OBRABOTKAMETALLOV Vol. 27 No. 3 2025 104 EQUIPMENT. INSTRUMENTS Numerical and experimental investigation of heat transfer augmentation in roughened pipes Siddhanath Nishandar 1, a, Ashok Pise 1, b, Pramodkumar Bagade 2, c, * 1 Department of Mechanical Engineering, Government College of Engineering, Karad, Shivaji University, Kolhapur, Maharashtra 445414, India 2 Department of Mechanical Engineering, TSSM’s Bhivarabai Sawant College of Engineering and Research (BSCOER), Narhe, Pune, Maharashtra 445414, India a https://orcid.org/0000-0001-6190-3412, siddhant.nishandar04@gmail.com; b https://orcid.org/0009-0003-0276-8996, ashokpise@gmail.com; c https://orcid.org/0000-0002-4069-1542, pramodbagade@gmail.com Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2025 vol. 27 no. 3 pp. 87–107 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.3-87-107 ART I CLE I NFO Article history: Received: 23 June 2025 Revised: 04 July 2025 Accepted: 10 July 2025 Available online: 15 September 2025 Keywords: Heat transfer enhancement Surface roughness Turbulent kinetic energy (TKE) Pulsating fl ow Turbulent fl ow Nusselt number (Nu) ABSTRACT Introduction. In many technical applications, such as thermal energy systems, chemical processing, power production, and HVAC, effi cient heat transfer (HT) is essential. Research on improving HT performance in circular pipes is still crucial, especially when it comes to changes that cause thermal boundary layers to be disrupted and turbulence to grow. Purpose of the work: The purpose of this work is to thoroughly examine how convective heat transfer can be improved in circular pipes with purposefully roughened surfaces. It focuses on how surface roughness, fl ow pulsations, Reynolds number (Re), and heat fl ow rate (Q) aff ect thermal performance. Methods of investigation. A combination of experimental and numerical methods is employed to assess the thermo-fl uid dynamics inside the pipe. Lab-scale experiments and computational fl uid dynamics (CFD) simulations are used to investigate temperature distribution, velocity and pressure fi elds, turbulent kinetic energy (TKE), vorticity, eddy viscosity, local heat transfer coeffi cient (h), and Nusselt number (Nu). Additionally, sinusoidal pulsations are introduced at the inlet and the outlet, with regular oscillations in frequency (f) and amplitude (A), over a turbulent fl ow range (6,753 ≤ Re ≤ 31,000). Results and discussion. The results show that surface roughness enhances HT by signifi cantly increasing turbulence and disrupting the thermal boundary layer. TKE becomes a signifi cant factor when there is a strong correlation between higher HT coeffi cients and rising turbulence intensity. HT performance is further improved by introducing fl ow pulsations; downstream pulsation increases Nu by 20–22% and upstream pulsing by 16–19%. The outcomes demonstrate how eff ectively controlled fl ow pulsations and surface roughness combine to optimize heat transfer. This collaborative approach holds great potential for compact and highly effi cient thermal system designs in industrial environments. For citation: Nishandar S.V., Pise A.T., Bagade P.M. Numerical and experimental investigation of heat transfer augmentation in roughened pipes. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 3, pp. 87–107. DOI: 10.17212/1994-6309-2025-27.3-87-107. (In Russian). ______ * Corresponding author Bagade Pramodkumar M., Ph.D. (Aerospace Engineering), Professor Department of Mechanical Engineering, TSSM’s Bhivarabai Sawant College of Engineering and Research (BSCOER), Narhe, Pune, 445414, Maharashtra, India Tel.: +91 9075279575, e-mail: pramodbagade@gmail.co References 1. Ye Q., Zhang Y., Wei J. A comprehensive review of pulsating fl ow on heat transfer enhancement. Applied Thermal Engineering, 2021, vol. 196, p. 117275. DOI: 10.1016/j.applthermaleng.2021.117275. 2. YangB., GaoT., Gong J., Li J. Numerical investigationon fl owandheat transfer of pulsating fl owinvarious ribbed channels. Applied Thermal Engineering, 2018, vol. 145, pp. 576–589. DOI: 10.1016/j.applthermaleng.2018.09.041. 3. Duan D., Cheng Y., Ge M., Bi W., Ge P., Yang X. Experimental and numerical study on heat transfer enhancement by fl ow-induced vibration in pulsating fl ow. Applied Thermal Engineering, 2022, vol. 207, p. 118171. DOI: 10.1016/j.applthermaleng.2022.118171.
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