper, a kernel approximation-based semi-resolved CFD-DEM numerical model that allows the refinement of CFD grid is employed, and then coupled with the Volume of Fluid (VOF) method to reproduce the molten metal-gas interface. On this basis, the rigid motions of the powders, like entrainment and spattering, are finally simultaneously realized as the molten pool evolves at high efficiency. Powders remained in the unclosed molten pool trail defect are well explained with the proposed model as well. This model can also be applied to simulate the particle-fluid interactions in Directed Energy Deposition. It is believed that this semi-resolved VOF-DEM Additive Manufacturing model will serve as a good tool for future investigations into the particle behaviors in powder-based additive manufacturing. [Display omitted] • Semi-resolved VOF-DEM Additive Manufacturing model is developed. • Particle rigid motion is simultaneously modeled with molten pool evolution. • Spattered powders left in the defect are well explained. • Modeling of complex particulate flows in Directed Laser Deposition is realized. [ABSTRACT FROM AUTHOR]

Abrasive air jet (AAJ) machining is attractive for micromachining hard and brittle materials, while it is usually a big challenge to numerically investigate the particle velocity and concentration distribution in the particle erosion process in the AAJ. In this work, a recently developed semi-resolved CFD-DEM approach which bridges the simulation gap between the resolved and unresolved CFD-DEM, is further improved to reconstruct the background information with a double cosine kernel function. The semi-resolved CFD-DEM is then employed to numerically investigate the gas-particle two-phase flow in the AAJ and numerical results show that this semi-resolved CFD-DEM is more accurate in modeling particulate flow in the fine AAJ nozzle than the conventional unresolved CFD-DEM. We further conduct mechanism investigations on the AAJ micromachining process including particle flow characteristics inside the cylindrical nozzle, velocity, and concentration distribution over the nozzle exit, which are essential jet characteristic features. We identified the particle flow patterns, analyzed the particle distribution, and its correlation with air pressure, abrasive mass flow rate, and turbulence effects. The present simulation results and analyses can be great helpful in understanding the erosion mechanism and optimizing the setting parameters to improve the cutting performance of AAJ. The semi-resolved CFD-DEM approach is used to investigate the gas-particle two-phase flow in AAJ. Unlabelled Image • A double cosine kernel function (SCKF) was introduced into a recently developed semi-resolved CFD-DEM. • The semi-resolved CFD-DEM with SCKF was shown to be effective in investigating abrasive air jet (AAJ). • The particle-scale distribution information in a fine AAJ nozzle was studied. • The effects of process parameters and turbulence on particle distribution were analyzed. [ABSTRACT FROM AUTHOR]