An analysis of the spectral turbulent kinetic energy budget in a fully developed turbulent plane channel flow is performed. Direct numerical simulation data are evaluated at friction Reynolds numbers Re_τ of 180 and 1000. The analysis is focused on the influence of the Reynolds number on the spectral cascade of energy and the corresponding energy cascade in physical space in the presence of inhomogeneity and anisotropy. The turbulent kinetic energy distribution is compared for both Reynolds numbers, and the relevant characteristics of the energy transfer process in a wall-bounded turbulent flow are described. Differences in energy cascade are noted between the Reynolds number at both low and high wavenumbers. The results of the analysis are further assessed with a comparison to an earlier study of spectral energy transfer at Re_τ = 180.

The present paper provides an analysis of the statistical uncertainties associated with direct numerical simulation (DNS) results and experimental data for turbulent channel and pipe flows, showing a new physically based quantification of these errors, to improve the determination of the statistical deviations between DNSs and experiments. The analysis is carried out using a recently proposed criterion by Thompson et al. [“A methodology to evaluate statistical errors in DNS data of plane channel flows,” Comput. Fluids 130, 1–7 (2016)] for fully turbulent plane channel flows, where the mean velocity error is estimated by considering the Reynolds stress tensor, and using the balance of the mean force equation. It also presents how the residual error evolves in time for a DNS of a plane channel flow, and the influence of the Reynolds number on its convergence rate. The root mean square of the residual error is shown in order to capture a single quantitative value of the error associated with the dimensionless averaging time. The evolution in time of the error norm is compared with the final error provided by DNS data of similar Reynolds numbers available in the literature. A direct consequence of this approach is that it was possible to compare different numerical results and experimental data, providing an improved understanding of the convergence of the statistical quantities in turbulent wall-bounded flows.

Establishing precise welding parameters is essential to achieving the desired bead geometry and ensuring consistent quality in manufacturing processes. However, determining the optimal configuration of parameters remains a challenge, particularly when relying on limited experimental data. This study proposes the use of artificial neural networks (ANNs), with their architecture optimized via differential evolution (DE), to predict key MAG welding parameters based on target bead geometry. To address data limitations, cross-validation and data augmentation techniques were employed to enhance model generalization. In addition to the ANN model, machine learning algorithms commonly recommended for small datasets, such as K-nearest neighbors (KNNs) and support vector machines (SVMs), were implemented for comparative evaluation. The results demonstrate that all models achieved good predictive performance, with SVM showing the highest accuracy among the techniques tested, reinforcing the value of integrating traditional ML models for benchmarking purposes in low-data scenarios.

The CFD simulation of cyclone separators has remarkably evolved over the past decades. Nowadays, computational models are essential for designing, analyzing, and optimizing these devices. Due to the intrinsic anisotropy of the flow inside these separators, the Reynolds stress model (RSM) has been mostly employed. However, RSM models fail to solve most time and space scales, including those relevant to particle behavior. Consequently, the prediction of the grade collection efficiency may be hindered, particularly for low-Stokes-number particles. For example, the precessing vortex core phenomenon (PVC), a well-known phenomenon that is relevant for particle motion, is not usually captured in Reynolds-averaged Navier–Stokes (RANS) simulations. Alternatively, the large-eddy simulation (LES) has been proven to be a superior approach since it captures many time and space scales that would have been otherwise dissipated, allowing for more accurate predictions of particle collection. However, this accuracy comes at a considerable computational cost. To combine the advantages of these two models, the main objective of this research was to evaluate a new hybrid RSM-LES model applied to the cyclone’s flow. The results were compared to experimental data and with RSM model results. It showed that, compared to a RANS model given by the RSM closure model, the grade collection efficiency curve obtained by the hybrid model is closer to the experimental one, even for the coarser mesh. Beyond that, the results showed that while the improvement in results was not proportional to mesh refinement for RANS modeling, the hybrid model showed significant improvement with mesh refinement.

Cyclone separators are widely used in fluid catalytic cracking (FCC) units due to their lack of moving parts and relatively low-pressure drop. However, cyclone separators are prone to erosion-related issues, which is a major drawback. In this paper, a large eddy simulation (LES) of the particle-gas flow in a cyclone separator is investigated using a four-way Euler-Lagrange approach to model inter-particle collisions and the exchange of momentum between particles and fluid. The effects of inter-particle and particle-wall collisions are characterized in terms of erosive wear. Additional effects involving the exchange of momentum between the fluid and the particles are also discussed. The results show that considering the interparticle collisions between solid particles may be the key to predicting erosion.