A NEW EXPLICIT SIMULATION FOR MOULD FILLING WITH HIGH VISCOUS FEEDSTOCK

In the simulation of the metal injection moulding (MIM), the behaviours of feedstock are much di?erent from which of the polymer injection. It is a mixture of the metallic powder in high concentration and some plastic binder. The advance in simu…     

基于全矢量显式算法注射填充软件的研究与开发

基于前人模拟注射填充的显式算法,提出了一种新的全矢量化运算显式算法。对于各类注射填充的模拟,此算法避免了压力场的全局求解,矩阵操作仅在单元一级进行,通过反馈修正,在各时间增量步使已填充的区域满足不可压缩条件。由于避免了所有的全局耦合求解,计算代价与节点的自由度近似成正比,可实现填充模拟过程的高效运算。由于矢量化算法是完全脱耦的,容易实现并行计算。基于这种新算法,应用有限元法进行了注射填充仿真软件的初步开发。其填充模拟结果与商业软件MOLDFLOW的三维模拟结果比较,证实了该软件的有效性。     

A Markov chain model of mixing kinetics for ternary mixture of dissimilar particulate solids

This paper presents a simple but informative mathematical model to describe the mixing of three dissimilar components of particulate solids that have the tendency to segregate within one another. A nonlinear Markov chain model is proposed to describe the process. At each time step, the exchange of particulate solids between the cells of the chain is divided into two virtual stages. The first is pure stochastic mixing accompanied by downward segregation. Upon the completion of this stage, some of the cells appear to be overfilled with the mixture, while others appear to have a void space. The second stage is related to upward segregation. Components from the overfilled cells fill the upper cells (those with the void space) according to the proposed algorithm. The degree of non-homogeneity in the mixture (the standard deviation) is calculated at each time step, which allows the mixing kinetics to be described. The optimum mixing time is found to provide the maximum homogeneity in the ternary mixture. However, this “common” time differs from the optimum mixing times for individual components. The model is verified using a lab-scale vibration vessel, and a reasonable correlation between the calculated and experimental data is obtained.     

Foucault Pendulum-like problems: A tensorial approach

The paper offers a comprehensive study of the motion in a central force field with respect to a rotating non-inertial reference frame. It is called Foucault Pendulum-like motion and it is a generalization of a classic Theoretical Mechanics problem. A closed form vectorial solution to this famous problem is presented. The vectorial time-explicit solution for the classic Foucault Pendulum problem is obtained as a particular case of the considerations made in the present approach. New interesting conservation laws for the Foucault Pendulum-like motion are deduced by using simple differential and vectorial computations. They help to visualize the shape of the trajectories. Exact vectorial expressions for the law of motion and the velocity are also offered. The case of the driven Foucault Pendulum is also analyzed, and a closed form solution is deduced based on the general considerations. In the end, an new tensorial prime integral for the Foucault Pendulum problem is offered. It helps to reveal in a concise form, within a single entity, all the scalar and vectorial conservation laws for the Foucault Pendulum motion.Two important engineering applications to this approach are presented: the motion of a satellite with respect to a rotating reference frame and the Keplerian relative orbital motion. The latter has a great importance in modeling the problems concerning satellite formation flying, satellite constellations and space terminal rendezvous. The classic problem of the harmonic oscillator in an electromagnetic field is also solved by using the instruments presented in this paper.     

On a modified Monte-Carlo method and variable soft sphere model for rarefied binary gas mixture flow simulation

The effect of new terms in the improved algorithm, the modified direct simulation Monte-Carlo (MDSMC) method, is investigated by simulating a rarefied binary gas mixture flow inside a rotating cylinder. Dalton law for the partial pressures contributed by each species of the binary gas mixture is incorporated into our simulation using the MDSMC method and the direct simulation Monte-Carlo (DSMC) method. Moreover, the effect of the exponent of the cosine of deflection angle (α) in the inter-molecular collision models, the variable soft sphere (VSS) and the variable hard sphere (VHS), is investigated in our simulation. The improvement of the results of simulation is pronounced using the MDSMC method when compared with the results of the DSMC method. The results of simulation using the VSS model show some improvements on the result of simulation for the mixture temperature at radial distances close to the cylinder wall where the temperature reaches the maximum value when compared with the results using the VHS model.     

Parallel computing of discrete element method on multi-core processors

This paper describes parallel simulation techniques for the discrete element method (DEM) on multi-core processors. Recently, multi-core CPU and GPU processors have attracted much attention in accelerating computer simulations in various fields. We propose a new algorithm for multi-thread parallel computation of DEM, which makes effective use of the available memory and accelerates the computation. This study shows that memory usage is drastically reduced by using this algorithm. To show the practical use of DEM in industry, a large-scale powder system is simulated with a complicated drive unit. We compared the performance of the simulation between the latest GPU and CPU processors with optimized programs for each processor. The results show that the difference in performance is not substantial when using either GPUs or CPUs with a multi-thread parallel algorithm. In addition, DEM algorithm is shown to have high scalability in a multi-thread parallel computation on a CPU.     

A complete closed form vectorial solution to the Kepler problem

The paper gives an exact vectorial solution to the Kepler problem. A vectorial regularization that linearizes the Kepler problem is given using a Sundman transformation. Closed form expressions describing the Keplerian motion are deduced. A unified approach to the classic Kepler problem is offered, by studying both rectilinear and non-rectilinear Keplerian motions with the same instrument. The approach is an elementary one and only simple vectorial computations are involved.     

Parameter tuning of ADRC and its application based on CCCSA

Active disturbance rejection controller can effectively adjust uncertain factors and the disturbance of the model by compensation. However, this advantageous controller has met with a technical bottleneck in its extensive use of engineering application because of its multiplicity of the parameters and the difficulty of integrating them. This paper proposes a chaotic cloud cloning selection algorithm by referring to cloud model and immune cloning selection, generating initial population by employing chaotic initialization to improve the quality of the initial antibodies, realizing mutation with basic normal cloud generator to improve the diversity of antibodies. Then the chaotic cloning selection algorithm is applied to the optimization of parameter integration. This new algorithm is tested and verified as to its convergence speed, convergence precision, and robustness with classic function. The results of simulation experiments for a time-delay system demonstrate that the optimized control system not only possesses excellent control performance but also exhibits strong robustness and anti-interference ability.     

Plane Horizontal Transverse Waves in Elastic Piezopowders

A procedure and results of computer simulation of plane horizontal transverse waves are described. Three materials — gallium arsenide, bismuth germanate, and lead zirconate–titanate ceramics — are selected as the piezoelectric phase. The second phase of the powder is always lead. To describe waves in the powder, the microstructural theory of two-phase mixtures is used. Therefore, the computer simulation was intended to study the influence of the lead content by volume on the wave velocities and the microstructural wave-propagation pattern — decomposition of a wave into two modes, simultaneous propagation of both modes in each phase of the powder, etc. First, sets of physical constants (elastic, piezoelectric, and dielectric) of mixture theory were evaluated for three types of powders (with the piezoelectric phase as one of the above-mentioned materials) with the volume piezoelectric-phase content varying from 0.01 to 0.5 with step 0.005. Further, dispersion curves for both modes and 3D-graphs of amplitudes as functions of the wave propagation time and distance were plotted for 300 compositions of powders (three types, each of 100 modifications). Of the phenomena described, we should first of all point out that all the phase velocities increase twice upon changing the content of the powder in the piezoelectric phase from a very small amount to the maximum possible     

Transition of axial segregation patterns in a long rotating drum

Axial segreganon or a bidisperse mixture of particles in a long rotating drum is studied using the discrete element method. Simulation results show that particle interaction is responsible for axial segregation, the patterns of which are influenced by the end wall effect. Axial segregation patterns transform under competing influences of the end walls and the particle interaction forces. The two influential factors vary with various rotational speeds and end wall friction levels. The result is the transition of different axial segregation patterns： two large-particle bands at both ends, two small-particle bands at both ends, or a random segregation pattern where either a large-particle band or small-particle band may appear at either end.     

遗传算法改进及其在岩土参数反分析中的应用

本文的主要目的是开发基于实数编码的杂交遗传算法来识别土体的本构参数。该杂交遗传算法在经典遗传算法框架下开发,融合两个新开发的交叉算子,形成了一个新的杂交策略。为了保持种群的多样性,在算法中采用了一个动态随机变异算子。另外,为了提高算法收敛性,采用了一个基于混沌的局部搜索技术。分别基于室内试验和现场试验,通过识别土的本构参数来测试新算法的搜索能力和搜索效率。为了测试新开发算法的突出表现,特选用5种经典的随机类算法（遗传算法、粒子群算法、模拟退火算法、差分算法和蜂巢算法）,分析同样的案例进行比较。结果表明,在收敛速度和最优解的准确度方面,新改进的算法可以很好地处理岩土工程的参数反演。     

Estimation of structural element sizes in sand and compacted blocks of ground calcium carbonate using a void network model

An algorithm has been developed for the calculation of the size of the effective structural or skeletal elements which make up the solid phase of an unconsolidated or consolidated porous block. It is based on a previously presented algorithm, but it has now been validated on unconsolidated samples and tested on consolidated samples. It also includes a virtual reality representation of the structures. First, a network model named Pore-Cor is made to reproduce the percolation behaviour of the experimental sample, by matching its simulated percolation characteristics to an experimental mercury intrusion curve. The algorithm then grows skeletal elements between the cubic pores and cylindrical throats of the void network model until they touch up to four of the adjacent void features. The size distributions of the simulated solid elements are compared with each other and with experimentally determined particle size distributions, using a Mann–Whitney test. The algorithm was shown to simulate skeletal elements with the correct trends in size distribution for two different sand samples, provided the sand packed itself optimally under the applied mercury pressure. It was also applied to two samples of variously compressed calcium carbonate powder, having fine and coarse particle size distributions respectively. The simulation demonstrated that on compressing the powder at the minimum force, the skeletal elements differed from the constituent particle sizes, as expected. The average size of the skeletal elements increased as the compression force was increased on the calcium carbonate powders. The results suggest that the method could be useful as a tool for probing the effect of compaction on aggregation or sintering, and for studying other effects such as cementation in geological samples, where other more direct techniques cannot be applied.     

Fast, Robust and Accurate Digital Image Correlation Calculation Without Redundant Computations

High-efficiency and high-accuracy deformation analysis using digital image correlation (DIC) has become increasingly important in recent years, considering the ongoing trend of using higher resolution digital cameras and common requirement of processing a large sequence of images recorded in a dynamic testing. In this work, to eliminate the redundant computations involved in conventional DIC method using forward additive matching strategy and classic Newton–Raphson (FA-NR) algorithm without sacrificing its sub-pixel registration accuracy, we proposed an equivalent but more efficient DIC method by combining inverse compositional matching strategy and Gauss-Newton (IC-GN) algorithm for fast, robust and accurate full-field displacement measurement. To this purpose, first, an efficient IC-GN algorithm, without the need of re-evaluating and inverting Hessian matrix in each iteration, is introduced to optimize the robust zero-mean normalized sum of squared difference (ZNSSD) criterion to determine the desired deformation parameters of each interrogated subset. Then, an improved reliability-guided displacement tracking strategy is employed to achieve further speed advantage by automatically providing accurate and complete initial guess of deformation for the IC-GN algorithm implemented on each calculation point. Finally, an easy-to-implement interpolation coefficient look-up table approach is employed to avoid the repeated calculation of bicubic interpolation at sub-pixel locations. With the above improvements, redundant calculations involved in various procedures (i.e. initial guess of deformation, sub-pixel displacement registration and sub-pixel intensity interpolation) of conventional DIC method are entirely eliminated. The registration accuracy and computational efficiency of the proposed DIC method are carefully tested using numerical experiments and real experimental images. Experimental results verify that the proposed DIC method using IC-GN algorithm and the existing DIC method using classic FA-NR algorithm generate similar results, but the former is about three to five times faster. The proposed reliability-guided IC-GN algorithm is expected to be a new standard full-field displacement tracking algorithm in DIC.     

Comparison of roller-spreading and blade-spreading processes in powder-bed additive manufacturing by DEM simulations

The roller-spreading and blade-spreading are main powder spreading methods in powder-bed additive manufacturing. The discrete element method was introduced to simulate nylon powder spreading by both roller and blade spreaders. The two spreading processes were compared from several aspects including particle flow behavior, particle contact forces, forces exerted on spreaders, particle segregation and powder layer density. It is found that powder spreading methods mainly affect the movement trajectory of particles, particle contact forces and forces exerted on spreaders. Complicated dispersion and circulation movement of particles occur inside the powder pile by roller-spreading, while particles have relatively weak dispersion by the blade-spreading. The normal force applied to the roller introduces a compacting effect on the powder pile and creates strong force chains that distribute uniformly in the powder pile. Therefore, the powder bed with higher density can be obtained by roller-spreading in thicker powder layer due to the compacting effect. The blade spreader sustains tangential force mainly, so the blade-spreading process limits its application to thicker powder layer. As the powder layer thickness increases, the roller-spreading is more sensitive to segregation index than that of the blade-spreading. The comprehensive comparison of two spreading processes provides criteria for selecting spreading methods.     

Improved atomization,collision and sub-grid scale momentum coupling models for transient vaporizing engine sprays

A computationally efficient spray model is presented for the simulation of transient vaporizing engine sprays. It is applied to simulate high-pressure fuel injections in a constant volume chamber and in mixture preparation experiments in a light-duty internal combustion engine. The model is based on the Lagrangian-Particle/Eulerian-Fluid approach, and an improved blob injection model is used that removes numerical dependency on the injected number of computational parcels. Atomization is modeled with the hybrid Kelvin–Helmholtz/Rayleigh–Taylor scheme, in combination with a drop drag model that includes Mach number and Knudsen number effects. A computationally efficient drop collision scheme is presented, tailored for large numbers of parcels, using a deterministic collision impact definition and kd-tree data search structure to perform radius-of-influence based, grid-independent collision probability estimations. A near-nozzle sub-grid scale flow-field representation is introduced to reduce numerical grid dependency, which uses a turbulent transient gas-jet model with a Stokes–Strouhal analogy assumption. An implicit coupling method was developed for the Arbitrary Lagrangian–Eulerian (ALE) turbulent flow solver. A multi-objective genetic algorithm was used to study the interactions of the various model constants, and to provide an optimal calibration. The optimal set showed similar values of the primary breakup constants as values used in the literature. However, different values were seen for the gas-jet model constants for accurate simulations of the initial spray transient. The results show that there is a direct correlation between the predicted initial liquid-phase transient and the global gas-phase jet penetration. Model validation was also performed in engine simulations with the same set of constants. The model captured mixture preparation well in all cases, proving its suitability for simulations of transient spray injection in engines.     

Discrete element method study of shear-driven granular segregation in a slowly rotating horizontal drum

Segregation and mixing of granular materials are complex processes and are not fully understood. Motivated by industrial need, we performed a simulation using the discrete element method to study size segregation of a binary mixture of granular particles in a horizontal rotating drum. Particles of two different sizes were poured into the drum until it was 50% full. Shear-driven segregation was induced by rotating the side-plates of the drum in the opposite direction to that of the cylindrical wall. We found that radial segregation diminished in these systems but did not completely vanish. In an ordinary rotating drum, a radial core of smaller particles is formed in the center of the drum, surrounded by larger revolving particles. In our system, however, the smaller particles were found to migrate toward the side-plates. The shear from anti-spinning side-plates reduces the voidage and increases the bulk density. As such, smaller particles in the mixer tend to move to denser regions. We varied the shear by changing the coefficient of friction on the side-plates to study the influence of shear rate on this migration. We also compared the extent of radial segregation with stationary side-plates and with side-plates moving in different angular directions.     

Role of the momentum interpolation mechanism of the Roe scheme in shock instability

The shock instability phenomenon is a well‐known problem for hypersonic flow computation by the shock‐capturing Roe scheme. The pressure checkerboard is another well‐known problem for low‐Mach‐number flow computation. The momentum interpolation method (MIM) is necessary for low‐Mach‐number flows to suppress the pressure checkerboard problem, and the pressure‐difference‐driven modification for cell face velocity can be regarded as a version of the MIM by subdividing the numerical dissipation of the Roe scheme. In this paper, MIM has been discovered through analysis and numerical tests to have the most important function in shock instability. MIM should be completely removed for nonlinear flows. However, the unexpected MIM is activated on the cell face nearly parallel to the flow for the high‐Mach‐number flows or low‐Mach‐number cells in numerical shock. Therefore, MIM should be retained for low‐Mach‐number flows and be completely removed for high‐Mach‐number flows and low‐Mach‐number cells in numerical shock. For such conditions, two coefficients are designed on the basis of the local Mach number and a shock detector. Thereafter, the improved Roe scheme is proposed. This scheme considers the requirement of MIM for incompressible and compressible flows, and is validated for good performance of numerical tests. An acceptable result can also be obtained with only the Mach number coefficient for general practical computation. Therefore, the objective of decreasing rather than increasing numerical dissipation to cure shock instability can be achieved with simple modification. Moreover, the mechanism of shock instability has been profoundly understood, in which MIM plays the most important role, although it is not the only factor. Copyright © 2016 John Wiley & Sons, Ltd.     

Eulerian equilibria of a triaxial gyrostat in the three body problem: rotational Poisson dynamics in Eulerian equilibria

We consider the noncanonical Hamiltonian dynamics of a triaxial gyrostat in the three body problem. By means of geometric-mechanics methods, we will study the approximated dynamics that arises when we develop the potential in series of Legendre and truncate the series to the second harmonics. Working in the reduced problem, we will study the existence of equilibria that we will denominate of Euler in analogy with classic results on the topic. In this way, we generalize the classical results on equilibria of the three-body problem and many of those obtained by other authors using more classic techniques for the case of rigid bodies. The instability of Eulerian equilibria is proven in this approximate dynamics if the gyrostat is close to the sphere. The rotational Poisson dynamics of the gyrostat placed at an Eulerian equilibrium and the study of the nonlinear stability of some equilibria is considered. The analysis is done in vectorial form avoiding the use of canonical variables and the tedious expressions associated with them.     

模拟滚弯非稳态过程的虚拟载荷法

采用传统的拉格朗日有限元模型模拟三辊滚弯的非稳态过程时,受到网格数量和接触算法的影响,计算效率难以提高.受计算流体力学的启发,将滚弯机跨内空间视作一维流场,工件挠曲线视作流场中的变量,采用欧拉观点建模,可以大大减小网格数量,同时降低接触处理的难度.将欧拉观点控制方程中的迁移项归结成一个附加的虚拟载荷,将其定义为型材空间...     

Two‐dimensional non‐Newtonian injection molding with a new control volume FEM/volume of fluid method

A new method based on volume of fluid for interface tracking in the simulation of injection molding is presented. The proposed method is comprised of two main stages: accumulation and distribution of the volume fraction. In the first stage the equation for the volume fraction with a noninterfacial flux condition is solved. In the second stage the accumulated volume of fluid that arises as a consequence of the application of the first one is dispersed. This procedure guarantees that the fluid fills the available space without dispersion of the interface. The mathematical model is based on two‐phase transport equations that are numerically integrated through the control volume finite element method. The numerical results for the interface position are successfully verified with analytical results and numerical data available in the literature for one‐dimensional and two‐dimensional domains. The transient position of the advance fronts showed an effective and consistent simulation of an injection molding process. The nondispersive volume of fluid method here proposed is implemented for the simulation of nonisothermal injection molding in two‐dimensional cavities. The obtained results are represented as transient interface positions, isotherms and pressure distributions during the injection molding of low density polyethylene. Copyright © 2012 John Wiley & Sons, Ltd.