The geometric complexity and high-pressure gradients that characterize the design of the flow field of gear pumps make it very difficult to obtain an accurate CFD simulation of the component. Usually, assumptions are made both in terms of geometrical features and physics being included in the analysis. The contact between the teeth, which is a key factor for the correct functioning of these pumps, represents a critical challenge in 3D CFD simulations, mainly due to the intrinsic limits of the dynamic meshing techniques that can hardly effectively manage a zero or close to zero gap point forming during gear rotation. The geometric complexity and high-pressure gradients that characterize the gear pump flow field make a CFD analysis quite difficult, and the contact between the gear teeth is usually avoided, thus being an extremely important feature. In this paper, a gear pump composed of inlet and outlet pipes was considered, and the contact between the gear’s teeth was modeled in two different ways, one where it is effectively implemented and one where it is avoided using distancing and a proper casing modification. Herein, a new methodology is proposed for the application of the dynamic mesh method in the Simcenter STAR-CCM+ environment using an adaptive remeshing technique. The proposed methodology is compared with the alternative overset meshing method available in the software. The new meshing method is implemented using a user-routing that reproduces the real geometry of the gears while rotating during the pump operation, with teeth contact included. The routine is optimized in order to limit the additional computation and time needed for the remeshing process. The results that can be obtained using the two meshing approaches for the gear pump are compared in terms of computational effort and the accuracy of the results. The two methods showed opposite results in almost all the reported results, with the overset being more precise in the radial pressure evaluation and the dynamic being more reliable in the cavitation/aeration extension cloud.

In a brake system the contact between the friction grooves of the discs and the steel elements leads to a consistent heat dissipation that is excised by the oil thermal vector in its flowing along the grooves channels. These are very complicated physical system were many variables may be taken in consideration, first of all the extensive integration of the different time scheduling actions that take place and that characterizes the translation of the interacting bodies and the correspondent deceleration, and also the heat dissipation derived from this contact. The simulations of similar physical system may result in too expensive computational efforts leading to very complicated simulations that need to take in account an extensive coupling between many physics, first of all the solid/liquid heat transfer and then the turbulence and the bi-phase models for the oil/air mixture that serves as thermal refrigerator vector in the braking system. Herein a simplified 3D model that focuses only on a discs / piston coupling is presented were the braking action is simulated in a simplified way modelling the velocity of rotation of the elements and the dissipated heat during the braking cycle. Focusing on the grooves channels the oil flows and thermal averaged flows are presented and detail contours are used to characterise a single brake event.

Waste heat recovery is a key strategy for improving the energy efficiency and sustainability of metallurgical processes, in which substantial energy is lost through high-temperature exhaust gases. This study numerically investigates an aluminum-block preheating chamber designed to recover thermal energy from furnace exhaust streams. A three dimensional computational fluid dynamics model was developed to simulate turbulent gas flow and conjugate heat transfer between the exhaust gases and solid aluminum blocks. Two geometric configurations, based on half- and full-block arrangements, and two operating conditions, with the extractor hood open or closed, were compared in terms of flow patterns, temperature distributions, and heat recovery performance. The results demonstrate that both operating conditions and block geometry strongly influence the system’s thermal behavior. Enhanced flow mixing promotes heat transfer, while the full-block configuration increases overall thermal energy absorption through greater interaction with the hot gas stream. The optimal configuration produces a substantial increase in block temperature and recovered energy. An economic assessment based on industrial production data estimates annual natural gas savings worth approximately €25,000.