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

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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

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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

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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

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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

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Virtual Structure Generation

(Geometry)

Software

Structure Characterization

(Prediction)

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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

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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

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Virtual WovenVirtual WovenVirtual WovenVirtual Woven

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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

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Virtual FabricVirtual FabricVirtual FabricVirtual Fabric Virtual FeltVirtual FeltVirtual FeltVirtual Felt

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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

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Simulation of Pore Size DistributionsSimulation of Pore Size DistributionsSimulation of Pore Size DistributionsSimulation of Pore Size Distributions

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Maximum Through PoreMaximum Through PoreMaximum Through PoreMaximum Through Pore

2coscp

r

σβ=

YoungYoungYoungYoung----Laplace EquationLaplace EquationLaplace EquationLaplace Equation Bubble PointBubble PointBubble PointBubble Point

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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)

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Darcy's law: K p

Qlµ

∆= ⋅

∆

Air / Water PermeabilityAir / Water PermeabilityAir / Water PermeabilityAir / Water Permeability

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Paper Forming

R. Rundqvist: Microstructure simulations of early paperforming (PRS 2009)

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Press Nip Simulation

Paper MachinePaper MachinePaper MachinePaper Machine Press SectionPress SectionPress SectionPress Section

100µm

10m

TomographyTomographyTomographyTomography

30 cm

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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

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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)

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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

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Software for Generation, Simulation, Visualization:

www.geodict.comThank You Very Much for Your Attention !

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