Water 16 03678
Water 16 03678
Abstract: This study investigates the influence of roughness on the transient flow behavior in the
chamber based on the performance requirements of the pump rotor–stator chamber, aiming to
elucidate the mechanism of roughness in real operating conditions. Three-dimensional models under
two types of flow (centrifugal and centripetal) are developed, and transient numerical analyses
are performed through numerical simulation and experimental validation. The results show that
roughness significantly accelerates turbulence development in centrifugal through-flow, particularly
in the middle- and high-radius regions, increasing the turbulent kinetic energy by approximately 18%
compared to smooth surfaces. Transient flow analyses indicate that roughness leads to an overall
pressure drop of around 10% within the cavity while facilitating the formation of high-pressure zones
near the rotor. In centrifugal flow, high-pressure regions develop rapidly in the high-radius area,
resulting in a stepped pressure distribution with a peak pressure increase of 12% at the outermost
Citation: Yao, Y.; Wang, C.; Wang, Y.; radius. In centripetal flow, the pressure distribution remains more uniform, yet significant pressure
Ge, J.; Chang, H.; Zhang, L.; Li, H. rise trends emerge over time, with pressure increasing by 8% due to the presence of roughness. This
Transient Flow Characterization of study presents a systematic analysis of the effects of roughness on transient flow characteristics
Rotor–Stator Cavities in Two in rotor–stator cavities across two flow modes for the first time, providing valuable insights for
Through-Flow Modes: Centrifugal optimizing pump design and performance under real-world conditions.
and Centripetal. Water 2024, 16, 3678.
https://doi.org/10.3390/w16243678 Keywords: rotor–stator cavity; roughness; through-flow pattern; flow characteristics; numerical simulation
Academic Editor: Giuseppe Pezzinga
an early model of the effect of turbulent structure and axial gap on the flow field in disk
cavity flow, which considered the interaction of turbulence with the boundary layer and
helped to predict the flow behavior with different gaps. The boundary layer theory of
Schlichting [7] has likewise had a significant impact on the theoretical study of rotor–stator
cavity flows, particularly in the prediction of turbulence development near the walls. Fac-
chini et al. [8], based on a lot of test data, investigated the spin ratio, vortex structure, and
boundary layer separation phenomena in the cavity at different Reynolds numbers and
pointed out that the spin pattern is a contributory factor affecting the flow characteristics.
Nguyen et al. [9] utilized Particle Image Velocimetry to accurately measure the transient
properties of the internal flow in a disk cavity, uncovering the formation and evolution
of vortex structures at high Reynolds numbers. Using computational fluid dynamics and
entropy generation doctrinal, Zhang et al. [10] examined the effect of pump chamber con-
figuration (guide vanes and volute) on the hydraulic loss space distribution of mixed flow
pumps. Geis et al. [11] employed laser Doppler velocimetry (LDV) to study the axial flow
characteristics within the disk cavity, providing insights into the flow behaviors under
various inlet conditions. Through numerical simulations, Raisee et al. [12] revealed the
turbulent pulsation characteristics of cooling air in the rotor–stator cavity, showing that
varying flow patterns have a direct impact on vortex formation and development. In their
study, Shen et al. [13] applied large eddy simulation (LES) to study the influence of various
axial gaps on flow fields and vortex structures. Their findings, which are consistent with
the experimental data, highlight the enhancement of vortex characteristics under small
gap conditions. Using the RANS and LES methods, Fernando et al. [14] modeled flow
properties affected by roughness and found that rough walls have a significant effect on
core flow and vortex structure changes.
Furthermore, the study of heat transfer characteristics is also crucial. Ekkad et al. [15]
utilized a transient liquid crystal technique to determine the local convective heat transfer
coefficients in a disk cavity in the radial direction and found that there was a strong correla-
tion between the temperature distribution, the heat transfer efficiency, and the flow pattern.
Karabay et al. [16] explored the heat transfer behavior at different inlet temperatures and
cooling flow rates, revealing that higher flow rates enhance the heat transfer efficiency of the
cooling gas. Hu et al. [17,18] analyzed the implications of the axial gap on heat transfer using
numerical simulation and an experiment, showing that as the gap decreases, heat transfer is
enhanced, but the mobility model becomes more complex. Additionally, Petkovic et al. [19]
simulated transient heat transfer characteristics in a disk cavity using CFD techniques, demon-
strating the dual effects of wall temperature gradient and cyclonic structure on heat transfer. In
their experimental study, Chang et al. [20] introduced a new concept of measurement, show-
ing that the rotor system’s relative temperature can be determined from the stator system’s
absolute parameters. The results highlight that speed and the inlet mass flow rate are the
primary factors affecting the flow characteristics in the disk cavity. Poncet et al. [21] performed
numerical predictions based on single-point mathematical modeling of second-order full
strain transport closure at low Reynolds numbers and presented comparisons with empirical
data from the literature, which showed a robust correlation between the numerical results
and the experimental observations. Luo et al. [22] utilized the transient thermochromic liquid
crystal (TLC) technique to survey pressure distribution and heat transfer in the disk cavity,
determining the convective heat transfer characteristics of rotating disk surfaces. Concurrently,
Liu et al. [23] presented research on flow and heat transfer characteristics in disk cavities using
conjugate CFD and fully coupled FE/CFD, comparing their findings with steady-state flow
research predictions and test results.
While the aforementioned studies have elucidated the flow and heat transfer charac-
teristics of disk cavities under various operating conditions, most have assumed smooth
wall surfaces and neglected the impact of roughness [24–27]. In practical applications, wall
roughness is prevalent, particularly under high temperatures and complex stress environ-
ments, where it can obviously affect the fabric of the boundary layer, flow distribution,
and heat transfer performance [28–31]. The turbulence-enhancing effects of roughness
Water 2024, 16, 3678 3 of 14
and flow separation phenomena can notably alter the heat transfer efficiency of cooling
air and the evolution of vortex structures. Recently, Yao et al. [32] demonstrated that rotor
roughness accelerates boundary layer separation on the stator, an effect that becomes more
pronounced under weak through-flow conditions. Regarding heat transfer, rotor roughness
not only contributes to an overall temperature increase in the cavity but also decreases the
thickness of the thermal boundary layer.
Given the oversight of roughness effects in existing studies, it is crucial to investigate
how roughness impacts flow and heat transfer characteristics in disk cavities. This research
examines the transient flow characteristics in both centrifugal and centripetal through-
flow disk cavities using numerical simulations and test validation under varying surface
roughness conditions. Notably, the selected flow modes encompass the majority of disk
cavity flows, offering valuable insights for future pump design.
2. Numerical Method
2.1. Theoretical Equation
This research uses numerical simulations which are based on the Reynolds-Averaged
Navier–Stokes (RANS) equations, which depict the mass, momentum, and energy conserva-
tion of an incompressible turbulent fluid. The control equations are formulated as follows:
Continuity equation:
∂ρ
+ ∇ · (ρν) = 0 (1)
∂t
where ρ represents the fluid density, v represents the velocity vector, ▽ denotes the scatter-
ing operator, and t represents the time.
Momentum equation:
∂(ρν)
+ ∇ · (ρνν) = −∇ p + ∇ · τ + f (2)
∂t
where p represents the static pressure, τ represents the stress tensor, and f represents the
volumetric force.
The expression for the stress tensor τ is given by
h i 2
τ = µ ∇ν + (∇ν)T − µ(∇ · ν) I (3)
3
where µ represents the dynamic viscosity of the fluid, and I represents the unit matrix.
Energy equation:
∂(ρE)
+ ∇ · (ν(ρE + p)) = ∇ · (k∇ T ) + Φ (4)
∂t
where E represents the total energy, T represents the temperature, k represents the thermal
conductivity, and Φ is the viscous dissipation term.
The total energy E is expressed as follows:
p v2
E = h− + (5)
ρ 2
where h represents the enthalpy and v2 /2 represents the kinetic energy term.
The Shear Stress Transport (SST) k-ω turbulence model has been used in this study
because of its advantages in predicting secondary flow characteristics, re-attachment, and
separation. The turbulent kinetic energy transport term (k) and the turbulent dissipation
rate (ω) in the SST k-ω turbulence equation can be calculated using Equations (6) and (7).
→ µ
∇ · (ρk ν ) = ∇ · µ + t ∇k + µt S2 − β∗ ρkω (6)
σk
Water 2024, 16, 3678 4 of 14
→ µt 1
∇ · (ρ ν ω ) = ∇ · µ+ ∇ · ω + 2(1 − F1 )ρ ∇ · ω + γρS2 − βρω 2 (7)
σω σω ω
where µt S2 and γρS2 represent the generation terms derived from the turbulence kinetic
energy and turbulence dissipation rate, respectively. µt is the turbulent viscosity. The
constants γ, β, σk , and σω can be obtained from the mixing factor F1 .
a1 k
ut = (8)
max( a1 ω, SF2 )
where a1 is a model constant, S is the magnitude of the mating rate, and F2 is the mixing
function. " √ ! !#4
k 500ν 4σω2 k
F1 = tanh min max , , (9)
β∗ ωy y2 ω CDkω y2
" √ !#2
2 k 500ν
F2 = tanh max , (10)
β∗ ωy y2 ω
where y is the distance to the wall and CDkω is the cross-derivative term of k and ω. Other
important model constants are σk = 0.85, σω = 0.5, β* = 0.09, α1 = 5/9, β1 = 0.075, and
σω2 = 0.856.
The SST k-ω turbulence model was chosen for this study due to its superior perfor-
mance in capturing key flow phenomena in rotor–stator cavities, particularly in regions
with high shear stresses and complex turbulence induced by surface roughness.
Figure
Figure 2. A schematic
2. A schematic representation
representation of
of the
the axial
axial surface
surface of
of the
the centrifugal
centrifugal and
and centripetal
centripetal through-
through-
flow in the rotor–stator cavity.
flow in the rotor–stator cavity.
Figure 3. Grid
Figure 3. Grid of
of rotor–stator
rotor–stator cavity.
cavity.
A grid independence study was performed to ensure the accuracy and reliability of
the numerical simulations. This assessment involved progressively refining the grid
density and monitoring the variations in key flow parameters, including the flow rates at
both the inlet and outlet, as shown in Figure 4. The relative difference in flow rates
decreased with an increasing grid density, indicating the convergence of the numerical
solution.
For all grids used in this study, the maximum deviation across simulations was less
than 0.15% once the grid count exceeded 2.289 million elements. This deviation is well
Water 2024, 16, 3678 6 of 14
within acceptable limits for engineering applications, demonstrating that further
refinement would have a negligible impact on the results. Consequently, a grid with 2.289
million elements
A grid was selected
independence studyfor theperformed
was simulations, balancing
to ensure computational
the accuracy efficiency
and reliability of and
the
solution accuracy.
numerical simulations. This assessment involved progressively refining the grid density
Additionally,
and monitoring the all grids used
variations in keyin flow
this study exhibited
parameters, a quality
including rating
the flow exceeding
rates 0.8,
at both the
inlet and outlet,
ensuring as shown
that the in Figure 4.
grid resolution andThequality
relativewere
difference in flow
sufficient forrates decreased
capturing the with
flow
an increasing grid
characteristics density, indicating the convergence of the numerical solution.
accurately.
Figure 4. Grid
Figure 4. Grid independence
independence test.
test.
For all grids used in this study, the maximum deviation across simulations was less than
0.15% once the grid count exceeded 2.289 million elements. This deviation is well within
acceptable limits for engineering applications, demonstrating that further refinement would
have a negligible impact on the results. Consequently, a grid with 2.289 million elements was
selected for the simulations, balancing computational efficiency and solution accuracy.
Additionally, all grids used in this study exhibited a quality rating exceeding 0.8, ensuring
that the grid resolution and quality were sufficient for capturing the flow characteristics
accurately.
+
1 + y
u = ln + + Br (11)
κ ks
where u+ represents the dimensionless velocity, y+ represents the dimensionless distance,
ks + represents the dimensionless roughness height, κ represents the Kármán constant, and
Br represents the modified wall constant.
CFX influences heat transfer characteristics indirectly by altering the velocity profile
and turbulence behavior of the boundary layer. When using the logistics law for wall
temperature for a smooth wall, the wall heat flux density may be possibly underestimated.
Thus, the logarithmic law for wall temperature is adjusted as below when performing
numerical analog simulations.
2
+
Tlog = 2.12 ln(Pr · y∗ ) + 3.85Pr1/3 − 1.3 − ∆Bth (12)
ωb2
Re = (14)
ν
where ω is the angular velocity of the disk, rad/s; b is the outer radius of the disk, mm; and
ν is the kinematic viscosity of air, m2 /s.
Parameter Range
Reynolds number Re 8.85 × 105 –1.77 × 106
Through-flow coefficient Cw 843–1966
Axial gap ratio G 0.1
Inlet total temperature Tin 300 K
Rotor surface temperature Tr 350–432.75 K
Roughness ks + 0–200 µm
(a)Smooth
(a) Smooth wall
wall Roughwall
(b)Rough
(b) wall
Figure
Figure 5. Transient 5.
5. Transient
evolution
Figure of TP inevolution
Transient of TP
centrifugal
evolution of TP incentrifugal
centrifugal
through-flow
in through-flow
in through-flow
rotor–stator ininrotor–stator
rotor–stator
cavity. cavity.
cavity.
(a)Smooth
(a) Smooth wall
wall (b)
(b)Rough
Roughwall
wall
Figure 6. TransientFigure 6. Transient
evolution evolution
of TP inevolution of TP
centripetal in centripetal
in through-flow in rotor–stator cavity.
Figure 6. Transient of through-flow
TP in centripetal rotor–stator
through-flow cavity.
in rotor–stator cavity.
In centripetal through-flow, while
Turbulent kinetic the pressure
energy distribution
(TKE) plays within
a vital role the cavityfluid
in determining is rela-
energy loss
tively uniform, the Turbulent kinetic
high-pressure energy
region at (TKE)
larger plays
radii a vital role
primarily in determining
results from the fluid energy los
interplay
overall system efficiency. In a disk cavity, the distribution and transfer pathways of T
overall system efficiency. In a disk cavity, the distribution and transfer pathways o
govern the energy conversion processes occurring within the cavity. A thoro
govern the energy conversion processes occurring within the cavity. A thor
investigation of the TKE distribution can lead to optimized hydrodynamic designs
investigation of the TKE distribution can lead to optimized hydrodynamic design
Water 2024, 16, 3678 9 of 14
of flow structure, boundary layer effects, kinetic energy conversion, and localized vortices.
The flow structure of centripetal through-flow is relatively homogeneous, with the fluid
flowing towards the center, forming a stable flow field. In this flow pattern, the fluid move-
ment is more regular, resulting in a more balanced overall pressure distribution. However,
at high radii, localized areas of high pressure may still form due to changes in the direction
of motion of the fluid and centrifugal forces. Significant pressurization occurs in the cavity
over time. Centripetal through-flow usually involves the contraction and acceleration of
the fluid towards a central region. As the flow duration increases, the contraction effect of
the fluid between the rotor and stator results in a gradual rise in the flow rate, with kinetic
energy being converted into static pressure, leading to a significant increase in the chamber
pressure. In this context, wall roughness enhances the pressure rise tendency within the
cavity. The roughness heightens the frictional resistance between the fluid and the wall,
resulting in greater energy losses during flow. While there is an overall pressure drop,
the effects of roughness near the rotor and in high-pressure regions can lead to localized
pressure increases and a propensity for pressure buildup. Collectively, these analyses not
only provide a scientific foundation for the design and optimization of pumps and related
applications but also highlight potential future research directions, carrying significant
theoretical and practical value.
Turbulent kinetic energy (TKE) plays a vital role in determining fluid energy loss and
overall system efficiency. In a disk cavity, the distribution and transfer pathways of TKE govern
the energy conversion processes occurring within the cavity. A thorough investigation of the
TKE distribution can lead to optimized hydrodynamic designs that minimize energy losses
and enhance system efficiency. The temporal variation in TKE in the centrifugal flow sub-
stator cavity is illustrated in Figure 7. The distribution of turbulent kinetic energy exhibits
axial stratification, indicating significant differences in turbulence intensity within different
regions. Overall, the values of turbulent kinetic energy exhibit a hierarchical pattern with respect
to axial position, closely tied to the rotational velocity gradient and shear stress within the
cavity. Notably, turbulence energy is significantly elevated near the rotor, likely due to the high
rotational speed creating a strong shearing effect that induces enhanced turbulence generation in
this area. In contrast, lower turbulent kinetic energy is observed near the stator, consistent with
its smaller velocity gradient and relatively stable flow conditions. Additionally, the temporal
variation in turbulent kinetic energy reflects the transient characteristics of the flow field within
the cavity. The trends of turbulent kinetic energy at different axial positions over time may
indicate a gradual development or adjustment of the flow, particularly in relation to boundary
layer formation and the evolution of vortex structures. Under rough walls, the turbulent kinetic
energy in the cavity rises overall and keeps moving towards the stator. Roughness disrupts
the laminar flow state within the boundary layer by increasing the flow resistance near the
wall, leading to the fluid having greater pulsation and vortex generation, thus increasing the
turbulent kinetic energy. The rough surface promotes the early development of turbulence
and causes it to be enhanced first in the region close to the rotor. This is due to the high-speed
rotation of the rotor which generates strong shear forces, which, together with the effect of
roughness, makes the generation and development of turbulence more intense in this region.
The variation in TKE with time for the centripetal flow disk cavity is shown in Figure 8.
A notable difference is that the region of high turbulent kinetic energy occurs at the lower
radius of the disk cavity, specifically at the exit. In centripetal flow, fluid moves from the outer
edge of the cavity towards the inner edge. The shortening of the flow path and reduction
in radius increase the fluid’s velocity gradient at the lower radius, resulting in greater shear
and stronger turbulence generation. Consequently, the area near the outlet (low radius)
exhibits higher turbulent kinetic energy. This elevated turbulent energy is primarily attributed
to the contraction effect of the centripetal flow and the flow disturbances caused by wall
roughness. The roughness amplifies the turbulent kinetic energy within the disk cavity and
intensifies the turbulence’s extension towards the mid-radius. This phenomenon highlights the
specific turbulence generation mechanisms present in centripetal flow and the enhancement
in turbulence intensity by rough walls.
outlet (low radius) exhibits higher turbulent kinetic energy. This elevated turbu
energy is primarily attributed to the contraction effect of the centripetal flow and the
disturbances caused by wall roughness. The roughness amplifies the turbulent ki
energy within the disk cavity and intensifies the turbulence’s extension towards the
Water 2024, 16, 3678 radius. This phenomenon highlights the specific turbulence generation 10 of 14 mechan
present in centripetal flow and the enhancement in turbulence intensity by rough wa
(a) Smooth
Water 2024, 17, x FOR PEER REVIEW wall (b) Rough wall 11
Figure
Figure 7. Transient 7. Transient
evolution of TKEevolution of TKE
in centrifugal in centrifugal
through-flow in through-flow in rotor–stator cavity.
rotor–stator cavity.
Figure
Figure 8. Transient 8. Transient
evolution of TKEevolution of TKE
in centripetal in centripetal
through-flow in through-flow in rotor–stator cavity.
rotor–stator cavity.
Ω
K= (15)
Ωf
where Ω represents the angular velocity of the disk, and Ωf represents the angular velocity
of the fluid.
Water 2024, 17, x FOR PEER REVIEW r 12
Water 2024, 17, x FOR PEER REVIEW x= (16) 12
b
(a)
(a)Re
Re==8.85
8.85××10
105
5 (b)
(b) Re
Re == 1.33
1.33 ×× 10
6
106 (c) Re
(c) Re == 1.77
1.77 ×× 10
6
106.
Figure 9. Effect ofFigure 9.
9. Effect
roughness
Figure of
of roughness
on core
Effect on
onincore
swirl ratio
roughness swirl
swirl ratio
a centrifugal
core in
in aa centrifugal
ratiothrough-flow through-flow
rotor–stator
centrifugal rotor–stator cav
cavity.
through-flow rotor–stator ca
(a)
(a)Re
Re==8.85
8.85××10
105
5 (b)
(b) Re
Re == 1.33
1.33 ×× 10
6
106 (c)
(c) Re
Re == 1.77
1.77 ×× 10
6
106
Figure
Figure 10.
10. Effect
Effect of
of roughness
roughness on core swirl
swirl ratio in
in aa centripetal through-flow rotor–stator ca
ca
Figure 10. Effect of roughness on core swirl ratioonincore ratiothrough-flow
a centripetal centripetal through-flow
rotor–stator rotor–stator
cavity.
To further explore To
To further
further explore
exploreflow
the transient the
the transient
transient flow
characteristicsflow characteristics
characteristics
in the disk cavity in
in the
the disk
disk the
under cavity unde
cavity unde
influence
influence of roughness,
influence we of roughness,
present thewe
of roughness, we present
transient the
presentvariations transient
the transient variations
in velocity
variations in
at in velocity
three at three
radialat three
velocity
positions, illustrated
positions,in Figures
positions, illustrated
illustrated11 and in 12. For11
in Figures
Figures 11centrifugal
and
and 12. 12. For through-flow,
For centrifugal the effect of the
centrifugal through-flow,
through-flow, the eff
eff
roughness on velocity
roughness is more
on limited
velocity at
is
roughness on velocity is more limited the
more low-radius
limited at location
the near
low-radius the inner
location diameter
near the inner dia
(x = 0.25). This is(xbecause
(x ==0.25). at this
0.25). This
This is location,
is because
because at the
at this
thisrotational
location,velocity
location, of the velocity
the rotational fluid is low, and
of the theis low, an
fluid
perturbations created by
perturbations the wall roughness have not yet significantly affected the main
perturbations created created by by thethe wall
wall roughness
roughness have not yet significantly affected the
flow of the fluid, leading to a smaller increase in velocity. The effect of roughness reaches
flow
flow of the fluid, leading to a smaller increase in velocity. The effect of roughness re
of the fluid, leading to a smaller
its maximum at the mid-radius position (x = 0.5). Figure 11 illustrates that at this location,
its maximum at
at the
the mid-radius position (x = 0.5). Figure 11 illustrates that at this loc
wall roughness its maximum
markedly enhances mid-radius
the momentum position exchange of the fluid by increasing
wall roughness markedly enhances the momentum exchange of the fluid by incre
the friction and wall roughness
turbulent kinetic markedly
energy at enhances
the fluid–wall interface, leading to a velocity
the
increase of 41.89%.the friction
friction
This and
and turbulent
phenomenon turbulent kinetic
suggestskinetic energy
energy
that at the of
the impact fluid–wall
roughness interface,
on the flowleading is to a ve
increase
most significantincrease of 41.89%.
of 41.89%. likely
at the mid-radius, This phenomenon
due to the moderate relative velocity of the fluid on the
This phenomenon suggests that the impact of roughness
in this region andis
is most
most significant at
at the
significantinteraction
the intensified the mid-radius,betweenlikely
mid-radius, due to
the shear the and
layer moderate relative
turbulence. Atvelocity
the high-radiusfluid in
in this
location
fluid region
close
this to the
region and the
the intensified
andouter diameter interaction
intensified (x = 0.75), the between
effectthe shear layer is
of roughness and turbu
somewhat diminished,
At
At the and despite
the high-radius
high-radius location the higher
location close rotational
close to speed of the fluid, the increase
to the outer diameter (x = 0.75), the effect of roughn in
velocity at the high radius diminished,
somewhat
somewhat fails to be asand
diminished, significant
and despite as
despite thethat at the
higher mid-radius,
rotational speedasofthe thefluid
fluid,isthe incre
already strongly perturbed
velocity
velocity at
at the
theathigh
the mid-radius.
high radius
radius fails fails totoHowever,
be the roughness
be as significant as that at still
theexerts some as the fl
mid-radius,
enhancement onalreadythe fluid velocity, which is manifested as a sustained increase in velocity.
already strongly
strongly perturbed
perturbed at at the
the mid-radius. However, the roughness still exerts
Under centripetal through-flow conditions, the influence of disk roughness on the
enhancement
enhancement on the fluid velocity, which is manifested as a sustained increase in vel
on the fluid velocity,
velocity changes across the three radial locations displays a more uniform character, con-
Under centripetal through-flow conditions, the influence of disk roughness o
trasting slightly withUnderthe trend centripetal
observedthrough-flow
in centrifugal through-flow. However, the largest
velocity
velocity changes
changes across across the the three
three radial locations displays a more uniform char
contrasting
contrasting slightly
slightly with with the the trend
trend observed in centrifugal through-flow. Howeve
largest
largest increase
increase is is still
still exhibited
exhibited at at the mid-radius location (x = 0.5). This indicate
despite
despite the the different
different flow flow directions,
directions, the effect of roughness is still most prominent
mid-radius location,
mid-radius location, reflecting
reflecting the the sensitivity of the flow characteristics to roughn
Water 2024, 16, 3678 12 of 14
increase is still exhibited at the mid-radius location (x = 0.5). This indicates that despite the
different flow directions, the effect of roughness is still most prominent at the mid-radius
Water
location, reflecting the sensitivity of the flow characteristics to roughness at the mid-radius.
Water2024,
2024,17,
17,xxFOR
FOR PEER
PEER REVIEW
REVIEW 13
13
The analysis of velocity, turbulent kinetic energy, and core swirl ratio distributions for
different flow modes in the disk cavity can provide important guidance for design and
optimization in engineering applications. These findings can help to improve the cooling
effect and enhance equipment, as
as well
the stability
equipment, andas
well the
heat
as reliability
thetransfer and
and performance
efficiency
reliability of
of the
the equipment,
of the equipment,
performance by
as well as by
equipment, controllin
thecontrollin
roughness
reliability and performance effect.
of the equipment, by controlling the roughness effect.
roughness effect.
(a) xx == 0.25
(a) 0.25 (b) xx == 0.5
(b) 0.5 (c) x
(c) x == 0.75
0.75
Figure
Figure
Figure 11. Velocity 11.
11. Velocity
transientVelocity transient
transient
evolution evolution
evolution
for different for different
different radial
for positions
radial radial positions in centrifugalin
positionsthrough-flow
in centrifugal in centrifugal through-flo
through-flo
rotor–stator
rotor–stator cavity. cavity.
rotor–stator cavity.
(a)
(a) xx == 0.25
0.25 (b) x = 0.5 (c) x = 0.75
uniform, the increase in flow velocity due to roughness is notably pronounced at the
mid-radius position.
3. The increase in the Reynolds number leads to a significant impact on the transient
flow characteristics in both flow modes. In centrifugal flow, higher Reynolds numbers
result in a marked increase in turbulence intensity, with the turbulent kinetic energy
rising by approximately 22% as the Reynolds number increases from 8.85 × 105 to
1.77 × 106 . This enhancement in turbulence intensity promotes the conversion of
kinetic energy into static pressure, resulting in the development of high-pressure
zones, where pressure peaks increase by up to 18% at the outermost radius. Similarly,
in centripetal flow, an increase in the Reynolds number brings about notable changes
in the pressure distribution within the cavity, with pressure increasing by about
12% in the high-radius region as the Reynolds number increases from 8.85 × 105
to 1.77 × 106 . These findings highlight the critical role of the Reynolds number in
influencing both flow behavior and pressure distribution in rotor–stator cavities under
varying operating conditions.
4. Roughness significantly accelerates the transient response of flow in both centrifugal
and centripetal flows. In centrifugal flow, roughness enhances turbulent mixing,
resulting in a marked increase in local velocity and TKE, especially in the high-radius
district, where the local turbulent kinetic energy experiences a dramatic rise. This
phenomenon accelerates fluid flow rates and has a significant impact on pressure
distribution and flow structure within the cavity.
In conclusion, this study provides a thorough analysis of the transient flow character-
istics of the disk chamber under different flow modes and roughness conditions. The influ-
ence of roughness on the turbulent kinetic energy and flow structure is more pronounced
in centrifugal flow, while its effects on centripetal flow are more localized. These results
offer valuable theoretical insights for the design and optimization of rotor–stator cavity
systems under transient conditions, which are particularly relevant for high-performance
equipment such as pumps.
Author Contributions: Conceptualization, C.W. and Y.Y.; methodology, J.G. and Y.W.; software, Y.Y.,
C.W., H.L., Y.W. and H.C.; writing—original draft preparation, Y.Y.; writing—review and editing,
C.W. and L.Z.; visualization, Y.Y. and H.L. All authors have read and agreed to the published version
of the manuscript.
Funding: This research was funded by the Science and Technology Program of Jiangxi Education
Department (GJJ2209004), the Research project on Teaching Reform of Yangzhou University in 2022
(YZUJX2022-D17), the China Postdoctoral Science Foundation (2023M732828 and 2024T170726), and the
Open Foundation of Key Laboratory of Water-Saving Agriculture of Henan Province (KLWSAHP-2023-01).
Data Availability Statement: All data are contained within the article.
Conflicts of Interest: Author Jie Ge was employed by the company SHIMGE Pump Co., Ltd. The
remaining authors declare that the research was conducted in the absence of any commercial or
financial relationships that could be construed as a potential conflict of interest.
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