Numerical study to investigate the effect of sample size sensitivity on porous materials with respect to different geometrical parameters

Porous materials play a crucial role in various industrial applications, where precise determination of geometric parameters like dynamic tortuosity, as well as viscous and thermal characteristic lengths, is essential for optimizing acoustical performance. Up to this point, there has been no published size sensitivity test that recommends the ideal sample size for analyzing these parameters in an industrial environment. The present article analyzes different reconstructed porous material samples using conventional CFD and coupled FEA-CFD simulations and suggests optimal sample size and specific simulation setup optimized for industrial purposes, which grant high accuracy and reasonable computational cost. The present paper analyzed several samples, which were reconstructed by micro-CT and analyzed in Star-CCM + simulation environment. It was found that the optimal sample size (1.5×1.5×1.5 mm or 2.5×2.5×2.5 mm) is different for specific average pore sizes. It was proven through various numerical simulations based on reconstructed porous material samples that running only one coupled CFD-FEM simulation is satisfactory to directly determine all investigated parameters. It was demonstrated that the computationally demanding numerical model could be simplified in specific cases using a rigid body and highlight the limitations.