Abstract

This paper answers the question: “How can an appropriate turbulent rough pipe flow computational fluid dynamics (CFD) model be developed?” The Reynolds-averaged Navier-Stokes equations with the standard k-epsilon turbulence model and scalable wall functions were solved to obtain Fanning friction factors and mean velocity profiles in inflectional and monotonic rough pipes. CFD models with near-wall grid sizes from four dimensionless wall distances and two roughness treatment approaches were simulated. Eight roughness Reynolds numbers, covering the lower end of the transitionally rough regime through the fully rough regime, were studied for each roughness type. Appropriate roughness and turbulence model constants for turbulent rough pipe flows in the transitionally rough regime were determined. For model validation, the predicted mean axial velocity profiles for Reynolds numbers of 5 × 104and 5 × 105exhibited good agreement with the reference experimental data. A total of 208 CFD simulations (32 from our previous works and 176 from the present study) were analyzed. Finally, based on comparisons between predicted Fanning friction factors and established correlations, appropriate CFD models for turbulent flows in inflectional and monotonic rough pipes were identified. Suitable CFD models for accurately predicting mean velocity profiles at roughness Reynolds numbers below 11.225 were also obtained, although with the caution that improved mean velocity prediction may reduce Fanning friction factor accuracy. Furthermore, the present CFD work provides essential guidance for extending simulations to other rough surface types and rough-wall flow situations.OPEN ACCESS Received: 25/11/2025 Accepted: 30/12/2025

Abstract

This paper answers the question: “How can an appropriate turbulent rough pipe flow computational fluid dynamics (CFD) model be developed?” The Reynolds-averaged Navier-Stokes equations with the standard k-epsilon turbulence model and scalable wall functions were solved to obtain Fanning friction factors and mean velocity profiles in inflectional and monotonic rough pipes. CFD models with near-wall grid sizes from four dimensionless wall distances and two roughness treatment approaches were simulated. Eight roughness Reynolds numbers, covering the lower end of the transitionally rough regime through the fully rough regime, were studied for each roughness type. Appropriate roughness and turbulence model constants for turbulent rough pipe flows in the transitionally rough regime were determined. For model validation, the predicted mean axial velocity profiles for Reynolds numbers of 5 × 104and 5 × 105exhibited good agreement with the reference experimental data. A total of 208 CFD simulations (32 from our previous works and 176 from the present study) were analyzed. Finally, based on comparisons between predicted Fanning friction factors and established correlations, appropriate CFD models for turbulent flows in inflectional and monotonic rough pipes were identified. Suitable CFD models for accurately predicting mean velocity profiles at roughness Reynolds numbers below 11.225 were also obtained, although with the caution that improved mean velocity prediction may reduce Fanning friction factor accuracy. Furthermore, the present CFD work provides essential guidance for extending simulations to other rough surface types and rough-wall flow situations.OPEN ACCESS Received: 25/11/2025 Accepted: 30/12/2025