Tutorial 1 - Fluid Flow and Heat Transfer in A Mixing Elbow PDF
Tutorial 1 - Fluid Flow and Heat Transfer in A Mixing Elbow PDF
Introduction
This tutorial illustrates the setup and solution of a three-dimensional turbulent fluid
flow and heat transfer problem in a mixing elbow. The mixing elbow configuration
is encountered in piping systems in power plants and process industries. It is often
important to predict the flow field and temperature field in the area of the mixing region
in order to properly design the junction.
This tutorial demonstrates how to do the following:
• Set material properties and boundary conditions for a turbulent forced convection
problem.
• Visually examine the flow and temperature fields using the postprocessing tools
available in ANSYS FLUENT.
• Enable the second-order discretization scheme for improved prediction of the tem-
perature field.
• Adapt the mesh based on the temperature gradient to further improve the predic-
tion of the temperature field.
Prerequisites
This tutorial assumes that you have little or no experience with ANSYS FLUENT, and
so each step will be explicitly described.
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Problem Description
The problem to be considered is shown schematically in Figure 1.1. A cold fluid at 20◦ C
flows into the pipe through a large inlet, and mixes with a warmer fluid at 40◦ C that
enters through a smaller inlet located at the elbow. The pipe dimensions are in inches,
and the fluid properties and boundary conditions are given in SI units. The Reynolds
number for the flow at the larger inlet is 50,800, so a turbulent flow model will be required.
Note: Since the geometry of the mixing elbow is symmetric, only half of the elbow needs
to be modeled in ANSYS FLUENT.
4"
Ux = 0.4 m/s
1"
T = 20oC 4" Dia.
I = 5%
3"
1" Dia.
8"
Uy = 1.2 m/s
T = 40oC
I = 5%
Note: ANSYS FLUENT tutorials are prepared using ANSYS FLUENT on a Windows sys-
tem. The screen shots and graphic images in the tutorials may be slightly different
than the appearance on your system, depending on the operating system or graphics
card.
1. Click the ANSYS FLUENT icon ( ) in the ANSYS program group to open FLU-
ENT Launcher.
ANSYS FLUENT Launcher allows you to decide which version of ANSYS FLUENT
you will use, based on your geometry and on your processing capabilities.
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(a) Select 3D from the Dimension list by clicking the radio button or the text, so
that a green dot appears in the radio button.
(b) Select Serial from the Processing Options list.
(c) Make sure that the Display Mesh After Reading, Embed Graphics Windows, and
Workbench Color Scheme options are enabled.
Note: An option is enabled when there is a check mark in the check box, and
disabled when the check box is empty. To change an option from disabled
to enabled (or vice versa), click the check box or the text.
(d) Make sure that the Double-Precision option is disabled.
Extra: You can also restore the default settings by clicking the Default button.
3. Set the working path to the folder created when you unzipped introduction.zip.
(a) Click the Show More >> button.
(b) Enter the path to your working folder for Working Directory by double-clicking
the text box and typing.
Alternatively, you can click the browse button ( ) next to the Working
Directory text box and browse to the folder, using the Browse For Folder dialog
box.
Step 2: Mesh
1. Read the mesh file elbow.msh.
File −→ Read −→Mesh...
Select Read from the File menu, then select Mesh... to open the Select File dialog
box.
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(a) Select the mesh file by clicking elbow.msh in the introduction folder created
when you unzipped the original file.
(b) Click OK to read the file and close the Select File dialog box.
As the mesh file is read by ANSYS FLUENT, messages will appear in the console
reporting the progress of the conversion. ANSYS FLUENT will report that 13,852
hexahedral fluid cells have been read, along with a number of boundary faces with
different zone identifiers.
Note: The mesh is displayed in the graphics window by default.
Extra: You can use the mouse to probe for mesh information in the graphics win-
dow. If you click the right mouse button with the pointer on any node in the
mesh, information about the associated zone will be displayed in the console,
including the name of the zone.
Alternatively, you can click the probe button ( ) in the graphics toolbar and
click the left mouse button on any node. This feature is especially useful when
you have several zones of the same type and you want to distinguish between
them quickly.
For this 3D problem, you can make it easier to probe particular nodes by chang-
ing the view. You can perform any of the actions described in the following
table:
Roll view (not applicable) After clicking , press the left mouse but-
(clock- ton and drag the mouse side to side to roll the
wise, coun- view clockwise and counterclockwise.
terclock-
wise)
Translate Press the middle mouse but- After clicking , press the left mouse but-
view ton once at any point in the ton and drag the mouse until the view is sat-
display to center the view at isfactory.
that point.
Zoom in on Press the middle mouse but- After clicking , press the left mouse but-
view ton and drag the mouse to the ton and drag the mouse to the right and up
right and either up or down. or down. This action will cause a rectangle to
This action will cause a rect- appear in the display. When you release the
angle to appear in the display. mouse button, a new view will be displayed
When you release the mouse which consists entirely of the contents of the
button, a new view will be dis- rectangle.
played which consists entirely Alternatively, after clicking , press the
of the contents of the rectan- left mouse button and drag the mouse up.
gle.
Zoom out Press the middle mouse but- After clicking , press the left mouse but-
from view ton and drag the mouse to the ton and drag the mouse to the left and up or
right and either up or down. down. This action will cause a rectangle to
This action will cause a rect- appear in the display. When you release the
angle to appear in the display. mouse button, the magnification of the view
When you release the mouse will be reduced by an amount that is inversely
button, a new view will be dis- proportional to the size of the rectangle. The
new view will be centered at the center of the
played which consists entirely
rectangle.
of the contents of the rectan-
gle. Alternatively, after clicking , press the
left mouse button and drag the mouse up.
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Note: After you have clicked a button in the graphics toolbar, you can return to
the default mouse button settings by clicking .
2. Manipulate the mesh display to obtain a front view as shown in Figure 1.2.
Graphics and Animations −→ Views...
Select Graphics and Animations in the navigation pane, then click Views... in the
Graphics and Animations task page.
Mesh Check
Domain Extents:
x-coordinate: min (m) = -8.000000e+000, max (m) = 8.000000e+000
y-coordinate: min (m) = -9.134633e+000, max (m) = 8.000000e+000
z-coordinate: min (m) = 0.000000e+000, max (m) = 2.000000e+000
Volume statistics:
minimum volume (m3): 5.098261e-004
maximum volume (m3): 2.330738e-002
total volume (m3): 1.607154e+002
Face area statistics:
minimum face area (m2): 4.865882e-003
maximum face area (m2): 1.017924e-001
Checking number of nodes per cell.
Checking number of faces per cell.
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Note: The minimum and maximum values may vary slightly when running on
different platforms. The mesh check will list the minimum and maximum x
and y values from the mesh in the default SI unit of meters. It will also report
a number of other mesh features that are checked. Any errors in the mesh will
be reported at this time. Ensure that the minimum volume is not negative,
since ANSYS FLUENT cannot begin a calculation when this is the case.
2. Scale the mesh.
General −→ Scale...
(a) Make sure that Convert Units is selected in the Scaling group box.
(b) Select in from the Mesh Was Created In drop-down list by first clicking the
down-arrow button and then clicking the in item from the list that appears.
(c) Click Scale to scale the mesh.
4. Retain the default settings in the Solver group box of the General task page.
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Step 4: Models
Models
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Step 5: Materials
Materials
Extra: You could have copied the material water-liquid (h2o<l>) from the
materials database (accessed by clicking the FLUENT Database... button).
If the properties in the database are different from those you wish to use,
you can edit the values in the Properties group box in the Create/Edit
Materials dialog box and click Change/Create to update your local copy.
The original copy will not be affected.
(d) Make sure that there are now two materials (water and air) defined locally by
examining the FLUENT Fluid Materials drop-down list.
Both the materials will also be listed under Fluid in the Materials task page.
(e) Close the Create/Edit Materials dialog box.
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1. Set the cell zone conditions for the fluid zone (fluid).
Cell Zone Conditions −→ fluid −→ Edit...
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(a) Select Components from the Velocity Specification Method drop-down list.
The Velocity Inlet dialog box will expand.
(b) Enter 0.4 m/s for X-Velocity.
(c) Retain the default value of 0 m/s for both Y-Velocity and Z-Velocity.
(d) Select Intensity and Hydraulic Diameter from the Specification Method drop-
down list in the Turbulence group box.
(e) Enter 5% for Turbulent Intensity.
(f) Enter 4 inches for Hydraulic Diameter.
The hydraulic diameter Dh is defined as:
4A
Dh =
Pw
where A is the cross-sectional area and Pw is the wetted perimeter.
(g) Click the Thermal tab.
2. In a similar manner, set the boundary conditions at the hot inlet (velocity-inlet-6),
using the values in the following table:
Boundary Conditions −→ velocity-inlet-6 −→ Edit...
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3. Set the boundary conditions at the outlet (pressure-outlet-7), as shown in the Pres-
sure Outlet dialog box.
Boundary Conditions −→ pressure-outlet-7 −→ Edit...
Note: ANSYS FLUENT will use the backflow conditions only if the fluid is flowing
into the computational domain through the outlet. Since backflow might occur
at some point during the solution procedure, you should set reasonable backflow
conditions to prevent convergence from being adversely affected.
4. For the wall of the pipe (wall), retain the default value of 0 W/m2 for Heat Flux in
the Thermal tab.
Boundary Conditions −→ wall −→ Edit...
Step 8: Solution
In the steps that follow, you will set up and run the calculation using the task pages listed
under the Solution heading in the navigation pane.
(a) Make sure that Plot is enabled in the Options group box.
(b) Enter 1e-05 for the Absolute Criteria of continuity, as shown in the Residual
Monitor dialog box.
(c) Click OK to close the Residual Monitors dialog box.
Note: By default, all variables will be monitored and checked by ANSYS FLUENT
as a means to determine the convergence of the solution. It is a good practice
to also define a surface monitor that can help evaluate whether the solution is
truly converged. You will do this in the next step.
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(a) Retain the default entry of surf-mon-1 for the Name of the surface monitor.
(b) Enable the Plot and Write options for surf-mon-1.
(c) Retain the default entry of surf-mon-1.out for File Name.
(d) Set Get Data Every to 3 by clicking the up-arrow button.
This setting instructs ANSYS FLUENT to update the plot of the surface monitor
and write data to a file after every 3 iterations during the solution.
(e) Select Mass-Weighted Average from the Report Type drop-down list.
(f) Select Temperature... and Static Temperature from the Field Variable drop-down
lists.
(g) Select pressure-outlet-7 from the Surfaces selection list.
(h) Click OK to save the surface monitor settings and close the Surface Monitor
dialog box.
The name and report type of the surface monitor you created will be displayed in
the Surface Monitors selection list in the Monitors task page.
3. Initialize the flow field, using the boundary conditions settings at the cold inlet
(velocity-inlet-5) as a starting point.
Solution Initialization
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(a) Click the Solver tab and examine the Recommendation in the Manual Imple-
mentation group box.
The only recommendation for this case file is to use discretization of a higher
order. This recommendation can be ignored for the time being, as it will be
performed in a later step.
(b) Close the Case Check dialog box.
5. Save the case file (elbow1.cas.gz).
File −→ Write −→Case...
(a) (optional) Indicate the folder in which you would like the file to be saved.
By default, the file will be saved in the folder from which you read in elbow.msh
(i.e., the introduction folder). You can indicate a different folder by brows-
ing to it or by creating a new folder.
(b) Enter elbow1.cas.gz for Case File.
Adding the extension .gz to the end of the file name extension instructs ANSYS
FLUENT to save the file in a compressed format. You do not have to include
.cas in the extension (e.g., if you enter elbow1.gz, ANSYS FLUENT will
automatically save the file as elbow1.cas.gz). The .gz extension can also be
used to save data files in a compressed format.
(c) Make sure that the default Write Binary Files option is enabled, so that a binary
file will be written.
(d) Click OK to save the case file and close the Select File dialog box.
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You can display the residuals history (Figure 1.4), by selecting it from the
graphics window drop-down list.
Residuals
continuity
x-velocity
y-velocity
z-velocity 1e+01
energy
k
epsilon
1e+00
1e-01
1e-02
1e-03
1e-04
1e-05
1e-06
1e-07
0 20 40 60 80 100 120 140
Iterations
Scaled Residuals
FLUENT 12.0 (3d, pbns, rke)
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• The overall mass, momentum, energy, and scalar balances are obtained.
You can examine the overall mass, momentum, energy and scalar balances
in the Flux Reports dialog box. The net imbalance should be less than 0.2%
of the net flux through the domain when the solution has converged. In the
next step you will check to see if the mass balance indicates convergence.
(a) Make sure that Mass Flow Rate is selected from the Options list.
(b) Select pressure-outlet-7, velocity-inlet-5, and velocity-inlet-6 from the Boundaries
selection list.
(c) Click Compute.
The individual and net results of the computation will be displayed in the Re-
sults and Net Results boxes, respectively, in the Flux Reports dialog box, as well
as in the console.
The sum of the flux for the inlets should be very close to the sum of the flux
for the outlets. The net results show that the imbalance in this case is well
below the 0.2% criteria suggested previously.
(d) Close the Flux Reports dialog box.
1. Display filled contours of velocity magnitude on the symmetry plane (Figure 1.5).
Graphics and Animations −→ Contours −→ Set Up...
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(a) Select Temperature... and Static Temperature from the Contours of drop-down
lists.
3. Display velocity vectors on the symmetry plane (Figures 1.7 and 1.8).
Graphics and Animations −→ Vectors −→ Set Up...
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(a) Select Mesh... and Z-Coordinate from the Surface of Constant drop-down lists.
(b) Click Compute.
The range of values in the z direction will be displayed in the Min and Max
boxes.
(c) Retain the default value of 0 inches for Iso-Values.
(d) Select pressure-outlet-7 from the From Surface selection list.
(e) Enter z=0 outlet for New Surface Name.
(f) Click Create.
After the line surface z=0 outlet is created, a new entry will automatically
be generated for New Surface Name, in case you would like to create another
surface.
(g) Close the Iso-Surface dialog box.
5. Display and save an XY plot of the temperature profile across the centerline of the
outlet for the initial solution (Figure 1.9).
Plots −→ XY Plot −→ Set Up...
(a) Select Temperature... and Static Temperature from the Y Axis Function drop-
down lists.
(b) Select z=0 outlet from the Surfaces selection list.
(c) Click Plot.
(d) Enable Write to File in the Options group box.
The button that was originally labeled Plot will change to Write....
(e) Click Write... to open the Select File dialog box.
i. Enter outlet temp1.xy for XY File.
ii. Click OK to save the temperature data and close the Select File dialog
box.
(f) Close the Solution XY Plot dialog box.
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6. Define a custom field function for the dynamic head formula (ρ|V |2 /2).
Define −→ Custom Field Functions...
(a) Select Density... and Density from the Field Functions drop-down lists, and click
the Select button to add density to the Definition field.
(b) Click the X button to add the multiplication symbol to the Definition field.
(c) Select Velocity... and Velocity Magnitude from the Field Functions drop-down
lists, and click the Select button to add |V| to the Definition field.
(d) Click y^x to raise the last entry in the Definition field to a power, and click 2
for the power.
(e) Click the / button to add the division symbol to the Definition field, and then
click 2.
(f) Enter dynamic-head for New Function Name.
(g) Click Define and close the Custom Field Function Calculator dialog box.
(a) Select Custom Field Functions... and dynamic-head from the Contours of drop-
down lists.
Hint: Custom Field Functions... is at the top of the upper Contours of drop-
down list. After you have opened the drop-down list, scroll up by clicking
the up-arrow button on the scroll bar on the right.
(b) Make sure that symmetry is selected from the Surfaces selection list.
(c) Click Display and close the Contours dialog box.
Note: You may need to change the view by zooming out after the last vector display,
if you have not already done so.
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8. Save the settings for the custom field function by writing the case and data files
(elbow1.cas.gz and elbow1.dat.gz).
File −→ Write −→Case & Data...
(a) Ensure that elbow1.cas.gz is entered for Case/Data File.
Note: When you write the case and data file at the same time, it does not
matter whether you specify the file name with a .cas or .dat extension,
as both will be saved.
(b) Click OK to save the files and close the Select File dialog box.
2. (optional) Check the case to confirm that there are no recommendations for revi-
sions to the setup.
Run Calculation −→ Check Case
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Extra: To save the convergence history of the surface monitor for this set of itera-
tions as a separate output file, you would need to change the File Name in the
Surface Monitor dialog box to surf-mon-2.out prior to running the calculation.
(a) Make sure that 150 is entered for Number of Iterations.
(b) Click Calculate.
The solution will converge in approximately 63 additional iterations (Fig-
ure 1.11). The convergence history is shown in Figure 1.12.
Note: You should expect to see the residuals jump whenever you change the solution
control parameters.
4. Save the case and data files for the second-order solution (elbow2.cas.gz and
elbow2.dat.gz).
File −→ Write −→Case & Data...
(a) Enter elbow2.gz for Case/Data File.
(b) Click OK to save the files and close the Select File dialog box.
The files elbow2.cas.gz and elbow2.dat.gz will be saved in your default folder.
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(a) Make sure that Filled is enabled in the Options group box.
(b) Select Temperature... and Static Temperature from the Contours of drop-down
lists.
(c) Make sure that symmetry is selected from the Surfaces selection list.
(d) Click Display (Figure 1.13) and close the Contours dialog box.
Figure 1.13 shows the thermal spreading of the warm fluid layer near the outer wall
of the bend. To see the effects of second-order discretization, compare Figure 1.13
with Figure 1.6.
6. Display and save an XY plot of the temperature profile across the centerline of the
outlet for the second-order solution (Figure 1.14).
Plots −→ XYPlot −→ Set Up...
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(b) Make sure that Temperature... and Static Temperature are selected from the Y
Axis Function drop-down lists.
(c) Make sure that z=0 outlet is selected from the Surfaces selection list.
(d) Click Plot.
(a) Make sure that Refine is enabled in the Options group box.
ANSYS FLUENT will not coarsen beyond the original mesh for a 3D mesh.
Hence, it is not necessary to deselect Coarsen in this instance.
(b) Select Temperature... and Static Temperature from the Gradients of drop-down
lists.
(c) Click Compute.
ANSYS FLUENT will update the Min and Max values to show the minimum
and maximum temperature gradient.
(d) Enter 0.004 for Refine Threshold.
It is a good rule of thumb to use 10% of the maximum gradient when setting
the value for Refine Threshold.
(e) Click Mark.
ANSYS FLUENT will report in the console that approximately 940 cells were
marked for adaption.
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(f) Click Manage... to open the Manage Adaption Registers dialog box.
i. Click Display.
ANSYS FLUENT will display the cells marked for adaption in the graphics
window (Figure 1.15).
Extra: You can change the way ANSYS FLUENT displays cells marked
for adaption (Figure 1.16) by performing the following steps:
A. Click Options... in the Manage Adaption Registers dialog box to open
the Adaption Display Options dialog box.
C. Ensure that only the Edges option is enabled in the Options group
box.
D. Select Feature from the Edge Type list.
E. Select all of the items except default-interior from the Surfaces selec-
tion list.
F. Click Display and close the Mesh Display dialog box.
G. Enable Filled in the Options group box in the Adaption Display Op-
tions dialog box.
H. Enable Wireframe in the Refine group box.
I. Click OK to close the Adaption Display Options dialog box.
J. Click Display in the Manage Adaption Registers dialog box.
K. Rotate the view and zoom in to get the display shown in Figure 1.16.
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L. After viewing the marked cells, rotate the view back and zoom out
again to return to the angle and magnification shown in Figure 1.13.
ii. Click Adapt in the Manage Adaption Registers dialog box.
A Question dialog box will open, confirming your intention to adapt the
mesh. Click Yes to proceed.
Note: There are two different ways to adapt. You can click Adapt in the
Manage Adaption Registers dialog box as was just done, or close this
dialog box and perform the adaption using the Gradient Adaption dialog
box. If you use the Adapt button in the Gradient Adaption dialog box,
ANSYS FLUENT will recreate an adaption register. Therefore, when
the Manage Adaption Registers dialog box is open, use the Adapt button
in it to save time.
iii. Close the Manage Adaption Registers dialog box.
(g) Close the Gradient Adaption dialog box.
(a) Make sure that All is selected from the Edge Type list.
(b) Deselect all of the highlighted items from the Surfaces selection list except for
symmetry.
(c) Click Display and close the Mesh Display dialog box.
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3. (optional) Check the case to confirm that there are no recommendations for revi-
sions to the setup.
Run Calculation −→ Check Case
The solution will converge after approximately 100 additional iterations (Figures 1.18
and 1.19).
5. Save the case and data files for the second-order solution with an adapted mesh
(elbow3.cas.gz and elbow3.dat.gz).
File −→ Write −→ Case & Data...
(a) Enter elbow3.gz for Case/Data File.
(b) Click OK to save the files and close the Select File dialog box.
The files elbow3.cas.gz and elbow3.dat.gz will be saved in your default folder.
6. Examine the filled temperature distribution (using node values) on the revised mesh
(Figure 1.20).
Graphics and Animations −→ Contours −→ Set Up...
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7. Display and save an XY plot of the temperature profile across the centerline of the
outlet for the adapted second-order solution (Figure 1.21).
Plots −→ XY Plot −→ Set Up...
Figure 1.21: Outlet Temperature Profile for the Adapted Second-Order Solution
(a) Click the Add... button to open the Select File dialog box.
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Extra: You can perform additional rounds of mesh adaption based on temperature
gradient and run the calculation to see how the temperature profile changes
at the outlet. A case and data file (elbow4.cas.gz and elbow4.dat.gz) has
been provided in the solution files folder, in which the mesh has undergone
three more levels of adaption. The resulting temperature profiles have been
plotted with outlet temp2.xy and outlet temp3.xy in Figure 1.23.
Figure 1.23: Outlet Temperature Profiles for Subsequent Mesh Adaption Steps
It is evident from Figure 1.23 that as the mesh is adapted further, the profiles
converge on a mesh-independent profile. The resulting wall temperature at the
outlet is predicted to be around 300.2 K after mesh independence is achieved.
If the adaption steps had not been performed, the wall temperature would have
incorrectly been estimated at around 299.75 K.
If computational resources allow, it is always recommended to perform succes-
sive rounds of adaption until the solution is independent of the mesh (within an
acceptable tolerance). Typically, profiles of important variables are examined
(in this case, temperature) and compared to determine mesh independence.
Summary
A comparison of the filled temperature contours for the first solution (using the original
mesh and first-order discretization) and the last solution (using an adapted mesh and
second-order discretization) clearly indicates that the latter is much less diffusive. While
first-order discretization is the default scheme in ANSYS FLUENT, it is good practice to
use your first-order solution as a starting guess for a calculation that uses a higher-order
discretization scheme and, optionally, an adapted mesh.
In this problem, the flow field is decoupled from temperature, since all properties are
constant. For such cases, it is more efficient to compute the flow-field solution first (i.e.,
without solving the energy equation) and then solve for energy (i.e., without solving
the flow equations). You will use the Equations dialog box to turn the solution of the
equations on and off during such a procedure.
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Introduction to Using ANSYS FLUENT: Fluid Flow and Heat Transfer in a Mixing Elbow