| The fluid flow patterns in a paper-machine headbox have a strong influence on the quality of the paper produced by the machine. Due to increasing demand for high quality paper there is a need to investigate the details of the fluid flow in the paper machine headbox.; The objective of this thesis is to use experimental and computational methods of modeling the flow inside a typical headbox in order to evaluate and understand the mean flow patterns and turbulence created there. In particular, spatial variations of the mean flow and of the turbulence quantities and the turbulence generated secondary flows are studied. In addition to the flow inside the headbox, the flow leaving the slice is also modeled both experimentally and computationally.; Comparison of the experimental and numerical results indicated that streamwise mean components of the velocities in the headbox are predicted well by all the turbulence models considered in this study. However, the standard k-ϵ model and the algebraic turbulence models fail to predict the turbulence quantities accurately. Standard k-ϵ-model also fails to predict the direction and magnitude of the secondary flows.; Significant improvements in the k-ϵ model predictions were achieved when the turbulence production term was artificially set to zero. This is justified by observations of the turbulent velocities from the experiments and by a consideration of the form of the kinetic energy equation. A better estimation of the Reynolds normal stress distribution and the degree of anisotropy of turbulence was achieved using the Reynolds stress turbulence model.; Careful examination of the measured turbulence velocity results shows that after the initial decay of the turbulence in the headbox, there is a short region close to the exit, but inside the headbox, where the turbulent kinetic energy actually increases as a result of the distortion imposed by the contraction. The turbulence energy quickly resumes its decay in the free jet after the headbox.; The overall conclusion from this thesis, obtained by comparison of experimental and computational simulations of the flow in a headbox, is that numerical simulations show great promise for predictions of headbox flows. Mean velocities and turbulence characteristics can now be predicted with fair accuracy by careful use of specialized turbulence models. Standard engineering turbulence models, such as the k-ϵ model and its immediate relatives, should not be used to estimate the turbulence quantities essential for predicting pulp fiber dispersion within the contracting region and free jet of a headbox, particularly when the overall contraction ratio is greater than about five. (Abstract shortened by UMI.)... |
