COMSOL V4.4 Heat PDF

CO
L
SO
MULTIPHYSIC
S
V4
1. Introduction
2. Heat Sink
3. Droplet Breakup in a T-Junction
4. Cooling of an Injection Mold
5. Electroosmotic Micromixer
6. Fluid-Structure Interaction
COMSOL MULTIPHYSICS
Introduction
Heat Transfer and Fluid Flow
COMSOL V4.4 Product Suite
Heat Transfer Module

Conduction, convection and radiation
Radiation
- Surface to surface, Surface to ambient,
- External Radiation Source
- Sun Radiation
- Multi-Wavelength Heat Radiation
Easy to use for modeling a phase change
of materials
Add Moist air fluid type
Bio heat
Thermal contact
Easy to evaluate for heat and energy
balance
CFD Module
Model laminar and turbulent flows in single

or multi phases
Simulation in the free and porous media

flow
Ready coupling of heat and mass transport

to fluid flow
- heat exchangers, turbines, separations
units, and ventilation systems
Thin Screen
Interior Wall
Wall Roughness(k-, k-w model)
Mixer Module
Impeller and a vessel in containing

machinery-based mixers
Used in many industrial processes, such

as the production of consumer products,
pharmaceuticals, food, and fine chemicals.
Free surface
Add-on to the CFD Module
Microfluidics Module
Easy-to-use tools for the study

microfluidic devices and rarefied
gas flows.
Set up to coupled electrokinetic

and magnetodynamic simulations
easily including electrophoresis,
magnetophoresis, dielectrophoresis,
electroosmosis, and electrowetting.
Slip flow Analysis
Subsurface Flow Module
Model single and coupled processes

related to subsurface flow
Oil and gas flow in porous media, the

modeling of groundwater flow, and
the spread of pollution through soil
Pipe Flow Module

Flow, heat, and mass transport in
pipe networks.
Two-Phase Flow(gas-liquid
mixtures) in Pipes
Velocity, pressure variation,
temperature
1D lines or curves embedded in 2D
or 3D model.
Piping components such as Bend,
Valves, Pumps, T-junctions.
Molecular Module
Applies to the transitional flow and free

molecular flow regimes.
Fast computations of steady-state free

molecular flow with Angular Coefficient
Method
Design and simulation of vacuum systems
Adsorption, desorption, and deposition
Particle Tracing Module
Lets you compute trajectories of

particles in a fluid or an electromagnetic
field.
- Including particle-field interactions,
particle-particle interaction force.
Applications include:
flow visualization
mixing
spraying
particle separation
mass spectrometry
ion optics
beam physics
ion energy distribution functions
acoustic streaming
ray tracing
Mixing in a static mixer
COMSOL MULTIPHYSICS
Heat Sink
Heat Sink
Preview
Fluid Flow
Porous
Small pores
Saturated
Darcy
Free
Large pores
Brinkman
Unsaturated
Richards
Laminar
Navier-Stokes
Newtonian
Non-Newtonian
Turbulent
RANS
Preview
Inlet / Outlet Condition Inflow, Outflow
Preview
Incompressible flow / Compressible flow
Newtonian fluid / Non-Newtonian fluid
Preview
Interior wall
no thickness
Preview
Heat transfer in solid / fluid
- Conduction / Convection Domain
Domain / Boundary / Line / Point Heat Source
Temperature
Outflow Convection outlet

Initial values
Preview
Heat Flux
Convective Heat Flux
Highly Conductive Layer / Thin Thermally Resistive Layer
Preview
Surface to ambient / surface radiation
Radiation Group
Preview
Heat Balance(Global variables)
dEiInt
ntfluxInt
QInt
WnsInt
Energy Balance(Global variables)
dEi0Int
ntefluxInt
QInt
WInt
Model
Convection -> Cooling
Inlet
Outlet
Heat
Aluminum 3003-H18
Physics
Heat Transfer in Solid + Laminar flow = Conjugate Heat Transfer
Navier-stokes equation
(Steady-State, Compressible flow)
Heat Transfer equation
Modeling - condition
Layer
1 [W]
Result
Inlet
5 [cm/s], 293.15 [K]
Outlet
Pressure, no viscous stress
Initial temperature
293.15[K]
Wall condition
No slip, Thermal insulation
Solved with COMSOL Multiphysics 4.4
Heat Sink
Introduction
This model is intended as a first introduction to simulations of fluid flow and conjugate
heat transfer. It shows the following important points:
How to draw an air box around a device in order to model convective cooling in
this box.
How to set a total heat flux on a boundary using automatic area computation.
How to display results in an efficient way using selections in data sets.
The model is also described in detail in the book Introduction to the Heat Transfer
Module. An extension of the model that takes surface-to-surface radiation into account
is also available; see Heat Sink with Surface-to-Surface Radiation.
Model Definition
The modeled system consists of an aluminum heat sink for cooling of components in
electronic circuits mounted inside a channel of rectangular cross section (see Figure 1).
Such a set-up is used to measure the cooling capacity of heat sinks. Air enters the
channel at the inlet and exits the channel at the outlet. The base surface of the heat
1 |
HEAT SINK
sink receives a 1 W heat flux from an external heat source. All other external faces are
thermally insulated.
inlet
outlet
base surface
Figure 1: The model set-up including channel and heat sink.

The cooling capacity of the heat sink can be determined by monitoring the
temperature of the base surface of the heat sink.
The model solves a thermal balance for the heat sink and the air flowing in the
rectangular channel. Thermal energy is transported through conduction in the
aluminum heat sink and through conduction and convection in the cooling air. The
temperature field is continuous across the internal surfaces between the heat sink and
the air in the channel. The temperature is set at the inlet of the channel. The base of
the heat sink receives a 1 W heat flux. The transport of thermal energy at the outlet is
dominated by convection.
The flow field is obtained by solving one momentum balance for each space coordinate
(x, y, and z) and a mass balance. The inlet velocity is defined by a parabolic velocity
profile for fully developed laminar flow. At the outlet, a constant pressure is combined
with the assumption that there are no viscous stresses in the direction perpendicular to
the outlet. At all solid surfaces, the velocity is set to zero in all three spatial directions.
2 |
HEAT SINK
The thermal conductivity of air, the heat capacity of air, and the air density are all
temperature-dependent material properties.
You can find all of the settings mentioned above in the physics interface for Conjugate
Heat Transfer in COMSOL Multiphysics. You also find the material properties,
including their temperature dependence, in the Material Browser.
Results
In Figure 2, the hot wake behind the heat sink visible in the plot is a sign of the
convective cooling effects. The maximum temperature, reached at the heat sink base,
is slightly less than 376 K.
Figure 2: The surface plot shows the temperature field on the channel walls and the heat
sink surface, while the arrow plot shows the flow velocity field around the heat sink.
Model Library path: Heat_Transfer_Module/

Tutorial_Models,_Forced_and_Natural_Convection/heat_sink
3 |
HEAT SINK
Modeling Instructions
From the File menu, choose New.
NEW
1 In the New window, click the Model Wizard button.

MODEL WIZARD
1 In the Model Wizard window, click the 3D button.

2 In the Select physics tree, select Heat Transfer>Conjugate Heat Transfer>Laminar Flow
(nitf).
3 Click the Add button.
4 Click the Study button.
5 In the tree, select Preset Studies>Stationary.
6 Click the Done button.
GEOMETRY 1
1 On the Geometry toolbar, click Insert Sequence.

2 Browse to the models Model Library folder and double-click the file
heat_sink_geom_sequence.mph.
Import 1
The geometry sequence contains an imported binary file. Follow the steps below to
make sure that the import path is correct.
1 In the Model Builder window, under Component 1>Geometry 1 click Import 1.
2 In the Import settings window, locate the Import section.
3 Click the Browse button.
heat_sink.mphbin.
5 Click the Import button.

6 Click the Build All Objects button.
7 Click the Go to Default 3D View button on the Graphics toolbar.
To facilitate face selection in the next steps, use the wireframe rendering option
4 |
HEAT SINK
8 Click the Wireframe Rendering button on the Graphics toolbar.
MATERIALS
On the Home toolbar, click Add Material.

ADD MATERIAL
1 Go to the Add Material window.

2 In the tree, select Built-In>Air.
3 In the Add material window, click Add to Component.
ADD MATERIAL

2 In the tree, select Built-In>Aluminum 3003-H18.
5 |
HEAT SINK
MATERIALS
Aluminum 3003-H18
1 In the Model Builder window, under Component 1>Materials click Aluminum
3003-H18.
2 Select Domain 2 only.
ADD MATERIAL

2 In the tree, select Built-In>Silica glass.
MATERIALS
Silica glass
1 In the Model Builder window, under Component 1>Materials click Silica glass.
Material 4
1 In the Model Builder window, right-click Materials and choose New Material.
2 Right-click Material 4 and choose Rename.
3 Go to the Rename Material dialog box and type Thermal Grease in the New name
edit field.
4 Click OK.
5 In the Material settings window, locate the Geometric Entity Selection section.
6 From the Geometric entity level list, choose Boundary.
7 Select Boundary 34 only.
8 Click to expand the Material properties section. Locate the Material Properties
section. In the Material properties tree, select Basic Properties>Thermal Conductivity.

9 Click Add to Material.
10 Locate the Material Contents section. In the table, enter the following settings:
6 |
Property
Name
Value
Unit
Property group
Thermal conductivity
2[W/m/K]
W/(mK)
Basic
HEAT SINK
GLOBAL DEFINITIONS
Parameters
1 In the Model Builder window, expand the Global Definitions node, then click
Parameters.
2 In the Parameters settings window, locate the Parameters section.
3 In the table, enter the following settings:
Name
Expression
Value
Description
U0
5[cm/s]
0.05000 m/s
Mean inlet velocity
T0
20[degC]
293.2 K
Inlet temperature
P_tot
1[W]
1.000 W
Total power dissipated

by the electronic
package
Now define the physical properties of the model. Start with the fluid domain.
C O N J U G A T E H E A T TR A N S F E R
Fluid 1
1 In the Model Builder window, under Component 1>Conjugate Heat Transfer click Fluid
1.
Next use the Ptot parameter to define the total heat source in the electronic package.
Heat Source 1
1 On the Physics toolbar, click Domains and choose Heat Source.
3 In the Heat Source settings window, locate the Heat Source section.
4 Click the Total power button.
5 In the Ptot edit field, type P_tot.
Wall, no slip, is the default boundary condition for the fluid. Define the inlet and outlet
conditions as described below.
Inlet 1
1 On the Physics toolbar, click Boundaries and choose Inlet.
3 In the Inlet settings window, locate the Boundary Condition section.
7 |
HEAT SINK
4 From the Boundary condition list, choose Laminar inflow.

5 Locate the Laminar Inflow section. In the Uav edit field, type U0.
Thermal insulation is the default boundary condition for the temperature. Define the
inlet temperature and the outlet condition as described below.
Outlet 1
1 On the Physics toolbar, click Boundaries and choose Outlet.
2 Click the Zoom Extents button on the Graphics toolbar.
Temperature 1
1 On the Physics toolbar, click Boundaries and choose Temperature.
3 In the Temperature settings window, locate the Temperature section.
4 In the T0 edit field, type T0.
Outflow 1
1 On the Physics toolbar, click Boundaries and choose Outflow.
Thin Thermally Resistive Layer 1

1 On the Physics toolbar, click Boundaries and choose Thin Thermally Resistive Layer.
3 In the Thin Thermally Resistive Layer settings window, locate the Thin Thermally
Resistive Layer section.
4 In the ds edit field, type 50[um].
MESH 1
1 In the Model Builder window, under Component 1 click Mesh 1.

2 In the Mesh settings window, locate the Mesh Settings section.
3 From the Element size list, choose Extra coarse.
4 Click the Build All button.
To get a better view of the mesh, suppress some of the boundaries.

5 Click the Select and Hide button on the Graphics toolbar.
6 Click the Select Boundaries button on the Graphics toolbar.
8 |
HEAT SINK
7 Select Boundaries 1, 2, and 4 only.
The finished mesh should look like that in the figure below.
To improve the accuracy in the numerical results, this mesh can be refined by
choosing another predefined element size. However, doing so requires more
computational time and memory.
STUDY 1
On the Home toolbar, click Compute.

RESULTS
Velocity (nitf)
Two default plots are generated automatically. The first one shows the velocity
magnitude on five parallel slices. The second one shows the temperature on the wall
boundaries. Add an arrow plot to visualize the velocity field.
Temperature (nitf)
1 In the Model Builder window, under Results right-click Temperature (nitf) and choose
Arrow Volume.
You notice that the velocity field is represented by default.
9 |
HEAT SINK
2 In the Arrow Volume settings window, locate the Data section.

3 From the Data set list, choose Solution 1.
4 Locate the Arrow Positioning section. In the x grid points subsection, in the Points
edit field, type 40.

5 In the y grid points subsection, in the Points edit field, type 20.
6 From the Entry method list, choose Coordinates.
7 In the Coordinates edit field, type 5[mm].
8 Right-click Results>Temperature (nitf)>Arrow Volume 1 and choose Color Expression.
9 In the Color Expression settings window, click Replace Expression in the upper-right
corner of the Expression section. From the menu, choose Conjugate Heat Transfer
(Laminar Flow)>Velocity magnitude (nitf.U).
10 On the 3D plot group toolbar, click Plot.
Derived Values
1 On the Results toolbar, click Global Evaluation.
2 In the Global Evaluation settings window, click Replace Expression in the upper-right
(Heat Transfer in Solids)>Global>Net powers>Total net energy power (nitf.ntefluxInt).
3 Right-click Results>Derived Values>Global Evaluation 1 and choose Rename.
4 In the Rename Global Evaluation dialog box, type Net Energy Power in the New
name edit field.
5 Click OK.
6 Click the Evaluate button.
RESULTS
Derived Values
(Heat Transfer in Solids)>Global>Heat source powers>Total heat source (nitf.QInt).
3 Right-click Results>Derived Values>Global Evaluation 2 and choose Rename.
4 In the Rename Global Evaluation dialog box, type Heat Source in the New name edit
field.
5 Click OK.
10 |
HEAT SINK
The net power from the total energy flux and the total heat source should be close to
1 W.
11 |
HEAT SINK
COMSOL MULTIPHYSICS
Droplet Breakup in a T-Junction
Droplet Breakup in a T-Junction
Preview
Level Set and Phase Field
- Base fluid : fluid1, Setting fluid : fluid2
Wetted wall
- Level set : Dynamic contact angle(static contact angle + slip length)
- Phase field : Static contact angle
- Moving wetted wall : Only phase field.
Preview
Fluid 1 Fluid 2 Initial Values, Initial interface
Model
Inlet 2
Fluid 2
Inlet 1
Fluid 1
Outlet
Physics
Laminar Two-Phase Flow, Level Set
Momentum transport equation
Level set equation

Density and viscosity
Effective droplet diameter
Fluid 2
Symmetry
Fluid 1
Inlet1
Inlet2
0.4e-6/3600*step1(t[1/s])[m^3/s]
0.2e-6/3600*step1(t[1/s])[m^3/s]
Outlet
Pressure, no viscous stress
Wall condition
Wetted wall
Surface tension coefficient
5e-3 [N/m]
Result
D r o ple t Br e a k up i n a T- Ju n ct i on
Introduction
Emulsions consist of small liquid droplets immersed in another liquid, typically oil in
water or water in oil. Emulsions find wide application in the production of food,
cosmetics, and pharmaceutical products. The properties and quality of an emulsion
typically depend on the size and the distribution of the droplets. This model studies in
detail how to create uniform droplets in a microchannel T-junction.
Setting up the model you can make use of the Laminar Two-Phase Flow, Level Set
interface. The model uses the predefined wetted wall boundary condition at the solid
walls, with a contact angle of 135. From the results, you can determine the size of the
created droplets and the rate with which they are produced.
Model Definition
Figure 1 shows the geometry of the T-shaped microchannel with a rectangular cross
section. For the separated fluid elements to correspond to droplets, the geometry is
modeled in 3D. Due to symmetry, it is sufficient to model only half of the junction
geometry. The modeling domain is shown in Figure 1. The fluid to be dispersed into
1 |
D R O P L E T B R E A K U P I N A T- J U N C T I O N
small droplets, Fluid 2, enters through the vertical channel. The other fluid, Fluid 1,
flows from the right to left through the horizontal channel.
Inlet, fluid 2
Initial fluid interface
Inlet,
fluid 1
Outlet
Figure 1: The modeling domain of the T-junction.

The problem described is straight forward to set up with the Laminar Two-Phase Flow,
Level Set interface. The interface sets up a momentum transport equation, a continuity
equation, and a level set equation for the level set variable. The fluid interface is defined
by the 0.5 contour of the level set function.
The interface uses the following equations:
u
T
+ ( u )u = [ p I + ( u + ( u ) ) ] + F st
t
u = 0
------ + u = ( 1 ) --------+
In the equations above, denotes density (kg/m3), u velocity (m/s), t time (s),
dynamic viscosity (Pas), p pressure (Pa), and Fst the surface tension force (N/m3).
Furthermore, is the level set function, and and are numerical stabilization
parameters. The density and viscosity are calculated from
2 |
= 1 + ( 2 1 )
= 1 + ( 2 1 )
where 1, 2, 1, and 2 are the densities and viscosities of Fluid 1 and Fluid 2.
PHYSICAL PARAMETERS
The two liquids have the following physical properties:

QUANTITY
VALUE, FLUID 1
VALUE, FLUID 2
Density (kg/m3)
1000
1000
Dynamic viscosity (Pas)
0.00195
0.00671
The surface tension coefficient is 5103 N/m.

BOUNDARY CONDITIONS
At both inlets, Laminar inflow conditions with prescribed volume flows are used. At
the outflow boundary, the Pressure, no viscous stress condition is set. The Wetted wall
boundary condition applies to all solid boundaries with the contact angle specified as
135 and a slip length equal to the mesh size parameter, h. The contact angle is the
angle between the fluid interface and the solid wall at points where the fluid interface
attaches to the wall. The slip length is the distance to the position outside the wall
where the extrapolated tangential velocity component is zero (see Figure 2).
Fluid 1
Wall
Wall
Fluid 2
Figure 2: The contact angle, , and the slip length, .
3 |
Results and Discussion

Figure 3 shows the fluid interface (the level set function = 0.5 ) and velocity
streamlines at various times. The first droplet is formed after approximately 0.03 s.
Figure 3: Velocity streamlines, velocity on the symmetry plane, and the phase boundary at
t = 0.02 s, 0.04 s, 0.06 s, and 0.08 s.
You can calculate the effective diameter, deffthat is, the diameter of a spherical
droplet with the same volume as the formed dropletusing the following expression:
3
d eff = 2 3 -----4
( > 0.5 ) d
(1)
Here, represents the leftmost part of the horizontal channel, where x < 0.2 mm. In
this case, the results show that deff is about 0.12 mm. The results are in fair agreement
with those presented in Ref. 1.
Reference
1. S. van der Graaf, et al., Lattice Boltzmann Simulations of Droplet Formation in a
T-Shaped Microchannel, Langmuir, vol. 22, pp. 41444152, 2006.
4 |
Model Library path: CFD_Module/Multiphase_Benchmarks/droplet_breakup
From the File menu, choose New.
NEW

MODEL WIZARD

2 In the Select physics tree, select Fluid Flow>Multiphase Flow>Two-Phase Flow, Level
Set>Laminar Two-Phase Flow, Level Set (tpf).
5 In the tree, select Preset Studies>Transient with Initialization.
GEOMETRY 1
1 In the Model Builder window, under Component 1 click Geometry 1.

2 In the Geometry settings window, locate the Units section.
3 From the Length unit list, choose mm.
Work Plane 1
1 On the Geometry toolbar, click Work Plane.
2 In the Work Plane settings window, locate the Plane Definition section.
3 From the Plane list, choose xz-plane.
Rectangle 1
1 In the Model Builder window, under Component 1>Geometry 1>Work Plane 1
right-click Plane Geometry and choose Rectangle.

2 In the Rectangle settings window, locate the Size section.
3 In the Width edit field, type 0.1.
4 In the Height edit field, type 0.4.
5 |
5 Locate the Position section. In the yw edit field, type 0.1.
Rectangle 2
1 Right-click Plane Geometry and choose Rectangle.
3 In the Width edit field, type 1.
5 Locate the Position section. In the xw edit field, type -0.7.
Plane Geometry
1 On the Home toolbar, click Build All.
Polygon 1
1 Right-click Plane Geometry and choose Polygon.
2 In the Polygon settings window, locate the Object Type section.
3 From the Type list, choose Open curve.
4 Locate the Coordinates section. In the xw edit field, type 0 0.1.
5 In the yw edit field, type 0.2 0.2.
6 Click the Build Selected button.
Polygon 2
1 Right-click Plane Geometry and choose Polygon.
2 In the Polygon settings window, locate the Coordinates section.
3 In the xw edit field, type 0.1 0.1.
4 In the yw edit field, type 0 0.1.
Extrude 1
1 On the Geometry toolbar, click Extrude.
2 In the Extrude settings window, locate the Distances from Plane section.
Distances (mm)
0.05
6 |
Form Union
1 In the Model Builder window, under Component 1 >Geometry 1 right-click Form Union
and choose Build Selected. The model should look like in Figure 1.
MATERIALS
Material 1
1 In the Model Builder window, under Component 1 right-click Materials and choose
New Material.
3 In the Rename Material dialog box, type Fluid 1 in the New name edit field.
4 Click OK.
5 In the Material settings window, locate the Material Contents section.
Property
Name
Value
Unit
Property group
Density
rho
1e3[kg/m^3]
kg/m
Basic
Dynamic viscosity
mu
1.95e-3[Pa*s]
Pas
Basic
Material 2
3 In the Rename Material dialog box, type Fluid 2 in the New name edit field.
4 Click OK.
5 In the Material settings window, click to expand the Material properties section.
6 Locate the Material Properties section. In the Material properties tree, select Basic
Properties>Density.
8 In the Material properties tree, select Basic Properties>Dynamic Viscosity.
7 |
10 Locate the Material Contents section. In the table, enter the following settings:
Property
Name
Value
Unit
Property group
Density
rho
1e3[kg/m^3]
kg/m
Basic
Dynamic viscosity
mu
6.71e-3[Pa*s]
Pas
Basic
DEFINITIONS
Step 1
1 On the Home toolbar, click Functions and choose Global>Step.
2 In the Step settings window, locate the Parameters section.
3 In the Location edit field, type 1e-3.
4 Click to expand the Smoothing section. In the Size of transition zone edit field, type
2e-3.
Add an integration operator that you will use to calculate the effective droplet diameter
according to Equation 1 in the Model Definition section.
Integration 1
1 On the Definitions toolbar, click Component Couplings and choose Integration.
2 In the Integration settings window, locate the Source Selection section.
3 From the Selection list, choose All domains.
Variables 1
1 In the Model Builder window, right-click Definitions and choose Variables.
2 In the Variables settings window, locate the Variables section.
8 |
Name
Expression
Unit
Description
V1
0.4e-6/
3600*step1(t[1/
s])[m^3/s]
m/s
Volume flow, inlet 1
V2
0.2e-6/
3600*step1(t[1/
s])[m^3/s]
m/s
Volume flow, inlet 2
d_eff
2*(intop1((phils>0.
5)*(x<-0.2[mm]))*3/
(4*pi))^(1/3)
Effective droplet
diameter
L A M I N A R TW O - P H A S E F L O W, L E V E L S E T
The mesh can be controlled very well in this model, which makes it possible to use a
lower element order without reducing the accuracy.
1 In the Model Builder windows toolbar, click the Show button and select Discretization
in the menu.
2 In the Model Builder window, expand the Component 1>Laminar Two-Phase Flow,
Level Set node, then click Laminar Two-Phase Flow, Level Set.
3 In the Laminar Two-Phase Flow, Level Set settings window, click to expand the
Discretization section.
4 Find the Value types when using splitting of complex variables subsection. From the
Discretization of fluids list, choose P1 + P1.
Fluid Properties 1
1 In the Model Builder window, under Component 1>Laminar Two-Phase Flow, Level Set
click Fluid Properties 1.

2 In the Fluid Properties settings window, locate the Fluid 1 Properties section.
3 From the Fluid 1 list, choose Fluid 1.
4 Locate the Fluid 2 Properties section. From the Fluid 2 list, choose Fluid 2.
5 Locate the Surface Tension section. From the Surface tension coefficient list, choose
User defined. In the edit field, type 5e-3[N/m].
6 Locate the Level Set Parameters section. In the edit field, type 0.05[m/s].
7 In the ls edit field, type 5e-6[m].
Wall 1
Because this is the default boundary condition node, you cannot modify the selection
explicitly. Instead, you override the default condition where it is not applicable by
adding other boundary conditions.
click Wall 1.
2 In the Wall settings window, locate the Boundary Condition section.
3 From the Boundary condition list, choose Wetted wall.
4 In the w edit field, type 3*pi/4[rad].
5 In the edit field, type 5e-6[m].
9 |
Initial Interface 1
click Initial Interface 1.

Initial Values 2
1 On the Physics toolbar, click Domains and choose Initial Values.
3 In the Initial Values settings window, locate the Initial Values section.
4 Click the Fluid 2 button.
For Domains 1 and 2, the default initial value settings apply.
Inlet 1
5 Locate the Laminar Inflow section. Click the Flow rate button.
6 In the V0 edit field, type V1.
7 In the Lentr edit field, type 0.01[m].
Inlet 2
4 In the Vf edit field, type 1.
6 Locate the Laminar Inflow section. Click the Flow rate button.
8 In the Lentr edit field, type 0.01[m].
Outlet 1
10 |
Symmetry 1
1 On the Physics toolbar, click Boundaries and choose Symmetry.
2 Select Boundaries 5, 13, 14, and 21 only.
MESH 1 {MESH1}
Mapped 1
1 In the Model Builder window, under Component 1 right-click Mesh 1 and choose More
Operations>Mapped.
Distribution 1
1 Right-click Component 1>Mesh 1>Mapped 1 and choose Distribution.
2 Select Edge 3 only.
3 In the Distribution settings window, locate the Distribution section.
4 In the Number of elements edit field, type 160.
Distribution 2
1 Right-click Mapped 1 and choose Distribution.
2 Select Edges 1 and 9 only.
Distribution 3
4 From the Distribution properties list, choose Predefined distribution type.
6 In the Element ratio edit field, type 4.
Distribution 4
4 From the Distribution properties list, choose Predefined distribution type.
11 |
6 In the Element ratio edit field, type 3.

7 Select the Reverse direction check box.
Mapped 1
Right-click Mapped 1 and choose Build Selected.
Swept 1
1 Right-click Mesh 1 and choose Swept.
2 In the Swept settings window, click to expand the Source faces section.
3 Locate the Source Faces section. Select the Active toggle button.
4 Select Boundaries 2, 7, and 10 only.
Distribution 1
1 Right-click Component 1>Mesh 1>Swept 1 and choose Distribution.
12 |
STUDY 1
Step 2: Time Dependent

1 In the Model Builder window, expand the Study 1 node, then click Step 2: Time
Dependent.
2 In the Time Dependent settings window, locate the Study Settings section.
3 In the Times edit field, type range(0,5e-3,0.08).
4 Click to expand the Results while solving section. Locate the Results While Solving
section. Select the Plot check box.

5 From the Plot group list, choose Default.
This choice means that the Graphics window will show a surface plot of the volume
fraction of Fluid 1 while solving, and this plot will be updated at each 5 ms output
time step.
Manually tune the solver sequence for optimal performance and accuracy.
Solver 1
1 On the Study toolbar, click Show Default Solver.
2 In the Model Builder window, expand the Solver 1 node, then click Time-Dependent
Solver 1.
3 In the Time-Dependent Solver settings window, click to expand the Time stepping
section.
4 Locate the Time Stepping section. From the Method list, choose Generalized alpha.
5 Select the Time step increase delay check box.
6 In the associated edit field, type 3.
7 In the Amplification for high frequency edit field, type 0.3.
8 From the Predictor list, choose Constant.
9 In the Model Builder window, expand the Study 1>Solver Configurations>Solver
1>Time-Dependent Solver 1 node.
10 Right-click Study 1>Solver Configurations>Solver 1>Time-Dependent Solver 1 and
choose Iterative.
11 In the Iterative settings window, locate the Error section.
12 In the Factor in error estimate edit field, type 20.
13 In the Maximum number of iterations edit field, type 200.
14 Right-click Study 1>Solver Configurations>Solver 1>Time-Dependent Solver
1>Iterative 1 and choose Multigrid.
13 |

1>Time-Dependent Solver 1>Iterative 1>Multigrid 1 node.
16 Right-click Presmoother and choose SCGS.
17 In the SCGS settings window, locate the Main section.
18 Select the Vanka check box.
19 Under Variables, click Add.
20 Go to the Add dialog box.
21 In the Variables list, choose comp1.tpf.Pinlinl1 and comp1.tpf.Pinlinl2.
22 Click the OK button.
1>Time-Dependent Solver 1>Iterative 1>Multigrid 1>Postsmoother node.
24 Right-click Study 1>Solver Configurations>Solver 1>Time-Dependent Solver
1>Iterative 1>Multigrid 1>Postsmoother and choose SCGS.
25 In the SCGS settings window, locate the Main section.
26 Select the Vanka check box.
27 Under Variables, click Add.
28 Go to the Add dialog box.
29 In the Variables list, choose comp1.tpf.Pinlinl1 and comp1.tpf.Pinlinl2.
1>Time-Dependent Solver 1>Iterative 1>Multigrid 1>Coarse Solver node, then click
Direct.
32 In the Direct settings window, locate the General section.
33 From the Solver list, choose PARDISO.
34 In the Model Builder window, collapse the Study 1>Solver Configurations>Solver
STUDY 1
Solver 1
1 In the Model Builder window, collapse the Study 1>Solver Configurations>Solver
2 In the Model Builder window, collapse the Solver 1 node.
3 On the Home toolbar, click Compute.
14 |
RESULTS
The first default plot group shows the volume fraction of fluid 1 as slice plot, and the
second plot group shows a slice plot of the velocity combined with a contour plot of
the volume fraction of fluid 1. Follow these steps to reproduce the series of velocity
field plots shown in Figure 3.
3D Plot Group 3
1 On the Home toolbar, click Add Plot Group and choose 3D Plot Group.
2 In the Model Builder window, under Results right-click 3D Plot Group 3 and choose
Slice.
3 In the Slice settings window, click Replace Expression in the upper-right corner of the
Expression section. From the menu, choose Laminar Two-Phase Flow, Level
Set>Velocity magnitude (tpf.U).
4 Locate the Plane Data section. From the Plane list, choose zx-planes.
7 In the Model Builder window, right-click 3D Plot Group 3 and choose Isosurface.
8 In the Isosurface settings window, locate the Levels section.
9 From the Entry method list, choose Levels.
10 In the Levels edit field, type 0.5.
11 Locate the Coloring and Style section. From the Coloring list, choose Uniform.
12 From the Color list, choose Green.
13 Right-click 3D Plot Group 3 and choose Streamline.
14 In the Streamline settings window, locate the Streamline Positioning section.
15 From the Positioning list, choose Uniform density.
16 In the Separating distance edit field, type 0.05.
17 Locate the Coloring and Style section. From the Line type list, choose Tube.
18 Select the Radius scale factor check box.
19 In the associated edit field, type 2e-3.
20 From the Color list, choose Yellow.
21 In the Model Builder window, click 3D Plot Group 3.
22 In the 3D Plot Group settings window, locate the Data section.
23 From the Time (s) list, choose 0.02.
15 |

25 Click the Go to Default 3D View button on the Graphics toolbar.
Compare the resulting plot with the upper-left plot in Figure 3.

26 To reproduce the remaining three plots, plot the solution for the time values 0.04,
0.06, and 0.08 s.
Next, evaluate the effective droplet diameter computed according to Equation 1.
Derived Values
corner of the Expression section. From the menu, choose Definitions>Effective

droplet diameter (d_eff).
TABLE
The result, roughly 0.12 mm, is displayed in the table in the Table window.
Finally, generate a movie of the moving fluid interface and the velocity streamlines.
RESULTS
3D Plot Group 3
Player. COMSOL Multiphysics generates the movie and then plays it.
2 To replay the movie, click the Play button on the Graphics toolbar.
If you want to export a movie in GIF, Flash, or AVI format, right-click Export and
create an Animation feature.
16 |
COMSOL MULTIPHYSICS
Cooling of an Injection Mold
Preview
Simulations of fluid flow, heat and mass transfer, hydraulic transients, and acoustics in the
1D geometry.
Fluid Model Newtonian, Power law, Bingham
Pipe shape Round, Square, Rectangle, User defined(hydraulic diameter)
Inlet / Outlet Mass flow rate, Velocity, Volumetric flow rate, SCCM
Preview
Friction model
- Newtonian fluids
Churchill : Full range of Re (laminar, transition and turbulent) and e/d
Stokes : Laminar regime (Re < 2000)
Wood : 4*103 < Re < 1*107 and 1*10-5 < e/d < 4*10-2
Haaland : Commonly used for oil pipelines and wells, Re (4*103 < Re < 1*108)
Colebrook : Very low relative roughness e/d, Simple Haaland model
Von Karman : Very large relative roughness e/d, Simple Haaland model
Swamee-Jain : Alternative method of Haaland model
10-6 < e/d < 10-2 and for Re (5*103 < Re < 108)
- Non-Newtonian fluids
Irvine(Power law) : Full range of Re (laminar, transition and turbulent) and e/d
Stokes(Power law) : Laminar regime (Re < 2000)
Darby(Bingham) : Full range of Re (laminar, transition and turbulent) and e/d
Preview
Loss Coefficients
Preview
Wall Heat Transfer
Model
Steel AISI 4340
Polyurethane
44.5 [W/(m*K)]
0.32 [W/(m*K)]
Density
7850 [kg/]
1250 [kg/]
Heat capacity
475 [J/(kg*K)]
1540 [J/(kg*K)]
Physics
Pipe Flow + Heat Transfer in Pipes = Non-Isothermal Pipe Flow
+
Heat Transfer in Solid
Continuity and Momentum Equations
Churchill Model
Energy Equation
Pipe diameter : 1cm
Inlet
10 [Liter/min]
Outlet
1[atm]
Initial temperature of mold
473.15K
Surface roughness
Commercial steel(0.046 mm)
Result
Mold Material
Water flow rate Surface roughn average T after Line color

(l/min)
ess (mm)
10 min (K)
Steel
10
0.046
333
Blue
Steel
20
0.046
325
Green
Steel
10
0.46
328
Red
Aluminium
10
0.046
301
Magenta

Introduction
Cooling is an important process in the production of injection molded plastics. First
of all, the cooling time may well represent more than half of the production cycle time.
Second, a homogeneous cooling process is desired to avoid defects in the
manufactured parts. If plastic materials in the injection molding die are cooled down
uniformly and slowly, residual stresses can be avoided, and thereby the risk of warps
and cracks in the end product can be minimized.
As a consequence, the positioning and properties of the cooling channels become
important aspects when designing the mold.
The simulation of heat transfer in molds of relatively complex geometries requires a 3D
representation. Simulation of 3D flow and heat transfer inside the cooling channels are
computationally expensive. An efficient short-cut alternative is to model the flow and
heat transfer in the cooling channels with 1D pipe flow equations, and still model the
surrounding mold and product in 3D.
This example shows how you can use the Non-Isothermal Pipe Flow interface together
with the Heat Transfer in Solids interface to model a mold cooling process. The
equations describing the cooling channels are fully coupled to the heat transfer
equations of the mold and the polyurethane part.
Figure 1: The steering wheel of a car, made from polyurethane.
1 |
COOLING OF AN INJECTION MOLD
Model Definition
MODEL GEOMETRY AND PROCESS CONDITIONS
The polyurethane material used for a steering wheel is produced by several different
molds. The part considered in this model is the top half of the wheel grip, shown in
gray in Figure 2.
Figure 2: Polyurethane parts for a steering wheel. The top half of the grip is modeled in this
example.
2 |
The mold consists of a 50-by-50-by-15 cm steel block. Two cooling channels, 1 cm in

diameter, are machined into the block as illustrated in Figure 3.
Water inlets
Figure 3: Mold block and cooling channels.

The after injection of the polyurethane, the average temperature of the mold a the
plastic material is 473 K. Water at room temperature is used as cooling fluid and flows
through the channels at a rate of 10 liters/min. The model simulates a 10 min cooling
process.
For numerical stability reasons, the model is set up with an initial water temperature of
473 K, which is ramped down to 288 K during the first few seconds.
PIPE FLOW EQUATIONS
The momentum and mass conservation equations below describe the flow in the
cooling channels:
u
------- = p f D ---------- u u
t
2d h
(1)
A
----------- + ( Au ) = 0
t
(2)
3 |
Above, u is the cross section averaged fluid velocity (m/s) along the tangent of the
center line of a pipe. A (m2) is the cross section area of the pipe, (kg/m3) is the
density, and p (N/m2) is the pressure. For more information, refer to the section
Theory for the Pipe Flow Interface in the Pipe Flow Module Users Guide.
Expressions for the Darcy Friction Factor

The second term on the right hand side of Equation 2 accounts for pressure drop due
to viscous shear. The Pipe Flow physics uses the Churchill friction model (Ref. 1) to
calculate fD. It is valid for laminar flow, turbulent flow, and the transitional region in
between. The Churchill friction model is predefined in the Non-Isothermal Pipe Flow
interface and is given by:
-1.5
8 12
f D = 8 ------ + ( A + B )
Re
1 12
(3)
where
7 0.9
A = -2.457ln ------ + 0.27 ( e d )
Re
37530
B = ----------------
Re
4 |
16
16
(4)
(5)
As seen from the equations above, the friction factor depends on the surface roughness
divided by diameter of the pipe, e/d. Surface roughness values can be selected from a
list in the Pipe Properties feature or be entered as user-defined values.
Figure 4: The Friction model and Surface roughness settings are found in the Pipe
Properties feature.
In the Churchill equation, fD is also a function of the fluid properties, flow velocity and
geometry, through the Reynolds number:
ud
Re = ----------
(6)
The physical properties of water as function of temperature are directly available from
the softwares built-in material library.
H E A T TR A N S F E R E Q U A T I O N S
Cooling Channels
The energy equation for the cooling water inside the pipe is:
A
T
3
AC p ------- + AC p u T = Ak T + f D ---------- u + Q wall
2d h
t
(7)
where Cp (J/(kgK)) is the heat capacity at constant pressure, T is the cooling water
temperature (K), and k (W/(mK)) is the thermal conductivity. The second term on
the right hand side corresponds to heat dissipated due to internal friction in the fluid.
It is negligible for the short channels considered here. Qwall (W/m) is a source term
that accounts for the heat exchange with the surrounding mold block.
5 |
Mold Block and Polyurethane Part

Heat transfer in the solid steel mold block as well as the molded polyurethane part is
governed by conduction:
T 2
C p ---------- = k T 2
t
(8)
Above, T2 is the temperature in the solids. The source term Qwall comes into play for
the heat balance in Equation 8 through a line heat source where the pipe is situated.
This coupling is automatically done by the Wall Heat Transfer feature in the
Non-Isothermal Pipe Flow interface.
Heat Exchange
The heat exchange term Qwall (W/m) couple the two energy balances given by
Equation 7 and Equation 8:
The heat transfer through the pipe wall is given by
Q wall = hZ ( T ext T )
(9)
In Equation 9 Z (m) is the perimeter of the pipe, h (W/(m2K)) a heat transfer

coefficient and Text (K) the external temperature outside of the pipe. Qwall appears as
a source term in the pipe heat transfer equation.
The Wall heat transfer feature requires the external temperature and at least an internal
film resistance.
Text can be a constant, parameter, expression, or given by a temperature field
computed by another physics interface, typically a 3D Heat Transfer interface. h is
automatically calculated through film resistances and wall layers that are added as
subnodes. For details, refer to the section Theory for the Heat Transfer in Pipes
Interface in the Pipe Flow Module Users Guide.
In this model example, Text is given as the temperature field computed by a 3D heat
transfer interface, and automatic heat transfer coupling is done to the 3D physics side
as a line source. The temperature coupling between the pipe and the surrounding
domain is implemented as a line heat source in the 3D domain. The source strength is
proportional to the temperature difference between the pipe fluid and the surrounding
domain.
6 |
The Wall Heat Transfer feature is added to the Non-Isothermal Pipe Flow interface,
and the External temperature is set to the temperature of the Heat Transfer in solids
interface.
Figure 5: In the Wall Heat Transfer feature, set the External temperature to the
temperature field calculated by the Heat Transfer in Solids interface.
The heat transfer coefficient, h, depends on the physical properties of water and the
nature of the flow and is calculated from the Nusselt number:
k
h = Nu -----dh
(9-6)
where k is the thermal conductivity of the material, and Nu is the Nusselt number. dh
is the hydraulic diameter of the pipe.
COMSOL detects if the flow is laminar or turbulent. For the laminar flow regime, an
analytic solution is available that gives Nu = 3.66 for circular tubes (Ref. 2). For
turbulent flow inside channels of circular cross sections the following Nusselt
correlation is used (Ref. 3):
( f D 8 ) ( Re 1000 )Pr
Nu int = -----------------------------------------------------------------------------12
23
1 + 12.7 ( f D 8 ) ( Pr
1)
(10)
where Pr is the Prandtl number:

Cp
Pr = ----------k
(11)
Note that Equation 10 is a function of the friction factor, fD, and therefore that the
radial heat transfer will increase with the surface roughness of the channels.
Note: All the correlations discussed above are automatically used by the Wall Heat
Transfer feature in the Pipe Flow Module, and it detects if the flow is laminar or
turbulent for automatic selection of the correct correlation.
7 |

The steel mold and polyurethane part, initially at 473 K, are cooled for 10 minutes by
water at room temperature. Figures below show sample results when flow rate of the
cooling water is 10 liters/minute and the surface roughness of the channels is 46 m.
After two minutes of cooling, the hottest and coldest parts of the polyurethane part
differ by approximately 40 K (Figure 7).
Figure 7: Temperature distribution in the polyurethane part and the cooling channels
after 2 minutes of cooling.
8 |
Figure 8 shows the temperature distribution in the steel mold after 2 minutes. The
temperature footprint of the cooling channels is clearly visible.
Figure 8: Temperature distribution in the steel mold block after 2 minutes of cooling.
9 |
After 10 minutes of cooling, the temperature in the mold block is more uniform, with
a temperature at the center of approximately 333 K (Figure 9). Still, the faces with
cooling channel inlets and outlets are more than 20 K hotter.
Figure 9: Temperature distribution in the steel mold block after 10 minutes of cooling.
The blue line in Figure 10 shows the average temperature of the polyurethane part as
function of the cooling time. The temperature is 333 K after 10 minutes of cooling.
To evaluate the influence of factors affecting the cooling time, additional simulations
were run varying the flow rate of the cooling water, the surface roughness of the
cooling channels, and the mold material. The conditions are summarized in the table
below.
TABLE 1: COOLING CONDITIONS
10 |
MOLD
MATERIAL
WATER FLOW
RATE (L/MIN)
SURFACE
ROUGHNESS (MM)
AVERAGE T
AFTER 10 MIN (K)
LINE COLOR
Steel
10
0.046
333
Blue
Steel
20
0.046
325
Green
Steel
10
0.46
328
Red
Aluminium
10
0.046
301
Magenta
Figure 10: Average temperature of the polyurethane part as function of time and cooling
conditions.
Clearly, the thermal conductivity of the mold material is the most important factor in
this comparison, followed by flow rate and surface roughness of the cooling channels.
Assuming that 340 K is an acceptable temperature at the end of the production cycle,
it can be found that changing the mold material reduces the cooling time by 67%,
increasing the flow rate reduces the cooling time by 17%, and increasing surface
roughness reduces the cooling time by 11%.
References
1. S.W. Churchill, Friction factor equations span all fluid-flow regimes, Chem. Eng.,
vol. 84, no. 24, p.91, 1997.
2. F.P. Incropera, D.P. DeWitt. Fundamentals of Heat and Mass Transfer, 5th ed.,
John Wiley & Sons, pp. 486487, 2002.
3. V. Gnielinski, New Equation for Heat and Mass Transfer in Turbulent Pipe and
Channel Flow, Int. Chem. Eng. vol. 16, p. 359, 1976.
11 |
Model Library path: Pipe_Flow_Module/Heat_Transfer/mold_cooling
MODEL WIZARD
1 Go to the Model Wizard window.

2 Click Next.
3 In the Add physics tree, select Fluid Flow>Non-Isothermal Flow>Non-Isothermal Pipe
Flow (nipfl).
4 Click Add Selected.
5 In the Add physics tree, select Heat Transfer>Heat Transfer in Solids (ht).
6 Click Add Selected.
7 Click Next.
8 Find the Studies subsection. In the tree, select Preset Studies for Selected
Physics>Time Dependent.
9 Click Finish.
GLOBAL DEFINITIONS
Parameters
1 In the Model Builder window, right-click Global Definitions and choose Parameters.
Name
Expression
Description
T_init_mold
473.15[K]
Initial temperature, mold
T_coolant
288.15[K]
Steady-state inlet temperature, coolant
Step 1
Create a smooth step function to decrease the coolant temperature at the beginning of
the process.
1 Right-click Global Definitions and choose Functions>Step.
2 In the Step settings window, locate the Parameters section.
12 |
3 In the Location edit field, type 2.5.

4 In the From edit field, type 1.
5 In the To edit field, type 0.
6 Click to expand the Smoothing section. In the Size of transition zone edit field, type 5.
Optionally, you can inspect the shape of the step function:

7 Click the Plot button.
Variables 1
1 Right-click Global Definitions and choose Variables.
Name
Expression
Description
T_inlet
T_coolant+(T_init_moldT_coolant)*step1(t[1/s])
Ramped inlet temperature,

coolant
GEOMETRY 1
First, import the steering wheel part from a CAD design file.
Import 1
1 In the Model Builder window, under Model 1 right-click Geometry 1 and choose
Import.
13 |
2 In the Import settings window, locate the Import section.

3 Click the Browse button.
mold_cooling_top.mphbin.
5 Click the Import button.
Second, draw the mold and cooling channels. To simplify this step, insert a prepared
geometry sequence from file. After insertion you can study each geometry step in
the sequence.
6 In the Model Builder window, right-click Geometry 1 and choose Insert Sequence from
File.
mold_cooling_geom_sequence.mph.

10 Click the Transparency button on the Graphics toolbar.
DEFINITIONS
Create the selections to simplify the model specification.
Explicit 1
1 In the Model Builder window, under Model 1 right-click Definitions and choose
Selections>Explicit.
2 In the Explicit settings window, locate the Input Entities section.
3 From the Geometric entity level list, choose Edge.
Select one segment of the upper channel and one segment of the lower.
14 |
5 Select the Group by continuous tangent check box to select entire channels.
6 Right-click Model 1>Definitions>Explicit 1 and choose Rename.

7 Go to the Rename Explicit dialog box and type Cooling channels in the New name
edit field.
8 Click OK.
MATERIALS
The next step is to specify material properties for the model. Select water and steel from
the built-in materials database.
Material Browser
1 In the Model Builder window, under Model 1 right-click Materials and choose Open
Material Browser.
2 In the Material Browser settings window, In the tree, select Built-In>Water, liquid.
3 Click Add to Current Geometry.
Water, liquid
1 In the Model Builder window, under Model 1>Materials click Water, liquid.
2 In the Material settings window, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Edge.
4 From the Selection list, choose Cooling channels.
Material Browser
1 In the Model Builder window, right-click Materials and choose Open Material Browser.
2 In the Material Browser settings window, In the tree, select Built-In>Steel AISI 4340.
3 Click Add to Current Geometry.
15 |
Steel AISI 4340

1 In the Model Builder window, under Model 1>Materials click Steel AISI 4340.
Next, create a material with the properties of polyurethane.
Material 3
1 In the Model Builder window, right-click Materials and choose Material.
Property
Name
Value
0.32
Density
rho
1250
Heat capacity at constant pressure
Cp
1540
5 Right-click Model 1>Materials>Material 3 and choose Rename.

6 Go to the Rename Material dialog box and type Polyurethane in the New name edit
field.
7 Click OK.
NON-ISOTHERMAL PIPE FLOW
1 In the Non-Isothermal Pipe Flow settings window, locate the Edge Selection section.
Pipe Properties 1
1 In the Model Builder window, under Model 1>Non-Isothermal Pipe Flow click Pipe
Properties 1.
2 In the Pipe Properties settings window, locate the Pipe Shape section.
3 From the list, choose Round.
4 In the di edit field, type 1[cm].
5 Locate the Flow Resistance section. From the Surface roughness list, choose
Commercial steel (0.046 mm).
Temperature 1
1 In the Model Builder window, under Model 1>Non-Isothermal Pipe Flow click
Temperature 1.
16 |
2 In the Temperature settings window, locate the Temperature section.

3 In the Tin edit field, type T_inlet.
Inlet 1
1 In the Model Builder window, right-click Non-Isothermal Pipe Flow and choose the
point condition Pipe Flow>Inlet.

2 Select Points 3 and 4 only.
3 In the Inlet settings window, locate the Inlet Specification section.
4 From the Specification list, choose Volumetric flow rate.
5 In the qv,0 edit field, type 10[dm^3/min].
Heat Outflow 1
1 Right-click Non-Isothermal Pipe Flow and choose the point condition Heat Transfer
in Pipes>Heat Outflow.
2 Select Points 269 and 270 only.
Wall Heat Transfer 1

1 Right-click Non-Isothermal Pipe Flow and choose the edge condition Heat Transfer in
Pipes>Wall Heat Transfer.
2 In the Wall Heat Transfer settings window, locate the Edge Selection section.
4 Locate the Heat Transfer Model section. From the Text list, choose Temperature (ht).
5 Right-click Model 1>Non-Isothermal Pipe Flow>Wall Heat Transfer 1 and choose
Internal Film Resistance.
Initial Values 1
1 In the Model Builder window, under Model 1>Non-Isothermal Pipe Flow click Initial
Values 1.
3 In the u edit field, type 0.1.
4 In the T edit field, type T_init_mold.
H E A T TR A N S F E R I N S O L I D S
1 In the Model Builder window, expand the Model 1>Heat Transfer in Solids node, then
click Initial Values 1.

3 In the T2 edit field, type T_init_mold.
17 |
Heat Flux 1
1 In the Model Builder window, right-click Heat Transfer in Solids and choose Heat Flux.
2 In the Heat Flux settings window, locate the Boundary Selection section.
3 From the Selection list, choose All boundaries.
4 Locate the Heat Flux section. Click the Inward heat flux button.
5 In the h edit field, type 2.
MESH 1
Edge 1
1 In the Model Builder window, under Model 1 right-click Mesh 1 and choose More
Operations>Edge.
2 In the Edge settings window, locate the Edge Selection section.
Size 1
1 Right-click Model 1>Mesh 1>Edge 1 and choose Size.
2 In the Size settings window, locate the Element Size section.
3 From the Predefined list, choose Extra fine.
Free Tetrahedral 1
In the Model Builder window, right-click Mesh 1 and choose Free Tetrahedral.
Size 1
1 In the Model Builder window, under Model 1>Mesh 1 right-click Free Tetrahedral 1
and choose Size.

2 In the Size settings window, locate the Geometric Entity Selection section.
3 From the Geometric entity level list, choose Domain.
5 Locate the Element Size section. From the Predefined list, choose Fine.
STUDY 1

1 In the Model Builder window, under Study 1 click Step 1: Time Dependent.
18 |
3 In the Times edit field, type range(0,30,600).

4 In the Model Builder window, right-click Study 1 and choose Compute.
RESULTS
Data Sets
1 In the Model Builder window, under Results right-click Data Sets and choose Solution.
2 Right-click Results>Data Sets>Solution 2 and choose Add Selection.
3 In the Selection settings window, locate the Geometric Entity Selection section.
6 In the Model Builder window, right-click Data Sets and choose Solution.
7 Right-click Results>Data Sets>Solution 3 and choose Add Selection.
10 Select Boundaries 3 and 5 only.
Temperature (nipfl)
1 In the Model Builder window, expand the Results>Temperature (nipfl) node, then
click Line 1.1.

2 In the Line settings window, locate the Coloring and Style section.
5 Clear the Color legend check box.
6 Locate the Data section. From the Data set list, choose Solution 1.
7 From the Time list, choose 120.
8 In the Model Builder window, right-click Temperature (nipfl) and choose Surface.
9 In the Surface settings window, locate the Data section.
Temperature (ht)
1 In the Model Builder window, under Results click Temperature (ht).
19 |

5 Click the Transparency button on the Graphics toolbar.
6 In the Model Builder window, expand the Temperature (ht) node, then click Surface.
7 In the Surface settings window, locate the Coloring and Style section.
8 From the Color table list, choose Rainbow.
3D Plot Group 6
1 In the Model Builder window, right-click Results and choose 3D Plot Group.
2 Right-click 3D Plot Group 6 and choose Surface.
5 In the Model Builder window, right-click 3D Plot Group 6 and choose Slice.
6 In the Slice settings window, locate the Plane Data section.
7 In the Planes edit field, type 4.
8 Click to expand the Inherit Style section. From the Plot list, choose Surface 1.
9 Right-click 3D Plot Group 6 and choose Surface.
13 From the Color list, choose Gray.
14 Right-click 3D Plot Group 6 and choose Line.
15 In the Line settings window, click Replace Expression in the upper-right corner of the
Expression section. From the menu, choose Non-Isothermal Pipe Flow (Heat Transfer
in Pipes)>Temperature (T).
16 Locate the Coloring and Style section. From the Line type list, choose Tube.
17 In the Tube radius expression edit field, type 0.5*nipfl.dh.
19 From the Coloring list, choose Uniform.
20 From the Color list, choose Blue.
20 |
Derived Values
1 In the Model Builder window, under Results right-click Derived Values and choose
Average>Volume Average.
2 In the Volume Average settings window, locate the Selection section.
3 Click Paste Selection.
4 Go to the Paste Selection dialog box.
5 In the Selection edit field, type 2.
8 In the Table window, click Table Graph.
21 |
COMSOL MULTIPHYSICS
Electroosmotic Micromixer
Electroosmotic Micromixer
Preview
Particle release(Inlet, Release) Mesh based (refine^dimension)
Refinement factor = 1
Refinement factor = 3
Preview
Particle release(Inlet, Release) Density
The resulting distribution will look a bit random, and it will depend on
the order in which the mesh elements are numbered.
Expression = 1
Expression = x+y2
Preview
Particle release Grid(Release of grid), uniform density(inlet)
Release uniformly from 0.3 to 0.7
Uniform release on a boundary
Preview
Bounce
- This option specularly reflects from the wall such that the particle momentum is conserved.
- This option is not available for Massless particle tracing
- This option is typically used when tracing microscopic particles in a fluid.
Freeze
- This option (default) fixes the particle position and velocity at the instant a wall is struck.
- This is useful to recover the velocity and energy distribution function of particles when
they strike the wall
- Used to compute the ion energy distribution function in plasma models
Stick
- This option fixes the particle position at the instant the wall is struck.
- This can be used if the velocity or energy of the particles striking a wall is not of interest.
Preview
Disappear
- This option means that the particle is not displayed once it has made contact with the wall.
- This option should be used if display of the particle location after contact with the wall is
not of interest.
Diffuse reflection
- Particles bounce off surfaces according to Knudsens cosine law
General reflection
- Specify an arbitrary expression for the post collision particle velocity

- In the example to the right particles will be specularly reflected off a wall with half of their
incident velocity
- This option gives complete freedom over
Model
Mixing
Inlet
Electroosmotic velocity
Outlet
Property
Density
Dynamic viscosity
Name
rho
mu
Electric conductivi sigma

ty
Relative permittivi epsilonr
ty
Value
1e3[kg/m^3]
1e-3[Pa*s]
0.11845[S/m]
80.2
Physics
Electric Currents + Laminar Flow + Transport of Diluted Species
Navier-stokes equation
(Compressible flow)
Ohms law
Convection-diffusion equation
1 [mol/]
0 [mol/]
Result
Inlet
0.1 [mm/s]
Outlet
Normal stress is zero
Wall condition
Electroosmotic velcity
Electroosmotic Micromixer 1
Introduction
Microlaboratories for biochemical applications often require rapid mixing of different
fluid streams. At the microscale, flow is usually highly ordered laminar flow, and the
lack of turbulence makes diffusion the primary mechanism for mixing. While
diffusional mixing of small molecules (and therefore of rapidly diffusing species) can
occur in a matter of seconds over distances of tens of micrometers, mixing of larger
molecules such as peptides, proteins, and high molecular-weight nucleic acids can
require equilibration times from minutes to hours over comparable distances. Such
delays are impractically long for many chemical analyses. These problems have led to
an intense search for more efficient mixers for microfluidic systems.
Most microscale mixing devices are either passive mixers that use geometrical stirring,
or active mixers that use moving parts or external forces, such as pressure or electric
field.
In a passive mixer, one way of increasing the mixing is by shredding two or several
fluids into very thin alternating layers, which decreases the average diffusion length for
the molecules between the different fluids. However, these mixers often require very
long mixing channels because the different fluids often run in parallel. Another way of
improving mixing efficiency is to use active mixers with moving parts that stir the
fluids. At the microscale level moving parts in an active mixer are very fragile. One
alternative is to use electroosmotic effects to achieve a mixing effect that is
perpendicular to the main direction of the flow.
This model takes advantage of electroosmosis to mix fluids. The system applies a
time-dependent electric field, and the resulting electroosmosis perturbs the parallel
streamlines in the otherwise highly ordered laminar flow.
Model Definition
This example of a rather simple micromixer geometry (Figure 1) combines two fluids
entering from different inlets into a single 10 m wide channel. The fluids then enter
a ring-shaped mixing chamber that has four microelectrodes placed on the outer wall
at angular positions of 45, 135, 45, and 135 degrees, respectively. Assume that the
1. This model is courtesy of H. Chen, Y. T. Zhang, I. Mezic, C. D. Meinhart, and L. Petzold of the University
of California, Santa Barbara (Ref. 1 and Ref. 2).
1 |
ELECTROOSMOTIC MICROMIXER
aspect ratio (channel depth to width) is large enough that you can model the mixer
using a 2D cross-sectional geometry. The material parameters relevant for the model
are given in Table 1.
V0sin(t)
V0sin(t)
1
10 m
V0sin(t)
V0sin(t)
Figure 1: Geometry of the micromixer with four symmetric electrodes on the wall of the
mixing chamber. This example does not model the two inlet channels. Here you assume a
parabolic inflow at the beginning of the computational domain (the gray area).
The Navier-Stokes equations for incompressible flow describe the flow in the channels:
u
T
( u + ( u ) ) + u u + p = 0
t
u = 0
Here denotes the dynamic viscosity (kg/(ms)), u is the velocity (m/s), equals the
fluid density (kg/m3), and p refers to the pressure (Pa).
Because you do not model the two inlet channels, assume that the entrance channel
starts at a position where the flow has a fully developed laminar profile. The mixed fluid
flows freely out of the right end boundary, where you specify vanishing total stress
components normal to the boundary:
T
n [ pI + ( u + ( u ) ) ] = 0
When brought into contact with an electrolyte, most solid surfaces acquire a surface
charge. In response to the spontaneously formed surface charge, a charged solution
forms close to the liquid-solid interface. Known as an electric double layer, it forms
because of the charged groups located on the surface that faces the solution. When the
operator applies an electric field, the electric field generating the electroosmotic flow
displaces the charged liquid in the electric double layer. This scheme imposes a force
on the positively charged solution close to the wall surface, and the fluid starts to flow
2 |
in the direction of the electric field. The velocity gradients perpendicular to the wall
give rise to viscous transport in this direction. In the absence of other forces, the
velocity profile eventually becomes almost uniform in the cross section perpendicular
to the wall.
This model replaces the thin electric double layer with the Helmholtz-Smoluchowski
relation between the electroosmotic velocity and the tangential component of the
applied electric field:
w 0
u = ------------ TV
In this equation, w = 0r denotes the fluids electric permittivity (F/m), 0 represents

the zeta potential at the channel wall (V), and V equals the potential (V). This equation
applies on all boundaries except for the entrance and the outlet.
Assuming that there are no concentration gradients in the ions that carry the current,
you can express the current balance in the channel with Ohms law and the balance
equation for current density
( V ) = 0
where denotes conductivity (S/m) and the expression within parentheses represents
the current density (A/m2).
The electric potentials on the four electrodes are sinusoidal in time with the same
maximum value (V0 = 0.1 V) and the same frequency (8 Hz), but they alternate in
polarity. The potentials on electrodes 1 and 3 are V0sin(2ft), whereas those on
electrodes 2 and 4 are V0sin(2ft) (see Figure 1).
Assume all other boundaries are insulated. The insulation boundary condition
V n = 0
sets the normal component of the electric field to zero.
At the upper half of the inlet (see Figure 1) the solute has a given concentration, c0; at
the lower half the concentration is zero. Thus, assume that the concentration changes
abruptly from zero to c0 at the middle of the inlet boundary. The mixed solution flows
out from the right outlet by convection, and all other boundaries are assumed
insulated.
Inside the mixer, the following convection-diffusion equation describes the
concentration of the dissolved substances in the fluid:
3 |
c
----- + ( Dc ) = R u c
t
(1)
Here c is the concentration, D represents the diffusion coefficient, R denotes the

reaction rate, and u equals the flow velocity. In this model R = 0 because the
concentration is not affected by any reactions.
TABLE 1: MODEL INPUT DATA
PARAMETER
VALUE
1000 kg/m3
10-3 Pas
DESCRIPTION
Dynamic viscosity of the fluid
U0
0.1 mm/s
Average velocity through the inlet
80.2
Relative electric permittivity of the fluid
-0.1 V
Zeta potential on the wall-fluid boundary
0.11845 S/m
Conductivity of the ionic solution
10-11 m2/s
Diffusion coefficient
c0
1 mol/m3
Initial concentration
Density of the fluid

Figure 2 shows a typical instantaneous streamline pattern. It reveals that
electroosmotic recirculation of the fluid vigorously stirs the flow, typically in the form
of two rotating vortices near the electrodes.
The fundamental processes of effective mixing involve a combination of repeated
stretching and folding of fluid elements in combination with diffusion at small scales.
As the system applies the AC field (Figure 3), the resulting electroosmotic flow
perturbs the laminar pressure-driven flow such that it pushes the combined stream
pattern up and down at the beginning of the mixing chamber, causing extensive
folding and stretching of material lines.
4 |
Figure 2: Fluid streamlines in an electroosmotic micromixer at t = 0.0375 s.
Figure 3: Electric potential lines for an electroosmotic micromixer. The contour lines show
the shape when the device uses maximal potentials (V0).
5 |
The following plots further exemplify how the mixer operates. Figure 4 shows the
concentration at steady state when the electric field is not applied. The flow is laminar
and the diffusion coefficient is very small, so the two fluids are well separated also at
the outlet. When the alternating electric field is applied, the mixing increases
considerably owing to the alternating swirls in the flow. Figure 5 depicts the system at
the instant when the electric field and the electroosmotic velocity have their largest
magnitudes during the cycle (that is, when |sin t| = 1). From the plot you can
estimate that the concentration at the output fluctuates with the same frequency as the
electric field. Thus, this mixer should be further improved to get a steadier output.
Figure 4: Steady-state solution in the absence of an electric field.
6 |
Figure 5: Time-dependent solution at the time when the alternating electric field has its
largest magnitude.
This example demonstrates a rather simple and effective use of electrokinetic forces for
mixing. The scheme is easy to implement, and you can easily control both the
amplitude and the frequency. At low Reynold numbers the inertial forces are small,
which makes it possible to calculate stationary streamlines patterns using the
parametric solver to control amplitude.
Notes About the COMSOL Implementation

Cummings and others (Ref. 3) have shown that in order to use the
Helmholtz-Smoluchowski equation at the fluid-solid boundaries, the electric field
must be at least quasi-static to neglect transient effects. In other words, the time scale
of the unsteady electric field must be much larger than that of the transient flow. Y. T.
Zhang and others (Ref. 1) estimated that the time scale of the transient effect in the
modeled micromixer (with a channel width of 10 microns) is roughly 0.0127 s. In this
simulation the frequency of the applied electric potential is 8 Hz, which corresponds
to a time scale of the electric field 10 times larger than that of the flow.
7 |
Because you can model the time-dependent electric field as a product of a stationary
electric field and a time-dependent phase factor (sint), it is possible to reduce the
simulation time and memory requirements by dividing the solution into two stages. In
the first, calculate the amplitude of the electric potential field and the initial state for
the time-dependent flow model using a stationary solver. In the second stage, you
deactivate the Electric Currents interface and calculate the transient solution for the
Laminar Flow and the Transport of Diluted Species interfaces. You obtain the
tangential electric field components used in the electroosmotic velocity boundary
condition by multiplying the stationary DC solution by sin(t). This approach is
permissible because there is only a one-way coupling between the electric field and the
fluid fields.
References
1. H. Chen, Y.T. Zhang, I. Mezic, C.D. Meinhart, and L. Petzold, Numerical
Simulation of an Electroosmotic Micromixer, Proc Microfluidics 2003 (ASME
IMECE), 2003.
2. Y.T. Zhang, H. Chen, I. Mezic, C.D. Meinhart, L. Petzold, and N.C. MacDonald,
SOI Processing of a Ring Electrokinetic Chaotic Micromixer, Proc NSTI
Nanotechnology Conference and Trade Show (Nanotech 2004), vol. 1, pp. 292295,
2004.
3. E. Cummings, S. Griffiths, R. Nilson, and P. Paul, Conditions for Similitude
Between the Fluid Velocity and the Electric Field in Electroosmotic Flow, Anal.
Chem., vol. 72, pp. 25262532, 2000.
Model Library path: Microfluidics_Module/Micromixers/

electroosmotic_mixer
NEW

MODEL WIZARD
8 |
2 In the Select physics tree, select Fluid Flow>Single-Phase Flow>Laminar Flow (spf).
4 In the Select physics tree, select AC/DC>Electric Currents (ec).
6 In the Select physics tree, select Chemical Species Transport>Transport of Diluted
Species (chds).
9 In the tree, select Preset Studies for Selected Physics>Stationary.
GLOBAL DEFINITIONS
Parameters
1 On the Home toolbar, click Parameters.
9 |

Name
Expression
Value
Description
U0
0.1[mm/s]
1.000E-4 m/s
Mean inflow velocity
sigma_w
0.11845[S/m]
0.1185 S/m
Conductivity of the ionic

solution
eps_r
80.2
80.20
Relative permittivity of
the fluid
zeta
-0.1[V]
-0.1000 V
Zeta potential
V0
0.1[V]
0.1000 V
Maximum value of the AC

potential
omega
2*pi[rad]*8[Hz]
50.27 Hz
Angular frequency of the

AC potential
0[s]
1e-11[m^2/s]
1.000E-11 m/s
Diffusion coefficient of
the solution
c0
1[mol/m^3]
1.000 mol/m
Initial concentration
0s
Start time
You need the constant t (used in the scalar expressions below) when first solving the
model using a stationary solver. In the time-dependent simulation, the internal time
variable, t, overwrites this constant.
Now define a smoothed step function that you will later use to impose a step in the
concentration in the middle of the channel entrance.
Step 1
1 On the Home toolbar, click Functions and choose Global>Step.
2 In the Step settings window, click to expand the Smoothing section.
3 In the Size of transition zone edit field, type 0.1e-6.
GEOMETRY 1

3 From the Length unit list, choose m.
Rectangle 1
1 Right-click Component 1>Geometry 1 and choose Rectangle.
10 |
4 In the Height edit field, type 10.

5 Locate the Position section. From the Base list, choose Center.
Circle 1
1 In the Model Builder window, right-click Geometry 1 and choose Circle.
2 In the Circle settings window, locate the Size and Shape section.
3 In the Radius edit field, type 15.
Circle 2
1 Right-click Geometry 1 and choose Circle.
2 In the Circle settings window, locate the Size and Shape section.
3 In the Radius edit field, type 5.
Compose 1
1 On the Geometry toolbar, click Compose.
2 Click the Select All button in the Graphics window to select all objects.
3 In the Compose settings window, locate the Compose section.
4 In the Set formula edit field, type (r1+c1)-c2.
5 Clear the Keep interior boundaries check box.
To add vertices for the electrode endpoints on the outer boundary, first add a square
whose boundaries intersect the outer circle at the desired locations.
Square 1
1 Right-click Geometry 1 and choose Square.
2 In the Square settings window, locate the Size section.
3 In the Side length edit field, type 22.27.
4 Locate the Position section. From the Base list, choose Center.
11 |
Next, remove the parts of the square not contained inside the mixer geometry.
Compose 2
1 On the Geometry toolbar, click Compose.
2 Select both objects (co1 and sq1).
3 In the Compose settings window, locate the Compose section.
4 In the Set formula edit field, type co1*sq1+co1.
Here, co1*sq1 is the intersection of co1 and sq1.

5 Clear the Keep interior boundaries check box.
To see the effects of these operations, switch to point selection mode.
12 |
7 Click the Select Points button on the Graphics toolbar.
The model geometry is now essentially complete. However, before proceeding to

the Materials branch, add an auxiliary vertex midway along the inlet boundary for
use when creating the mesh.
Point 1
1 Right-click Geometry 1 and choose Point.
2 In the Point settings window, locate the Point section.
3 In the x edit field, type -40.
13 |
Form Union
1 In the Model Builder window, under Component 1 >Geometry 1 right-click Form Union
and choose Build Selected.
MATERIALS
Material 1
New Material.
Property
Name
Value
Unit
Property group
Density
rho
1e3[kg/m^3]
kg/m
Basic
Dynamic viscosity
mu
1e-3[Pa*s]
Pas
Basic
Electrical conductivity
sigma
sigma_w
S/m
Basic
Relative permittivity
epsilonr
eps_r
Basic
LAMINAR FLOW
1 In the Model Builder windows toolbar, click the Show button and select Discretization
in the menu.
14 |
2 In the Model Builder window, under Component 1 click Laminar Flow.

3 In the Laminar Flow settings window, click to expand the Discretization section.
4 From the Discretization of fluids list, choose P2 + P1.
Using higher-order elements can improve the accuracy of the solution significantly
for low Reynolds number flows such as those in this model.
Inlet 1
An alternative to left clicking to select these boundaries, is to click the Paste Selection
button in the Boundary Selection section of the Settings window and enter the
boundary numbers in the dialog box that appears. Another possibility is to copy the
text '1 and 3' from this document, click in the Selection box, and then press Ctrl+V.
5 Locate the Laminar Inflow section. In the Uav edit field, type U0.
6 Select the Constrain endpoints to zero check box.
Outlet 1
Wall 1
1 In the Model Builder window, under Component 1>Laminar Flow click Wall 1.
2 In the Wall settings window, locate the Boundary Condition section.
3 From the Boundary condition list, choose Electroosmotic velocity.
4 Specify the E vector as
ec.Ex*sin(omega*t)
ec.Ey*sin(omega*t)
5 From the Electroosmotic mobility list, choose Built-in expression.

6 In the edit field, type zeta.
7 In the r edit field, type eps_r.
15 |
ELECTRIC CURRENTS
Electric Potential 1
1 In the Model Builder window, under Component 1 click Electric Currents.
2 On the Physics toolbar, click Boundaries and choose Electric Potential.
4 In the Electric Potential settings window, locate the Electric Potential section.
5 In the V0 edit field, type -V0.
Electric Potential 2
1 On the Physics toolbar, click Boundaries and choose Electric Potential.
16 |
3 In the Electric Potential settings window, locate the Electric Potential section.
TR A N S P O R T O F D I L U T E D S P E C I E S
Raise the element order to match that of the Laminar Flow interface.
1 In the Model Builder window, under Component 1 click Transport of Diluted Species.
2 In the Transport of Diluted Species settings window, click to expand the Discretization
section.
3 From the Concentration list, choose Quadratic.
Convection and Diffusion 1

1 In the Model Builder window, expand the Transport of Diluted Species node, then click
Convection and Diffusion 1.
2 In the Convection and Diffusion settings window, locate the Diffusion section.
3 In the Dc edit field, type D.
4 Locate the Model Inputs section. From the u list, choose Velocity field (spf/fp1).
Concentration 1
1 On the Physics toolbar, click Boundaries and choose Concentration.
17 |

3 In the Concentration settings window, locate the Concentration section.
4 Select the Species c check box.
5 In the c0,c edit field, type c0*step1(y[1/m]).
The concentration condition on Boundaries 1 and 3 gives a sharp but smooth

concentration gradient in the middle of the channel entrance.
Outflow 1
1 On the Physics toolbar, click Boundaries and choose Outflow.
MESH 1
Size
1 In the Model Builder window, under Component 1 right-click Mesh 1 and choose Free
Triangular.
3 From the Predefined list, choose Extra fine.
Size 1
1 In the Model Builder window, under Component 1 >Mesh 1 right-click Free Triangular
1 and choose Size.
5 Locate the Element Size section. Click the Custom button.
6 Locate the Element Size Parameters section. Select the Maximum element size check
box.
7 In the associated edit field, type 0.2.
8 Select the Maximum element growth rate check box.
Size 2
1 Right-click Free Triangular 1 and choose Size.
3 From the Geometric entity level list, choose Point.
18 |
4 Select Point 2 only.

5 Locate the Element Size section. Click the Custom button.
6 Locate the Element Size Parameters section. Select the Maximum element size check
box.
8 Select the Maximum element growth rate check box.
STUDY 1
Set up the study to start by computing the stationary solution for velocity, pressure,
concentration, and electric potential. Then, add a transient simulation stage that solves
only for the variables of the Laminar Flow and Transport of Diluted Species interfaces.
Begin by adding a study step for the transient part.

1 On the Study toolbar, click Study Steps and choose Time Dependent>Time Dependent.
3 In the Times edit field, type range(0,0.125/60,0.5).
19 |
4 Locate the Physics and Variables Selection section. In the table, enter the following
settings (disable the Electric Currents physics):

Physics
Solve for
Discretization
Electric Currents
physics
5 In the Model Builder window, click Study 1.

6 In the Study settings window, locate the Study Settings section.
7 Clear the Generate default plots check box.
This is convenient if you want to create specialized plots while keeping the number
of plot groups down.
RESULTS
The following instructions show how to reproduce the plots in the Results and
Discussion section.
2D Plot Group 1
4 Right-click Results>2D Plot Group 1 and choose Streamline.
10 Click the Zoom In button on the Graphics toolbar.
Compare the result with Figure 2.
2D Plot Group 2
4 Right-click Results>2D Plot Group 2 and choose Contour.
5 In the Contour settings window, locate the Expression section.
20 |
6 Click Replace Expression in the upper-right corner of the Expression section. From
the menu, choose Electric Currents>Electric>Electric potential (V). On the 2D plot

group toolbar, click Plot.
2D Plot Group 3
Surface.
3 In the Surface settings window, locate the Expression section.
4 Click Transport of Diluted Species>Species c>Concentration (c) in the Replace
expression menu.
5 In the Model Builder window, right-click 2D Plot Group 3 and choose Streamline.
11 From the Time (s) list, choose 0.
14 Click the Zoom In button on the Graphics toolbar.

21 |
COMSOL MULTIPHYSICS
Fluid-Structure Interaction
Model
Fluid
Flow
Solid
Physics
Solid Mechnics + Laminar Flow + Moving Mesh = Fluid-Structure Interaction
Navier-Stokes
equations
Inlet velocity
Fluid-solid interface
Flow
Fluid
Solid
Fixed
Inlet
U*t^2/sqrt(t^4-0.07[s^2]*t^2+0.0016[s^4]) [m/s]
Outlet
0 [Pa]
Result
Introduction
The following example demonstrates techniques for modeling fluid-structure
interactions in COMSOL Multiphysics. It illustrates how fluid flow can deform
structures and how to solve for the flow in a continuously deforming geometry using
the arbitrary Lagrangian-Eulerian (ALE) technique.
The model geometry consists of a horizontal flow channel in the middle of which is an
obstacle, a narrow vertical structure (Figure 1). The fluid flows from left to right,
except where the obstacle forces it into a narrow path in the upper part of the channel,
and it imposes a force on the structures walls resulting from the viscous drag and fluid
pressure. The structure, being made of a deformable material, bends under the applied
load. Consequently, the fluid flow also follows a new path, so solving the flow in the
original geometry would generate incorrect results.
The ALE method handles the dynamics of the deforming geometry and the moving
boundaries with a moving grid. COMSOL Multiphysics computes new mesh
coordinates on the channel area based on the movement of the structures boundaries
and mesh smoothing. The Navier-Stokes equations that solve the flow are formulated
for these moving coordinates.
The structural mechanics portion of the model does not require the ALE method, and
COMSOL Multiphysics solves it in a fixed coordinate system as usual. However, the
strains the model computes in this way are the only source for computing the
deformed coordinates with ALE.
1 |
FLUID-STRUCTURE INTERACTION
Figure 1: Fluid flows into this horizontal flow channel from the left, and it enters with a
parabolic velocity profile. A narrow vertical structure in the channel (the straight vertical
structure) forces the flow into a narrow path. Due to fluid pressure and viscous drag, the
originally vertical structure bends. This simulation models the fluid flow in a deformed,
moving mesh that follows the movement of the bending structure.
Model Definition
In this example the flow channel is 100 m high and 300 m long. The vertical
structure5 m wide, 50 m high, and with a semicircular topsits 100 m away
from the channels left boundary. Assume that the structure is long in the direction
perpendicular to the image.
The fluid is a water-like substance with a density = 1000 kg/m3 and dynamic
viscosity = 0.001 Pas. To demonstrate the desired techniques, assume the structure
consists of a flexible material with a density = 7850 kg/m3 and Youngs modulus
E = 200 kPa.
2 |
FLUID FLOW
The fluid flow in the channel is described by the incompressible Navier-Stokes

equations for the velocity field, u = (u, v), and the pressure, p, in the spatial
(deformed) moving coordinate system:
u
T
[ p I + ( u + ( u ) ) ] + ( ( u um ) )u = F
t
u = 0
(1)
In these equations, I denotes the unit diagonal matrix and F is the volume force
affecting the fluid. Assume that no gravitation or other volume forces affect the fluid,
so that F = 0. The coordinate system velocity is um = (um, vm).
At the channel entrance on the left, the flow has fully developed laminar characteristics
with a parabolic velocity profile but its amplitude changes with time. At first flow
increases rapidly, reaching its peak value at 0.215 s; thereafter it gradually decreases to
a steady-state value of 5 cm/s. The centerline velocity in the x direction, uin (see
Figure 4), with the steady-state amplitude U comes from the equation
2
Ut
u in = ----------------------------------------------------------2 2
2
( 0.04 t ) + ( 0.1t )
(2)
where t must be expressed in seconds.

At the outflow (right-hand boundary), the condition is p = 0. On the solid
(nondeforming) walls, no-slip conditions are imposed, u = 0, v = 0, while on the
deforming interface the velocities equal the deformation rate, u0 = ut and v0 = vt (the
default condition; note that u and v on the right-hand sides refer to the displacement
components).
STRUCTURAL MECHANICS
The structural deformations are solved for using an elastic formulation and a nonlinear
geometry formulation to allow large deformations.
The obstacle is fixed to the bottom of the fluid channel. All other object boundaries
experience a load from the fluid, given by
T
F T = n ( p I + ( u + ( u ) ) )
(3)
where n is the normal vector to the boundary. This load represents a sum of pressure
and viscous forces.
3 |
MOVING MESH
The Navier-Stokes equations are solved on a freely moving deformed mesh, which
constitutes the fluid domain. The deformation of this mesh relative to the initial shape
of the domain is computed using Winslow smoothing. This is the default smoothing
when using the Fluid-Structure Interaction interface. For more information, please
refer to the Fluid-Structure Interaction interface in the MEMS Module Users Guide.
Inside the obstacle, the moving mesh follows the deformations of the obstacle. At the
exterior boundaries of the flow domain, the deformation is set to zero in all directions.

Figure 2 shows the geometry deformation and flow at t = 4 s when the system is close
to its steady state. Due to the channels small dimensions, the Reynolds number of the
flow is small (Re << 100), and the flow stays laminar in most of the area. The swirls are
restricted to a small area behind the structure. The amount of deformation as well as
the size and location of the swirls depend on the magnitude of the inflow velocity.
Figure 2: Flow velocity and geometry deformation at t = 4 s. The streamlines indicate the
flow direction and the color indicates flow-velocity magnitude.
Figure 3 shows the mesh velocity at t = 0.15 s. The boundaries of the narrow structure
are the only moving boundaries of the flow channel. Therefore the mesh velocity also
4 |
has its largest values near the structure. Depending on the current state of the
deformationwhether it is increasing, decreasing or stationarythe mesh velocity can
have a very different distribution. Figure 4 further illustrates this point; it compares the
average inflow velocity to the horizontal mesh velocity and the horizontal mesh
displacement just beside the top of the structure. Most of the time the deformation
follows the inflow velocity quite closely. Whenever the inflow velocity starts to
decrease, the deformation also decreases, which you can observe as the negative values
on the horizontal mesh velocity. Toward the end of the simulation, when inflow and
structure deformation approach their steady-state values, the mesh velocity also
decreases to zero.
Figure 3: Mesh velocity (arrows) and mesh and geometry deformation at t = 0.15 s.
5 |
Figure 4: Inflow velocity, horizontal mesh velocity, and mesh deformation. The blue curve
shows the average x direction velocity at the inflow boundary (m/s); the green shows
104 mesh displacement in the x direction (dx_ale; m) at the geometry point
(1.0510-4, 0.510-4); and the red curve shows 103 mesh velocity in the x direction (xt; m/
s), also at the point (1.0510-4, 0.510-4).
Figure 5 compares the meshes at different times. The first image shows the initial
mesh, which you generate prior to solving the model. This mesh is equally distributed
around the top of the structure. The second image shows the mesh in its deformed
form. Because the structure deforms more in the horizontal direction, the mesh also
6 |
changes more in this direction: On the left, the mesh elements are stretched; on the
right, they are compressed in the x direction.
Figure 5: Geometry and mesh near the top of the structure at t = 0 s and 2 s.
Notes About the COMSOL Implementation

This example implements the model using Fluid-Structure Interaction interface. By
default the Fluid-Structure Interaction interface treats all domains as fluid. Activate
solid material model node in the area of the narrow structure. To get a more accurate
computation of the large strains, large deformation analysis is the default setting. The
interface automatically identifies the fluid-solid interaction boundaries and assigns the
boundary condition to those boundaries.
Model Library path: MEMS_Module/Microfluidics/

fluid_structure_interaction
1 From the File menu, choose New.
NEW

MODEL WIZARD

2 In the Select physics tree, select Fluid Flow>Fluid-Structure Interaction (fsi).
7 |

5 In the tree, select Preset Studies>Time Dependent.
GLOBAL DEFINITIONS
Parameters
1 On the Home toolbar, click Parameters.
Name
Expression
Value
Description
3.33[cm/s]
0.03330 m/s
Inlet mean velocity at steady state
100[um]
1.000E-4 m
Channel height
Variables 1
1 In the Model Builder window, right-click Global Definitions and choose Variables.
Name
Expression
Unit
Description
u_mean
U*t^2/sqrt(t^4-0.07[s^2]*t^2
+0.0016[s^4])
m/s
Inlet mean velocity
GEOMETRY 1

3 From the Length unit list, choose m.
Rectangle 1 (r1)
1 Right-click Component 1 (comp1)>Geometry 1 and choose Rectangle.
4 In the Height edit field, type H.
8 |
Rectangle 2 (r2)
1 In the Model Builder window, right-click Geometry 1 and choose Rectangle.
5 Locate the Position section. In the x edit field, type 100.
Fillet 1 (fil1)
1 On the Geometry toolbar, click Fillet.
2 On the object r2, select Points 3 and 4 only.
3 In the Fillet settings window, locate the Radius section.
4 In the Radius edit field, type 2.5.
The geometry should look like that in the figure below.
By default the Fluid-Structure Interaction interface treats all domains as fluid. Add the
appropriate domain selection to the default node for the solid domain and proceed to
the material specification.
9 |
Linear Elastic Material 1

1 In the Model Builder window, expand the Component 1>Fluid-Structure Interaction
node, then click Linear Elastic Material 1.

MATERIALS
Material 1
New Material.
Property
Name
Value
Unit
Property group
Density
rho
1e3
kg/m
Basic
Dynamic viscosity
mu
1e-3
Pas
Basic
Material 2
Property
Name
Value
Unit
Property group
Young's modulus
2e5
Pa
Basic
Poisson's ratio
nu
0.33
Basic
Density
rho
7850
kg/m
Basic
1 In the Model Builder window, under Component 1 click Fluid-Structure Interaction.

2 In the Fluid-Structure Interaction settings window, locate the Physical Model section.
3 From the Compressibility list, choose Incompressible flow.
4 Locate the Free Deformation Settings section. From the Mesh smoothing type list,
choose Hyperelastic.
10 |
Inlet 1
3 In the Inlet settings window, locate the Velocity section.
4 In the U0 edit field, type u_mean*6*(H-Y)*Y/H^2.
This gives a parabolic velocity profile with the specified mean velocity appropriate for
laminar inflow. If you have a license for the CFD Module or Microfluidics Module, you
can use the predefined Laminar inflow boundary condition with average velocity
u_mean- a boundary condition that works for general inlet shapes.
Outlet 1
Fixed Constraint 1
1 On the Physics toolbar, click Boundaries and choose Fixed Constraint.
MESH 1
Free Triangular 1
1 In the Model Builder window, under Component 1 right-click Mesh 1 and choose Free
Triangular.
2 In the Free Triangular settings window, locate the Domain Selection section.
3 From the Geometric entity level list, choose Entire geometry.
Size
1 In the Model Builder window, under Component 1>Mesh 1 click Size.
3 From the Predefined list, choose Fine.
4 From the Calibrate for list, choose Fluid dynamics.
STUDY 1

1 In the Model Builder window, expand the Study 1 node, then click Step 1: Time
Dependent.
11 |
3 In the Times edit field, type range(0,0.005,0.75) range(1,0.25,4).
4 Select the Relative tolerance check box.
You can ignore the non-ideal constraints related warning shown in the log.
RESULTS
Flow and Stress (fsi)

The first default plot shows the velocity field together with the von Mises stress.
Proceed to reproduce Figure 2, which shows the streamlines instead of the arrows.
3 In the Model Builder window, under Results>Flow and Stress (fsi) right-click Arrow
Surface 1 and choose Disable.
4 Right-click Flow and Stress (fsi) and choose Streamline.
5 In the Streamline settings window, locate the Expression section.
6 Select Fluid Structure Interaction (Laminar Flow)>Velocity field (Spatial)
(u_fluid,...,v_fluid) from the menu that appears when clicking Replace Expression in
the upper-right corner of the section. Locate the Streamline Positioning section.
From the Positioning list, choose Start point controlled.
8 In the x edit field, type 0^(range(1,15)) 125*1^(range(1,2)).
9 In the y edit field, type range(0,100/14,100) 20 5.
10 Locate the Coloring and Style section. From the Color list, choose Red.
To animate flow around the structure, do the following:
Export
1 On the Results toolbar, click Player.
2 In the Player settings window, locate the Animation Editing section.
3 From the Time selection list, choose Interpolated.
4 In the Times (s) edit field, type range(0.025,0.025,0.5).
12 |
5 Right-click Results>Export>Player 1 and choose Play.
To inspect the deformed geometry and deformed mesh near the top of the structure
(Figure 5), proceed with the following steps.
Data Sets
1 On the Results toolbar, click More Data Sets and choose Solution.
2 In the Model Builder window, under Results>Data Sets right-click Solution 2 and
choose Add Selection.

2D Plot Group 3
2 In the 2D Plot Group settings window, locate the Plot Settings section.
3 From the Frame list, choose Spatial (x, y, z).
4 Locate the Data section. From the Time (s) list, choose 0.
5 Right-click Results>2D Plot Group 3 and choose Surface.
6 In the Surface settings window, locate the Expression section.
7 In the Expression edit field, type 1.
9 From the Color list, choose Blue.
10 Select the Wireframe check box.
11 Click to expand the Quality section. On the 2D plot group toolbar, click Plot.
12 In the Model Builder window, right-click 2D Plot Group 3 and choose Surface.
16 Locate the Expression section. In the Expression edit field, type 1.
Click the Zoom Box button on the Graphics toolbar and then use the mouse to zoom
in on the obstacle.
1 In the Model Builder window, under Results click 2D Plot Group 3.
13 |

4 In the Model Builder window, under Results>2D Plot Group 3 click Surface 2.
Add the arrow plot, to reproduce Figure 3.

11 In the Model Builder window, under Results>2D Plot Group 3 click Surface 2.
14 In the Model Builder window, right-click 2D Plot Group 3 and choose Arrow Surface.
15 In the Arrow Surface settings window, locate the Expression section.
16 In the x component edit field, type xt.
17 In the y component edit field, type yt.
18 Locate the Coloring and Style section. Select the Scale factor check box.
Finally, plot the horizontal mesh velocity, the mesh deformation at the point beside the
top of the structure, and inflow velocity (Figure 4).
1D Plot Group 4
2 On the 1D plot group toolbar, click Global.
3 In the Global settings window, locate the y-axis data section.
4 Choose Definitions>Inlet mean velocity (u_mean) from the Replace expression menu,
accessible from the upper-right corner of the section. On the 1D plot group toolbar,
click Plot.
Data Sets
1 On the Results toolbar, click Cut Point 2D.
14 |
2 In the Cut Point 2D settings window, locate the Point Data section.
3 In the x edit field, type 105.
4 In the y edit field, type 50.
1D Plot Group 4
1 On the 1D plot group toolbar, click Point Graph.
2 In the Point Graph settings window, locate the Data section.
3 From the Data set list, choose Cut Point 2D 1.
4 Locate the y-Axis Data section. In the Expression edit field, type xt.
5 From the Unit list, choose mm/s.
6 Click to expand the Legends section. Select the Show legends check box.
7 From the Legends list, choose Manual.
Legends
Mesh velocity in the x direction (mm/s)
9 Right-click Results>1D Plot Group 4>Point Graph 1 and choose Duplicate.

10 In the Point Graph settings window, locate the y-Axis Data section.
11 In the Expression edit field, type x-X.
12 From the Unit list, choose mm.
13 Locate the Legends section. In the table, enter the following settings:
Legends
Mesh displacement in the x direction (mm)
15 |
Verify and optimize your designs with COMSOL Multiphysics
() TEL: 02-547-2344 FAX: 02-547-2343 E-mail: comsol@altsoft.co.kr Homepage: www.altsoft.co.kr

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Heat Transfer and Fluid Flow

COMSOL V4.4 Product Suite

Heat Transfer Module

Model laminar and turbulent flows in single

Simulation in the free and porous media

Ready coupling of heat and mass transport

Wall Roughness(k-, k-w model)

Impeller and a vessel in containing

Used in many industrial processes, such

Add-on to the CFD Module

Easy-to-use tools for the study

Set up to coupled electrokinetic

Slip flow Analysis

Subsurface Flow Module

Model single and coupled processes

Oil and gas flow in porous media, the

Pipe Flow Module

Applies to the transitional flow and free

Fast computations of steady-state free

Design and simulation of vacuum systems

Adsorption, desorption, and deposition

Particle Tracing Module

Lets you compute trajectories of

Mixing in a static mixer

Newtonian fluid / Non-Newtonian fluid

Domain / Boundary / Line / Point Heat Source

Outflow Convection outlet

Convective Heat Flux

Highly Conductive Layer / Thin Thermally Resistive Layer

Energy Balance(Global variables)

5 [cm/s], 293.15 [K]

Pressure, no viscous stress

No slip, Thermal insulation

Solved with COMSOL Multiphysics 4.4

Solved with COMSOL Multiphysics 4.4

Figure 1: The model set-up including channel and heat sink.

Solved with COMSOL Multiphysics 4.4

Model Library path: Heat_Transfer_Module/

Solved with COMSOL Multiphysics 4.4

1 In the New window, click the Model Wizard button.

1 In the Model Wizard window, click the 3D button.

1 On the Geometry toolbar, click Insert Sequence.

5 Click the Import button.

Solved with COMSOL Multiphysics 4.4

8 Click the Wireframe Rendering button on the Graphics toolbar.

On the Home toolbar, click Add Material.

1 Go to the Add Material window.

1 Go to the Add Material window.

Solved with COMSOL Multiphysics 4.4

1 Go to the Add Material window.

section. In the Material properties tree, select Basic Properties>Thermal Conductivity.

Solved with COMSOL Multiphysics 4.4

Mean inlet velocity

Total power dissipated

Solved with COMSOL Multiphysics 4.4

4 From the Boundary condition list, choose Laminar inflow.

inlet temperature and the outlet condition as described below.

Thin Thermally Resistive Layer 1

1 In the Model Builder window, under Component 1 click Mesh 1.

To get a better view of the mesh, suppress some of the boundaries.

Solved with COMSOL Multiphysics 4.4