Sharp-interface VOF method for phase-change simulations on unstructured meshes

TL;DR

This paper introduces a novel phase-change simulation method on unstructured meshes combining algebraic VOF and geometric interface reconstruction, validated against analytical solutions and applied to boiling flow.

Contribution

It develops a phase-change model compatible with unstructured meshes that avoids empirical closures and can be integrated into existing finite-volume CFD codes.

Findings

Validated against Stefan, Sucking, and Scriven problems with good agreement.

Polyhedral meshes eliminate anisotropic growth and temperature overshoot effects.

Qualitative agreement with LES and experimental data in boiling flow simulations.

Abstract

Unstructured meshes are among the most versatile approaches for capturing non-canonical geometries in fluid dynamics simulations. Despite this, most high-fidelity first-principles phase-change models are developed and applied on structured meshes. We present a phase-change simulation method for unstructured meshes that combines the algebraic Volume-of-Fluid (VOF) technique with geometric interface reconstruction, implemented in an in-house open-source CFD code. Phase-change rates are computed from local temperature gradients evaluated at the reconstructed interface, without empirical closure models, using a reconstruction procedure that operates on arbitrary polyhedral cells. Because the method relies on the standard finite-volume framework, it can be integrated into other cell-centred codes supporting unstructured meshes. The approach is validated against the one-dimensional Stefan and Sucking problems and the three-dimensional Scriven bubble growth on both hexahedral and polyhedral meshes, showing good agreement with analytical solutions in all three cases. A detailed analysis of the Scriven problem reveals that the interface-modified least-squares gradient stencil on Cartesian meshes overestimates the interfacial temperature gradient, producing a persistent overshoot of the analytical bubble radius and a coherent four-fold anisotropy that elongates the bubble along grid diagonals. On polyhedral meshes, the irregular face orientations eliminate both effects, yielding isotropic growth and monotonic convergence. Finally, we demonstrate the framework on turbulent upward co-current annular boiling flow, where early transient results are qualitatively consistent with a previous LES study and experimental observations of wave-modulated evaporation.