Berlin

Electro-Magnetics & ANSYS CFX

- Theory and Applications Andreas Spille-Kohoff
CFX Berlin Software GmbH
Otterfing, 5.April 2005

Outline
Berlin

Introduction
Electro-Hydrodynamics
Ferro-Hydrodynamics
Magneto-Hydrodynamics
Summary
Slide 2

Introduction
Basics of CFD and Electro-Magnetics

Berlin

CFD is based on
conservation of mass, momentum (Navier-Stokes
equations), energy, chemical species
turbulence models
sources/sinks for forces, heating, reactions, phase
transition

Electro-Magnetics is based on
Maxwell equations and further relations
material relations for polarisation (permittivity),
conductivity and magnetisation (permeability)
Slide 3

Introduction
Basic equations of electro-magnetics

Berlin

Maxwell equations:

no magnetic monopoles: div B 0

div D e
charges as sources:

rot E
Induction law:
D
t
rot H j
Amperes law:
t
for
magn. induction B, field H, current density j,
electr. induction D, field E, charge e
Slide 4

Introduction
Basic equations of electro-magnetics II

Berlin

Electric induction and field:

D 0 E P 0 r E

with polarisation P and relative permittivity r

Magnetic induction
and

field:

B 0 r H 0 (1 m ) H

with rel. permeability r and suszeptibility m

Slide 5

Introduction
Basic equations of electro-magnetics III

Berlin

continuity equation for current follows from

Maxwell equations:

e
div j 0
t
Ohms law (approximation) for MHD:

1
1
j ( E u B)
jB
grad p
ene
2ene
Slide 6

Introduction
Comparison to external EM calculation

Berlin

+ only one program necessary ( lower costs,

shorter training, simpler handling)
+ strong internal coupling
+ only one simulation domain and mesh necessary
only same simulation domain and mesh possible
+ Implementation quite simple
own Implementation necessary
Implementation restricted to CFD solver
possibilities
Slide 7

Introduction
CFD and Electro-Magnetics

Berlin

Electro-Hydrodynamics (EHD): Electric field and

free charges
Ferro-Hydrodynamics (FHD): Magnetic field and
free dipoles
Magneto-Hydrodynamics (MHD): electric
conductivity, electric field and current, magnetic
field

Slide 8

Berlin

Electro-Hydrodynamics

Electro-Hydrodynamics
Introduction

Berlin

Distribution e of free charges as

discrete spatial distribution (charged particles) or
continuous distribution (concentration)

electric field as superposition of external and

generated field
Coulomb force on charges:

F QE bzw. f e E

Slide 10

Electro-Hydrodynamics
Applications

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Charged particle-tracking
electrochemistry:
electrophoresis
fuel cells
electro-deposition

microscopic plasma simulation

Slide 11

Electro-Hydrodynamics
Charged particle-tracking: Example

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Channel: length 100mm, height 25mm, depth 1mm (2D)

with cylindric hole of diameter 10mm (centered)
Water enters with 10mm/s
Alu particles: diameter 30 m, inlet velocity 10 mm/s and
mass flow rate 107 kg/s, specified charge
one-way coupling
cylinder wall at -1 V, channel walls at +1 V
constant electric conductivity in fluid domain

Slide 12

Electro-Hydrodynamics
Charged particle-tracking: Flow pattern

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Steady-state
solution of flow
field and
streamlines

Electric potential
(contour plot, -1 to
+1 V) and electric
field lines (black
vectors) around the
cylinder

Slide 13

Electro-Hydrodynamics
Charged particle-tracking: Particle paths

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negative charge

no charge

positive charge

Slide 14

Electro-Hydrodynamics
Electrophoresis methods

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Separation of electrically charged solutes in aqueous

solution by d.c. electric field:
Moving boundary electrophoresis (MBE)
Zone electrophoresis (ZE)
Isotachophoresis (ITP)
Isoelectric Focusing (IEF)
Related effects:
Electroosmosis: slip velocity at wall
Dielectrophoresis: electric dipoles in a.c. field
Slide 15

Electro-Hydrodynamics
Electrophoresis: Basic equations

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system of water and Ampholytes

chemical equilibria for reactions
local electric neutrality (gives pH value)
transport equations for concentrations with electrophoretic ion
mobility
electric conductivity from ion concentrations
Poisson equation for electric potential
Resistive heating
temperature depending mobilities

Slide 16

Electro-Hydrodynamics
Electrophoresis: Isoelectric Focusing

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Separation of glutamic acid

(Glu) and histidine (Arg):
t = 500
20
40
60
0s

Slide 17

Electro-Hydrodynamics
Electrophoresis: Isotachophoresis

150
50
0 min
min
min
100
200
250
300
min

terminator:
lactic
acid

Berlin

citric
maleic
acid
acid
malic
tartaric
leader: Chlor
acid
acid

Slide 18

Electro-Hydrodynamics
Electrophoresis: Zone electrophoresis

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0 min
2
4
6
9

Separation
of
histidine
and
lysine
in Cacodylic/Tris buffer of low (left) and high (right) concentration

Slide 19

Berlin

Ferro-Hydrodynamics

Ferro-Hydrodynamics
Introduction

Berlin

Distribution of magnetic dipoles as

discrete spatial distribution (diploe particles) or
continuous distribution (intensity of magnetisation)

magnetic field as superposition of external and

generated field
Kelvin force density onto dipoles:

f 0 ( M grad) H

Slide 21

Ferro-Hydrodynamics
Applications

Berlin

Ferrofluid with dipole intensity

rotatory shaft seals of disk drives
ferrofluidic ink jet printers

Magnetic dipole particle-tracking

Slide 22

Ferro-Hydrodynamics
Magnetic dipole particle-tracking

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External magnetic field influenced by

paramagnetic material (susceptibility)
Particle injection with known dipole strength
(magnetization)
Force and torque act in inhomogeneous magnetic
fields only
Torque is neglected assuming fast alignment of
magnetization direction to magnetic field

Slide 23

Ferro-Hydrodynamics
Magnetic dipole particle-tracking: Example

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Channel: length 100mm, height 25mm, depth 1mm (2D)

steel cylinder: diameter 10mm (centered)
Water enters with 10mm/s
Steel particles: diameter 30 m, inlet velocity 10 mm/s and
mass flow rate 107 kg/s
one-way coupling
homogeneous magnetic induction B =0.3 T at inlet
susceptibility 0 in the fluid domain
susceptibilty with linear susceptibility 104 and saturation
magnetization 106 A/m in steel cylinder
Slide 24

Ferro-Hydrodynamics
Magnetic dipole particle-tracking: Example

Berlin

Velocity field of water

around cylinder (up
to 20 mm/s).

Magnetic susceptibility
(colour, 0 to 9400) and
magnetic induction B
(vectors).

Slide 25

Ferro-Hydrodynamics
Magnetic dipole particle-tracking: Example

Berlin

Magnetic potential
(colour) and
magnetic field H
(vectors)

Velocity (colour) and

force divided by
magnetization
(vectors).

Slide 26

Ferro-Hydrodynamics
Magnetic dipole particle-tracking: Example

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Streamlines of steel
particles with M=0 A/m

Streamlines of steel particles

with M=1E-10 A/m

Streamlines of steel particles

with M=1E-9 A/m

Slide 27

Berlin

Magneto-Hydrodynamics

Magneto-Hydrodynamics
Introduction

Berlin

Description of electric properties of materials by

electric conductivity
Electric current driven by external electric field
and motion in magnetic field
Magnetic field as superposition of external and
generated field
Lorentz force density onto fluid:

f jB

Slide 29

Magneto-Hydrodynamics
Sketch of coupling
Hydrodynamics

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Electro-Magnetics

Ohms law
Navier-Stokes
equations

Lorentz force

Maxwell
equations

resistive heating

Magneto-Hydrodynamics
(MHD)

Slide 30

Magneto-Hydrodynamics
Assumptions

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Electromagnetic effects are fast compared to

hydrodynamics, i.e.
small capacities and inductivities
no delay, no oscillations
no phase shift between voltage and current
no electromagnetic waves, immediate effect

all time derivatives vanish

Slide 31

Magneto-Hydrodynamics
Equations to be solved

Current by motion:
Charge conservation:
Ohms law:
Magnetic potential:
Induced magnetic field :
Total magnetic field:

Berlin

jB u B

div grad div jB

j grad jB

A 0 j

BI rot A

B B0 BI
Slide 32

Magneto-Hydrodynamics
Implementation of MHD equations

algebraic equation:
Poisson equation:
algebraic equation:
3 Poisson equations:
algebraic equation:
algebraic equation:

Berlin

jB u B

div grad div jB

j grad jB

A 0 j

BI rot A

B B0 BI
Slide 33

Magneto-Hydrodynamics
Implementation with User Fortran

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User CEL Function for

Gradient of electric potential
Curl of magnetic vector potential
Divergence source term in Poisson equation for
electric potential

Slide 34

Magneto-Hydrodynamics
Coupling terms

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Hydrodynamics Electromagnetics
Current by motion:

jB u B

Electromagnetics Hydrodynamics
Lorentz force:

fL j B

Electromagnetics Thermodynamics
Resistive heating:

j2
Sh

Slide 35

Magneto-Hydrodynamics
Transport Equations in ANSYS CFX

Berlin

Diffusive Transport Equation since CFX-5.6

Poisson Equation since CFX-5.7
electro-magnetic boundary condition independent
of fluid boundary type since CFX-5.7.1
Connection of transported variables over FluidSolid Interfaces since ANSYS CFX-10

Slide 36

Magneto-Hydrodynamics
Applications

Berlin

heating, retarding and stirring of conducting casts

macroscopic plasma
Gas Metal Arc Welding (GMAW)
Plasma cutting
High-voltage circuit-breakers

Liquid-metal flow
Slide 37

Magneto-Hydrodynamics
Electro-magnetic stirring

electric potential, current density and

field lines

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velocity: vertical component,

vectors and streamline

Slide 38

Introduction
ChopArc project

Berlin

Research project funded by bmb+f:

Welding or soldering of thin metal sheets
Duration: 1.4.2001-30.9.2004
Technical University Berlin
Zeuna Strker, Augsburg (Arvin Meritor)
REHM Schweitechnik, Uhingen
Berlin

CFX Berlin
GFaI, Berlin
Inst. for Low-Temperature Plasmas, Greifswald
Slide 39

Introduction
The Reality

Berlin

4.000 Pictures/s

1,2 mm Steel, Ar + 2% CO2

Slide 40

Magneto-Hydrodynamics
GMAW: Physical issues
Free surface two phase flow
Multi-component gas phase
Argon + CO2 + Metal steam

Heat conduction and transport

Surface effects
Melting / Solidification
Radiation
Electro-Magnetics
Plasma Physics:
Arc Column in LTE
Cathode/Anode sheath layer

Evaporation / Condensation

Berlin

Solid Wire
Inert Gas

Inert Gas
Liquid
Metal
Arc

Liquid
Metal

Slide 41

Magneto-Hydrodynamics
GMAW: Short-circuit phase
Colours:

Vectors:

temperature

current density

velocities

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current density magnetic field

Lorentz force

Slide 42

Magneto-Hydrodynamics
GMAW: Steady-state arc simulation

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without sheath regions

Current

I = 255 A

Voltage

U=9V

Power

P = 2300 W

Velocity

u 115 m/s

Pressure

p 213 Pa

Temperature T 17,526 K

Slide 43

Magneto-Hydrodynamics
GMAW: Pulsed welding

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Frequency:

30 Hz (33 ms)

Current in A

Current in pulse: 255 A

Time in s

Length of pulse:

2 ms

Base current:

18 A

Slide 44

Magneto-Hydrodynamics
GMAW: Pulsed welding

Berlin

Frequency:

30 Hz (33 ms)

Current in A

Current in pulse: 255 A

Time in s

Length of pulse:

2 ms

Base current:

18 A

Slide 45

Magneto-Hydrodynamics
GMAW: Sheath model

Berlin

diffusion equation for electron density:

ambipolar diffusion
ionisation, recombination

current density includes diffusion current

electric conductivity:
calculation from collision cross sections

anode/cathode: heating/cooling by electron

absorption/emission
cathode: heating by ion absorption
Slide 46

Magneto-Hydrodynamics
GMAW: Mesh resolution for sheath layers

Berlin

Slide 47

Magneto-Hydrodynamics
GMAW: Steady-state with sheath regions

Berlin

Current

I = 255 A

Voltage

U = 12.6 V

Power

P = 3200 W

Velocity

u 410 m/s

Pressure

p 2740 Pa

Temperature T 17,510 K
Evaporation 70%
Without sheath regions:
Voltage
U=9V
Power
P = 2300 W
Velocity
u 115 m/s
Pressure
p 213 Pa
Temperature T 17,526 K

Slide 48

Magneto-Hydrodynamics
GMAW: Comparison to experiment

temperature in K

top

bottom

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mid

spectral measurement 250s after start

of pulse at INP
simulation without sheath layers
simulation with sheath layers

Slide 49

Magneto-Hydrodynamics
Project at TU Dresden
Funded by

Berlin

Research by
Technical University Dresden
Professur Fgetechnik und Montage
Institut fr Produktionstechnik
Prof. Dr.-Ing. habil. Uwe Fssel
Industrial partners
Kjellberg, Finsterwalde

Duration
01.01.2004 31.12.2005

Castolin Eutectic, Kriftel

TBi Industries, Fernwald

Aim: Optimization of shielding gas flow and

process gas flow in plasma cutting
and welding

Slide 50

Magneto-Hydrodynamics
Project at RWTH Aachen
Aim: Optimization of a
high-voltage circuit
breaker with ablation

Berlin

Research by
RWTH Aachen
Institute for High Voltage Technology
Univ.-Prof. Dr.-Ing. Armin Schnettler
Dipl.-Ing. Carsten Lders
non-moving part, conducting
moving part, conducting
moving part, non-conducting
valves
ceramic insulator
SF6

Slide 51

Magneto-Hydrodynamics
Further projects

Berlin

BMW Dingolfing:
Optimization of water
cooling system of GMAW
Optimization of inert gas
coverage

SLV Mnchen:
Optimization of PlasmaGMA process

FZ Karlsruhe:
Hartmann flow

Slide 52

Summary
Berlin

Electro-Magnetics succesfully implemented into

CFD solver CFX-5 for
Magneto-Hydrodynamics
Electro-Hydrodynamics
Ferro-Hydrodynamics
with varous applications, especially in electric arc
simulation.

Slide 53