Topology optimization for unsteady flow

A computational methodology for optimizing the conceptual layout of unsteady flow problems at low Reynolds numbers is presented. The geometry of the design is described by the spatial distribution of a fictitious material with continuously varying porosity. The flow is predicted by a stabilized finite element formulation of the incompressible Navier–Stokes equations. A Brinkman penalization is used to enforce zero‐velocities in solid material. The resulting parameter optimization problem is solved by a non‐linear programming method. The paper studies the feasibility of the material interpolation approach for optimizing the topology of unsteady flow problems. The derivation of the governing equations and the adjoint sensitivity analysis are presented. A design‐dependent stabilization scheme is introduced to mitigate numerical instabilities in porous material. The emergence of non‐physical artifacts in the optimized material distribution is observed and linked to an insufficient resolution of the flow field and an improper representation of the pressure field within solid material by the Brinkman penalization. Two numerical examples demonstrate that the designs optimized for unsteady flow differ significantly from their steady‐state counterparts. Copyright © 2011 John Wiley & Sons, Ltd.     

Eulerian elasto‐visco‐plastic formulations for residual stress prediction

A stabilized, Galerkin finite element formulation for modeling the elasto‐visco‐plastic response of quasi‐steady‐state processes, such as welding, laser surfacing, rolling and extrusion, is presented in an Eulerian frame. The mixed formulation consists of four field variables, such as velocity, stress, deformation gradient and internal variable, which is used to describe the evolution of the material's resistance to plastic flow. The streamline upwind Petrov–Galerkin method is used to eliminate spurious oscillations, which may be caused by the convection‐type of stress, deformation gradient and internal variable evolution equations. A progressive solution strategy is introduced to improve the convergence of the Newton–Raphson solution procedure. Two two‐dimensional numerical examples are implemented to verify the accuracy of the Eulerian formulation. Copyright © 2008 John Wiley & Sons, Ltd.     

Velocity‐based formulations for standard and quasi‐incompressible hypoelastic‐plastic solids

We present three velocity‐based updated Lagrangian formulations for standard and quasi‐incompressible hypoelastic‐plastic solids. Three low‐order finite elements are derived and tested for non‐linear solid mechanics problems. The so‐called V‐element is based on a standard velocity approach, while a mixed velocity–pressure formulation is used for the VP and the VPS elements. The two‐field problem is solved via a two‐step Gauss–Seidel partitioned iterative scheme. First, the momentum equations are solved in terms of velocity increments, as for the V‐element. Then, the constitutive relation for the pressure is solved using the updated velocities obtained at the previous step. For the VPS‐element, the formulation is stabilized using the finite calculus method in order to solve problems involving quasi‐incompressible materials. All the solid elements are validated by solving two‐dimensional and three‐dimensional benchmark problems in statics as in dynamics. Copyright © 2016 John Wiley & Sons, Ltd.     

Finite calculus formulation for incompressible solids using linear triangles and tetrahedra

Many finite elements exhibit the so‐called ‘volumetric locking’ in the analysis of incompressible or quasi‐incompressible problems.In this paper, a new approach is taken to overcome this undesirable effect. The starting point is a new setting of the governing differential equations using a finite calculus (FIC) formulation. The basis of the FIC method is the satisfaction of the standard equations for balance of momentum (equilibrium of forces) and mass conservation in a domain of finite size and retaining higher order terms in the Taylor expansions used to express the different terms of the differential equations over the balance domain. The modified differential equations contain additional terms which introduce the necessary stability in the equations to overcome the volumetric locking problem. The FIC approach has been successfully used for deriving stabilized finite element and meshless methods for a wide range of advective–diffusive and fluid flow problems. The same ideas are applied in this paper to derive a stabilized formulation for static and dynamic finite element analysis of incompressible solids using linear triangles and tetrahedra. Examples of application of the new stabilized formulation to linear static problems as well as to the semi‐implicit and explicit 2D and 3D non‐linear transient dynamic analysis of an impact problem and a bulk forming process are presented. Copyright © 2004 John Wiley & Sons, Ltd.     

A new rigid‐viscoplastic model for simulating thermal strain effects in metal‐forming processes

A new rigid‐viscoplastic model that includes the effect of thermal strains when modelling steady‐state metal‐forming processes was developed. A symmetric approximation to the resulting non‐symmetric stiffness matrix was derived. The thermo‐mechanical flow formulation was implemented using the pseudo‐concentrations technique. The new formulation was numerically tested showing that it provides reliable results. Copyright © 2003 John Wiley & Sons, Ltd.     

Numerical simulation of forging a ball from a cylindrical billet

Abstract

Rigid‐viscoplastic finite element equations are used for the analysis of metal forming process. With the view of solution accuracy and computation efficiency, the possible overconstraint of the incompressibility condition is avoided by modifying the penalty method in the variational formulation; and both the direct iterative method and Newton‐Raphson iterative method are combined to solve the finite element equations. The forging process of a ball from a cylindrical workpiece is completely simulated by a remesh procedure. The computed results agree well with the experimental measurements. It is shown, during the early stage of plastic deformation, the effect of friction is small, but gradually increases with further plastic deformation. In the finishing stage, the shear plastic deformation is found mainly in the flash portion. As the shape factor of workpiece increases, the filling of the die cavity is more complete, but the required forming energy increases and the variation of microstructure within the final forged product is intensified. The effect of die velocity also improves die cavity filling.     

Unconditionally stable operator splitting algorithms for the incompressible magnetohydrodynamics system discretized by a stabilized finite element formulation based on projections

In this article, we propose different splitting procedures for the transient incompressible magnetohydrodynamics (MHD) system that are unconditionally stable. We consider two levels of splitting, on one side we perform the segregation of the fluid pressure and magnetic pseudo‐pressure from the vectorial fields computation. At the second level, the fluid velocity and induction fields are also decoupled. This way, we transform a fully coupled indefinite multi‐physics system into a set of smaller definite ones, clearly reducing the CPU cost. With regard to the finite element approximation, we stick to an unconditionally convergent stabilized finite element formulation because it introduces convection stabilization, allows to circumvent inf‐sup conditions (clearly simplifying implementation issues), and is able to capture non‐smooth solutions of the magnetic subproblem. However, residual‐based finite element formulations are not suitable for segregation, because they lose the skew‐symmetry of the off‐diagonal blocks. Therefore, in this work, we have proposed a novel term‐by‐term stabilization of the MHD system based on projections that is still unconditionally convergent. Copyright © 2012 John Wiley & Sons, Ltd.     

Design sensitivity analysis in large deformation elasto‐plastic and elasto‐viscoplastic problems

Implicit time integration algorithm derived by Simo for his large‐deformation elasto‐plastic constitutive model is generalized, for the case of isotropy and associative flow rule, towards viscoplastic material behaviour and consistently differentiated with respect to its input parameters. Combining it with the general formulation of design sensitivity analysis (DSA) for non‐linear finite element transient equilibrium problem, we come at a numerically efficient, closed‐form finite element formulation of DSA for large deformation elasto‐plastic and elasto‐viscoplastic problems, with various types of design variables (material constants, shape parameters). The paper handles several specific issues, like the use of a non‐algorithmic coefficient matrix or sensitivity discontinuities at points of instantaneous structural stiffness change. Computational examples demonstrate abilities of the formulation and quality of results. Copyright © 2005 John Wiley & Sons, Ltd.     

On methods for stabilizing constraints over enriched interfaces in elasticity

Enriched finite element approaches such as the extended finite element method provide a framework for constructing approximations to solutions of non‐smooth problems. Internal features, such as boundaries, are represented in such methods by using discontinuous enrichment of the standard finite element basis. Within such frameworks, however, imposition of interface constraints and/or constitutive relations can cause unexpected difficulties, depending upon how relevant fields are interpolated on un‐gridded interfaces. This work address the stabilized treatment of constraints in an enriched finite element context. Both the Lagrange multiplier and penalty enforcement of tied constraints for an arbitrary boundary represented in an enriched finite element context can lead to instabilities and artificial oscillations in the traction fields. We demonstrate two alternative variational methods that can be used to enforce the constraints in a stable manner. In a ‘bubble‐stabilized approach,’ fine‐scale degrees of freedom are added over elements supporting the interface. The variational form can be shown to have a similar form to a second approach we consider, Nitsche's method, with the exception that the stabilization terms follow directly from the bubble functions. In this work, we examine alternative variational methods for enforcing a tied constraint on an enriched interface in the context of two‐dimensional elasticity. We examine several benchmark problems in elasticity, and show that only Nitsche's method and the bubble‐stabilization approach produce stable traction fields over internal boundaries. We also demonstrate a novel difference between the penalty method and Nitsche's method in that the latter passes the patch test exactly, regardless of the stabilization parameter's magnitude. Results for more complicated geometries and triple interface junctions are also presented. Copyright © 2008 John Wiley & Sons, Ltd.     

A three field element via Augmented Lagrangian for modelling bulk metal forming processes

A new 2D quadrilateral element is developed for the modelling of 2D incompressible rigid/viscoplastic problems: the QMITC-3F. The element formulation is based on the interpolation of three fields: velocities, strain rates and pressures. The incompressibility constraint is enforced using an Augmented Lagrangian technique. The new element is used in conjunction with the flow formulation and the pseudo-concentrations technique for modelling bulk metal forming processes.Dedicated to J. C. Simo     

The coupled radial–axial deformations analysis of flexible pipes conveying fluid

This paper presents large deformation analysis of pipes conveying fluid in which two complicated behaviours are taken into consideration. The first is the coupling between radial and axial deformations of pipe wall, and the other is the interaction between a deformed pipe and transported fluid having the variable internal flow velocity. The coupled radial–axial deformation theory of the pipes and the continuity theory of flow inside the moving deformed pipes are developed to undertake these coupling behaviours. All strong and weak forms of governing equations are obtained by carrying out the virtual work formulation. The hybrid‐finite element method is used to solve the highly non‐linear static problems, which configure the initial large deflection and large strain conditions of the pipes. The state‐space finite element model for use in analyses of non‐linear vibration and system stability is established as well as the suggested numerical solution procedures. The numerical studies of the pipes under circumstances of intense radial loads such as deep‐water risers demonstrate that even a slight change of the radial deformation has a significant effect in increasing non‐linear responses, and reducing stabilities of the pipes. Copyright © 2004 John Wiley & Sons, Ltd.     

Mixed finite element method for saturated poroelastoplastic media at large strains

A mixed finite element for hydro‐dynamic analysis in saturated porous media in the frame of the Biot theory is proposed. Displacements, effective stresses, strains for the solid phase and pressure, pressure gradients, and Darcy velocities for the fluid phase are interpolated as independent variables. The weak form of the governing equations of coupled hydro‐dynamic problems in saturated porous media within the element are given on the basis of the Hu–Washizu three‐field variational principle. In light of the stabilized one point quadrature super‐convergent element developed in solid continuum, the interpolation approximation modes for the primary unknowns and their spatial derivatives of the solid and the fluid phases within the element are assumed independently. The proposed mixed finite element formulation is derived. The non‐linear version of the element formulation is further derived with particular consideration of pressure‐dependent non‐associated plasticity. The return mapping algorithm for the integration of the rate constitutive equation, the consistent elastoplastic tangent modulus matrix and the element tangent stiffness matrix are developed. For geometrical non‐linearity, the co‐rotational formulation approach is used. Numerical results demonstrate the capability and the performance of the proposed element in modelling progressive failure characterized by strain localization due to strain softening in poroelastoplastic media subjected to dynamic loading at large strain. Copyright © 2003 John Wiley & Sons, Ltd.     

A stabilized volume‐averaging finite element method for flow in porous media and binary alloy solidification processes

A stabilized equal‐order velocity–pressure finite element algorithm is presented for the analysis of flow in porous media and in the solidification of binary alloys. The adopted governing macroscopic conservation equations of momentum, energy and species transport are derived from their microscopic counterparts using the volume‐averaging method. The analysis is performed in a single domain with a fixed numerical grid. The fluid flow scheme developed includes SUPG (streamline‐upwind/Petrov–Galerkin), PSPG (pressure stabilizing/Petrov–Galerkin) and DSPG (Darcy stabilizing/Petrov–Galerkin) stabilization terms in a variable porosity medium. For the energy and species equations a classical SUPG‐based finite element method is employed. The developed algorithms were tested extensively with bilinear elements and were shown to perform stably and with nearly quadratic convergence in high Rayleigh number flows in varying porosity media. Examples are shown in natural and double diffusive convection in porous media and in the directional solidification of a binary‐alloy. Copyright © 2004 John Wiley & Sons, Ltd.     

Simulation of two‐ and three‐dimensional viscoplastic flows using adaptive mesh refinement

This paper presents a finite element solver for the simulation of steady non‐Newtonian flow problems, using a regularized Bingham model, with adaptive mesh refinement capabilities. The solver is based on a stabilized formulation derived from the variational multiscale framework. This choice allows the introduction of an a posteriori error indicator based on the small scale part of the solution, which is used to drive a mesh refinement procedure based on element subdivision. This approach applied to the solution of a series of benchmark examples, which allow us to validate the formulation and assess its capabilities to model 2D and 3D non‐Newtonian flows.     

Finite element formulation for modelling large deformations in elasto‐viscoplastic polycrystals

Anisotropic, elasto‐viscoplastic behaviour in polycrystalline materials is modelled using a new, updated Lagrangian formulation based on a three‐field form of the Hu‐Washizu variational principle to create a stable finite element method in the context of nearly incompressible behaviour. The meso‐scale is characterized by a representative volume element, which contains grains governed by single crystal behaviour. A new, fully implicit, two‐level, backward Euler integration scheme together with an efficient finite element formulation, including consistent linearization, is presented. The proposed finite element model is capable of predicting non‐homogeneous meso‐fields, which, for example, may impact subsequent recrystallization. Finally, simple deformations involving an aluminium alloy are considered in order to demonstrate the algorithm. Copyright © 2004 John Wiley & Sons, Ltd.     

A comparison of Galerkin and streamline techniques for integrating strains from an Eulerian flow field

Two methods are compared for integrating the strains that can arise in finite element solutions for Eulerian velocity fields associated with large strain material forming processes. With the Galerkin formulation, partial differential equations for the deformation gradient are solved over the entire domain based on a weighted residual; with the streamline integrated technique, the corresponding ordinary differential equations are integrated along characteristic lines. Both methods have yielded accurate integrations for the radial flow and planar rolling problems studied. A finite element technique is also presented for ensuring that the free surfaces of the fluid flow are streamlines. This technique has been used for ensuring proper boundary conditions in the rolling analysis.     

Model reduction and process control of thermomechanical behaviour of non-linear material deformation

This paper describes a design procedure for metal forming processes by using the controllable subspace of the full system. The velocity profile of the moving die is designed using the reduced order system. The metal forming processes are simulated using non-linear finite element methods based on the rigid viscoplastic flow formulation. The balanced model reduction technique is applied to reduce the full state space model to a reduced order model that retains the controllable subspace of the thermomechanical system. The linear quadratic regulator theory with output tracking is used as an off-line design tool to design the die velocity schedule. The process design is carried out to maintain the strain rate of the critical portion of the billet at a desired value. The procedure for designing the process parameters is demonstrated using two case studies.     

A simultaneous solution procedure for strong interactions of generalized Newtonian fluids and viscoelastic solids at large strains

The paper presents a methodology for numerical analyses of coupled systems exhibiting strong interactions of viscoelastic solids and generalized Newtonian fluids. In the monolithic approach, velocity variables are used for both solid and fluid, and the entire set of model equations is discretized with stabilized space–time finite elements. A viscoelastic material model for finite deformations, which is based on the concept of internal variables, describes the stress‐deformation behaviour of the solid. In the generalized Newtonian approach for the fluid, the viscosity depends on the shear strain rate, leading to common non‐Newtonian fluid models like the power‐law. The consideration of non‐linear constitutive equations for solid and fluid documents the capability of the monolithic space–time finite element formulation to deal with complex material models. The methodology is applied to fluid‐conveying cantilevered pipes in order to determine the influence of material non‐linearities on stability characteristics of coupled systems. Copyright © 2005 John Wiley & Sons, Ltd.     

On the modelling of complex 3D bulk metal forming processes via the pseudo‐concentrations technique. Application to the simulation of the Mannesmann piercing process

The modelling of complex 3D metal forming processes using the flow formulation, implemented via the pseudo‐concentrations technique, requires the development of robust computational strategies for dealing with the velocity and pseudo‐concentration boundary conditions in the zone where the blank–tools contact is developed. A new algorithm, designed to fulfil those requirements, is presented in this paper. The Mannesmann piercing process is a metal forming operation used in industry for manufacturing metal seamless pipes. The results of the Mannesmann process finite element simulation are particularly dependent on the accuracy and stability of the algorithm used to describe the contact boundary conditions between the forming tools and the blank. The validation of the finite element model is performed by comparing the numerical predictions obtained using the new algorithm with the results of industrial tests. Copyright © 2005 John Wiley & Sons, Ltd.     

Finite element solution of free‐surface ship‐wave problems

An unstructured finite element solver to evaluate the ship‐wave problem is presented. The scheme uses a non‐structured finite element algorithm for the Euler or Navier–Stokes flow as for the free‐surface boundary problem. The incompressible flow equations are solved via a fractional step method whereas the non‐linear free‐surface equation is solved via a reference surface which allows fixed and moving meshes. A new non‐structured stabilized approximation is used to eliminate spurious numerical oscillations of the free surface. Copyright © 1999 John Wiley & Sons, Ltd.