Remeshing for metal forming simulations—Part II: Three‐dimensional hexahedral mesh generation

In the present study, a hexahedral mesh generator was developed for remeshing in three‐dimensional metal forming simulations. It is based on the master grid approach and octree‐based refinement scheme to generate uniformly sized or locally refined hexahedral mesh system. In particular, for refined hexahedral mesh generation, the modified Laplacian mesh smoothing scheme mentioned in the two‐dimensional study (Part I) was used to improve the mesh quality while also minimizing the loss of element size conditions. In order to investigate the applicability and effectiveness of the developed hexahedral mesh generator, several three‐dimensional metal forming simulations were carried out using uniformly sized hexahedral mesh systems. Also, a comparative study of indentation analyses was conducted to check the computational efficiency of locally refined hexahedral mesh systems. In particular, for specification of refinement conditions, distributions of effective strain‐rate gradient and posteriori error values based on a Z² error estimator were used. From this study, it is construed that the developed hexahedral mesh generator can be effectively used for three‐dimensional metal forming simulations. Copyright © 2002 John Wiley & Sons, Ltd.     

Quality improvement of non‐manifold hexahedral meshes for critical feature determination of microstructure materials

This paper describes a novel approach to improve the quality of non‐manifold hexahedral meshes with feature preservation for microstructure materials. In earlier works, we developed an octree‐based isocontouring method to construct unstructured hexahedral meshes for domains with multiple materials by introducing the notion of material change edge to identify the interface between two or more materials. However, quality improvement of non‐manifold hexahedral meshes is still a challenge. In the present algorithm, all the vertices are categorized into seven groups, and then a comprehensive method based on pillowing, geometric flow and optimization techniques is developed for mesh quality improvement. The shrink set in the modified pillowing technique is defined automatically as the boundary of each material region with the exception of local non‐manifolds. In the relaxation‐based smoothing process, non‐manifold points are identified and fixed. Planar boundary curves and interior spatial curves are distinguished, and then regularized using B‐spline interpolation and resampling. Grain boundary surface patches and interior vertices are improved as well. Finally, the optimization method eliminates negative Jacobians of all the vertices. We have applied our algorithms to two beta titanium data sets, and the constructed meshes are validated via a statistics study. Finite element analysis of the 92‐grain titanium is carried out based on the improved mesh, and compared with the direct voxel‐to‐element technique. Copyright © 2009 John Wiley & Sons, Ltd.     

The tetrahedral finite cell method: Higher‐order immersogeometric analysis on adaptive non‐boundary‐fitted meshes

The finite cell method (FCM) is an immersed domain finite element method that combines higher‐order non‐boundary‐fitted meshes, weak enforcement of Dirichlet boundary conditions, and adaptive quadrature based on recursive subdivision. Because of its ability to improve the geometric resolution of intersected elements, it can be characterized as an immersogeometric method. In this paper, we extend the FCM, so far only used with Cartesian hexahedral elements, to higher‐order non‐boundary‐fitted tetrahedral meshes, based on a reformulation of the octree‐based subdivision algorithm for tetrahedral elements. We show that the resulting TetFCM scheme is fully accurate in an immersogeometric sense, that is, the solution fields achieve optimal and exponential rates of convergence for h‐refinement and p‐refinement, if the immersed geometry is resolved with sufficient accuracy. TetFCM can leverage the natural ability of tetrahedral elements for local mesh refinement in three dimensions. Its suitability for problems with sharp gradients and highly localized features is illustrated by the immersogeometric phase‐field fracture analysis of a human femur bone. Copyright © 2016 John Wiley & Sons, Ltd.     

A finite element method with mesh‐separation‐based approximation technique and its application in modeling crack propagation with adaptive mesh refinement

This paper presents a FEM with mesh‐separation‐based approximation technique that separates a standard element into three geometrically independent elements. A dual mapping scheme is introduced to couple them seamlessly and to derive the element approximation. The novel technique makes it very easy for mesh generation of problems with complex or solution‐dependent, varying geometry. It offers a flexible way to construct displacement approximations and provides a unified framework for the FEM to enjoy some of the key advantages of the Hansbo and Hansbo method, the meshfree methods, the semi‐analytical FEMs, and the smoothed FEM. For problems with evolving discontinuities, the method enables the devising of an efficient crack‐tip adaptive mesh refinement strategy to improve the accuracy of crack‐tip fields. Both the discontinuities due to intra‐element cracking and the incompatibility due to hanging nodes resulted from the element refinement can be treated at the elemental level. The effectiveness and robustness of the present method are benchmarked with several numerical examples. The numerical results also demonstrate that a high precision integral scheme is critical to pass the crack patch test, and it is essential to apply local adaptive mesh refinement for low fracture energy problems. Copyright © 2014 John Wiley & Sons, Ltd.     

Robust generation of high‐quality unstructured meshes on realistic biomedical geometry

In this paper, we propose efficient and robust unstructured mesh generation methods based on computed tomography (CT) and magnetic resonance imaging (MRI) data, in order to obtain a patient‐specific geometry for high‐fidelity numerical simulations. Surface extraction from medical images is carried out mainly using open source libraries, including the Insight Segmentation and Registration Toolkit and the Visualization Toolkit, into the form of facet surface representation. To create high‐quality surface meshes, we propose two approaches. One is a direct advancing front method, and the other is a modified decimation method. The former emphasizes the controllability of local mesh density, and the latter enables semi‐automated mesh generation from low‐quality discrete surfaces. An advancing‐front‐based volume meshing method is employed. Our approaches are demonstrated with high‐fidelity tetrahedral meshes around medical geometries extracted from CT/MRI data. Copyright © 2005 John Wiley & Sons, Ltd.     

Fully‐automated hex‐dominant mesh generation with directionality control via packing rectangular solid cells

A new fully automatic hex‐dominant mesh generation technique of an arbitrary 3D geometric domain is presented herein. The proposed method generates a high‐quality hex‐dominant mesh by: (1) controlling the directionality of the output hex‐dominant mesh; and (2) avoiding ill‐shaped elements induced by nodes located too closely to each other. The proposed method takes a 3D geometric domain as input and creates a hex‐dominant mesh consisting mostly of hexahedral elements, with additional prism and tetrahedral elements. Rectangular solid cells are packed on the boundary of and inside the input domain to obtain ideal node locations for a hex‐dominant mesh. Each cell has a potential energy field that mimics a body‐centred cubic (BCC) structure (seen in natural substances such as NaCl) and the cells are moved to stable positions by a physically based simulation. The simulation mimics the formation of a crystal pattern so that the centres of the cells provide ideal node locations for a hex‐dominant mesh. Via the advancing front method, the centres of the packed cells are then connected to form a tetrahedral mesh, and this is converted to a hex‐dominant mesh by merging some of the tetrahedrons. Copyright © 2003 John Wiley & Sons, Ltd.     

Three‐dimensional grayscale‐free topology optimization using a level‐set based r‐refinement method

In this paper, we propose a three‐dimensional (3D) grayscale‐free topology optimization method using a conforming mesh to the structural boundary, which is represented by the level‐set method. The conforming mesh is generated in an r‐refinement manner; that is, it is generated by moving the nodes of the Eulerian mesh that maintains the level‐set function. Although the r‐refinement approach for the conforming mesh generation has many benefits from an implementation aspect, it has been considered as a difficult task to stably generate 3D conforming meshes in the r‐refinement manner. To resolve this task, we propose a new level‐set based r‐refinement method. Its main novelty is a procedure for minimizing the number of the collapsed elements whose nodes are moved to the structural boundary in the conforming mesh; in addition, we propose a new procedure for improving the quality of the conforming mesh, which is inspired by Laplacian smoothing. Because of these novelties, the proposed r‐refinement method can generate 3D conforming meshes at a satisfactory level, and 3D grayscale‐free topology optimization is realized. The usefulness of the proposed 3D grayscale‐free topology optimization method is confirmed through several numerical examples. Copyright © 2017 John Wiley & Sons, Ltd.     

Tetrahedral mesh generation using Delaunay refinement with non‐standard quality measures

This paper studies the practical performance of Delaunay refinement tetrahedral mesh generation algorithms. By using non‐standard quality measures to drive refinement, we show that sliver tetrahedra can be eliminated from constrained Delaunay tetrahedralizations solely by refinement. Despite the fact that quality guarantees cannot be proven, the algorithm can consistently generate meshes with dihedral angles between 18^circ and 154^°. Using a fairer quality measure targeting every type of bad tetrahedron, dihedral angles between 14^° and 154^° can be obtained. The number of vertices inserted to achieve quality meshes is comparable to that needed when driving refinement with the standard circumradius‐to‐shortest‐edge ratio. We also study the use of mesh improvement techniques on Delaunay refined meshes and observe that the minimum dihedral angle can generally be pushed above 20^°, regardless of the quality measure used to drive refinement. The algorithm presented in this paper can accept geometric domains whose boundaries are piecewise smooth. Copyright © 2011 John Wiley & Sons, Ltd.     

Localized remeshing techniques for three‐dimensional metal forming simulations with linear tetrahedral elements

The localized remeshing technique for three‐dimensional metal forming simulations is proposed based on a mixed finite element formulation with linear tetrahedral elements in the present study. The numerical algorithm to generate linear tetrahedral elements is developed for finite element analyses using the advancing front technique with local optimization method which keeps the advancing fronts smooth. The surface mesh generation using mesh manipulations of the boundary elements of the old mesh system was made to improve mesh quality of the boundary surface elements, resulting in reduction of volume change in forming simulations. The mesh quality generated was compared with that obtained from the commercial CAD package for the complex geometry like lumbar. The simulation results of backward extrusion and bevel gear and spider forgings indicate that the currently developed simulation technique with the localized remeshing can be used effectively to simulate the three‐dimensional forming processes with a reduced computation time. Copyright © 2006 John Wiley & Sons, Ltd.     

Hierarchical tree‐based finite element mesh generation

Hierarchical grid generation and its use as a basis for finite element mesh generation are considered in this paper. The hierarchical grids are generated by recursive subdivision using quadtrees in two dimensions and octrees in three dimensions. A numbering system for efficient storage of the quadtree grid information is examined, tree traversal techniques are devised for neighbour finding, and accurate boundary representation is considered. It is found that hierarchical grids are straightforward to generate from sets of seeding points which lie along domain boundaries. Quadtree grids are triangularized to provide finite element meshes in two dimensions. Three‐dimensional tetrahedral meshes are generated from octree grids. The meshes can be generated automatically to model complicated geometries with highly irregular boundaries and can be adapted readily at moving boundaries. Examples are given of two‐ and three‐dimensional hierarchical tree‐based finite element meshes and their application to modelling free surface waves. Copyright © 1999 John Wiley & Sons, Ltd.     

Advances in tetrahedral mesh generation for modelling of three‐dimensional regions with complex,curvilinear crack shapes

Advances in tetrahedral mesh generation for general, three‐dimensional domains with and without cracks are described and validated through extensive studies using a wide range of global geometries and local crack shapes. Automated methods are described for (a) implementing geometrical measures in the vicinity of the crack to identify irregularities and to improve mesh quality and (b) robust node selection on crack surfaces to ensure optimal meshing both locally and globally. The resulting numerical algorithms identify both node coincidence and also local crack surface penetration due to discretization of curved crack surfaces, providing a proven approach for removing inconsistencies. Numerical examples using the resulting 3D mesh generation program to mesh complex 3D domains containing a range of crack shapes and sizes are presented. Quantitative measures of mesh quality clearly show that the element shape and size distributions are excellent, including in regions surrounding crack fronts. Copyright © 2005 John Wiley & Sons, Ltd.     

Adaptive generation of hexahedral element meshes for finite element analysis of metal plastic forming process

A method for the adaptive generation of hexahedral element mesh based on the geometric features of solid model is proposed. The first step is to construct the refinement information fields of source points and the corresponding ones of elements according to the surface curvature of the analyzed solid model. A thickness refinement criterion is then used to construct the thickness-based refinement information field of elements from digital topology. The second step is to generate a core mesh through removing all the undesired elements using even and odd parity rules. Then the core mesh is magnified in an inside–out manner method through a surface node projection process using the closest position approach. Finally, in order to match the mesh to the characteristic boundary of the solid model, a threading method is proposed and applied. The present method was applied in the mesh construction of different engineering problems. The resulting meshes are well-shaped and capture all the geometric features of the original solid models.     

Q‐Morph: an indirect approach to advancing front quad meshing

Q‐Morph is a new algorithm for generating all‐quadrilateral meshes on bounded three‐dimensional surfaces. After first triangulating the surface, the triangles are systematically transformed to create an all‐quadrilateral mesh. An advancing front algorithm determines the sequence of triangle transformations. Quadrilaterals are formed by using existing edges in the triangulation, by inserting additional nodes, or by performing local transformations to the triangles. A method typically used for recovering the boundary of a Delaunay mesh is used on interior triangles to recover quadrilateral edges. Any number of triangles may be merged to form a single quadrilateral. Topological clean‐up and smoothing are used to improve final element quality. Q‐Morph generates well‐aligned rows of quadrilaterals parallel to the boundary of the domain while maintaining a limited number of irregular internal nodes. The proposed method also offers the advantage of avoiding expensive intersection calculations commonly associated with advancing front procedures. A series of examples of Q‐Morph meshes are also presented to demonstrate the versatility of the proposed method. Copyright © 1999 John Wiley & Sons, Ltd.     

Generation and optimization of tetrahedral meshes by advancing front technique

An algorithm for tetrahedron mesh generation and optimization with respect to a shape and a size criterion is presented. A well distributed set of nodes is first generated by an octree method, and the set is then triangulated. The advancing front technique is used to mesh the whole volume. Emphasis has been placed on management of the front. The method involves priority construction of enhanced quality tetrahedra. Each face is assigned to a front corresponding to the quality of the best tetrahedron which can be constructed. Elements are destroyed in the case of non-convergence. Optimization procedures make local use of the algorithm used to mesh the complete model. Industrial examples of relatively complex volumes are given, demonstrating that a high quality and optimized mesh can be obtained by the proposed method. © 1998 John Wiley & Sons, Ltd.     

Automated refinement of conformal quadrilateral and hexahedral meshes

Conformal refinement using a shrink and connect strategy, known as pillowing or buffer insertion, contracts and reconnects contiguous elements of an all‐quadrilateral or an all‐hexahedral mesh in order to locally increase vertex density without introducing hanging nodes or non‐cubical elements. Using layers as shrink sets, the present method automates the anisotropic refinement of such meshes according to a prescribed size map expressed as a Riemannian metric field. An anisotropic smoother further enhances vertex clustering to capture the features of the metric. Both two‐ and three‐dimensional test cases with analytic control metrics confirm the feasibility of the present approach and explore strategies to minimize the trade‐off between element shape quality and size conformity. Additional examples using discrete metric maps illustrate possible practical applications. Although local vertex removal and reconnection capabilities have yet to be developed, the present refinement method is a step towards an automated tool for conformal adaptation of all‐quadrilateral and all‐hexahedral meshes. Copyright © 2004 John Wiley & Sons, Ltd.     

A novel four‐node quadrilateral smoothing element for stress enhancement and error estimation

A four‐node, quadrilateral smoothing element is developed based upon a penalized‐discrete‐least‐squares variational formulation. The smoothing methodology recovers C¹‐continuous stresses, thus enabling effective a posteriori error estimation and automatic adaptive mesh refinement. The element formulation is originated with a five‐node macro‐element configuration consisting of four triangular anisoparametric smoothing elements in a cross‐diagonal pattern. This element pattern enables a convenient closed‐form solution for the degrees of freedom of the interior node, resulting from enforcing explicitly a set of natural edge‐wise penalty constraints. The degree‐of‐freedom reduction scheme leads to a very efficient formulation of a four‐node quadrilateral smoothing element without any compromise in robustness and accuracy of the smoothing analysis. The application examples include stress recovery and error estimation in adaptive mesh refinement solutions for an elasticity problem and an aerospace structural component. Copyright © 1999 John Wiley & Sons, Ltd.     

A new automatic hexahedral mesher based on cutting

A new method is presented leading to a 20‐node brick element mesh for an arbitrary structure based on a triangulation of the structure's surface. Starting from a hexahedral master mesh encompassing the structure, the elements which are intersected by the triangulation are determined, cut and remeshed. The resulting hexahedral mesh can be tied to the underlying elements by multiple point constraints or can be continued throughout the complete structure leading to a pure 20‐node brick mesh. Several examples show the effectiveness of the method. Copyright © 2001 John Wiley & Sons, Ltd.     

A new finite point generation scheme using metric specifications

A new approach to generate finite point meshes on 2D flat surface and any bi‐variate parametric surfaces is suggested. It can be used to generate boundary‐conforming anisotropic point meshes with node spacing compatible with the metric specifications defined in a background point mesh. In contrast to many automatic mesh generation schemes, the advancing front concept is abandoned in the present method. A few simple basic operations including boundary offsetting, node insertion and node deletion are used instead. The point mesh generation schemeis initialized by a boundary offsetting procedure. The point mesh quality is then improved by node insertion and deletion such that optimally spaced nodes will fill up the entire problem domain. In addition to the point mesh generation scheme, a new way to define the connectivity of a point mesh is also suggested. Furthermore, based on the connectivity information, a new scheme to perform smoothing for a point mesh is proposed toimprove the node spacing quality of the mesh. Timing shows thatdue to the simple node insertion and deletion operations, the generation speed of the new scheme is nearly 10 times faster than a similar advancing front mesh generator. Copyright © 2000 John Wiley & Sons, Ltd.     

Towards automatic structured multiblock mesh generation using improved transfinite interpolation

The quality of any numerical flowfield solution is inextricably linked to the quality of the mesh used. It is normally accepted that structured meshes are of higher quality than unstructured meshes, but are much more difficult to generate and, furthermore, for complex topologies a multiblock approach is required. This is the most resource‐intensive approach to mesh generation, since block structures, mesh point distributions, etc., need to be defined before the generation process, and so is seldom used in an industrial design loop, particularly where a novice user may be involved. This paper considers and presents two significant advances in multiblock mesh generation: the development of a fast, robust, and improved quality interpolation‐based generation scheme and a fully automatic multiblock optimization and generation method. A volume generation technique is presented based on a form of transfinite interpolation, but modified to include improved orthogonality and spacing control and, more significantly, an aspect ratio‐based smoothing algorithm that removes grid crossover and results in smooth meshes even for discontinuous boundary distributions. A fully automatic multiblock generation scheme is also presented, which only requires surface patch(es) and a target number of mesh cells. Hence, all user input is removed from the process, and a novice user is able to obtain a high‐quality mesh in a few minutes. It also means the code can be run in batch mode, or called as an external function, and so is ideal for incorporation into a design or optimization loop. To demonstrate the power and efficiency of the code, multiblock meshes of up to 256 million cells are presented for wings and rotors in hover and forward flight. Copyright © 2007 John Wiley & Sons, Ltd.