An adaptive Lagrangian boundary element approach for three‐dimensional transient free‐surface Stokes flow as applied to extrusion,thermoforming, and rheometry

An adaptive (Lagrangian) boundary element approach is proposed for the general three‐dimensional simulation of confined free‐surface Stokes flow. The method is stable as it includes remeshing capabilities of the deforming free surface and thus can handle large deformations. A simple algorithm is developed for mesh refinement of the deforming free‐surface mesh. Smooth transition between large and small elements is achieved without significant degradation of the aspect ratio of the elements in the mesh. Several flow problems are presented to illustrate the utility of the approach, particularly as encountered in polymer processing and rheology. These problems illustrate the transient nature of the flow during the processes of extrusion and thermoforming, the elongation of a fluid sample in an extensional rheometer, and the coating of a sphere. Surface tension effects are also explored. Copyright © 2001 John Wiley & Sons, Ltd.     

Three‐dimensional transient free‐surface flow of viscous fluids inside cavities of arbitrary shape

The three‐dimensional transient free‐surface flow inside cavities of arbitrary shape is examined in this study. An adaptive (Lagrangian) boundary‐element approach is proposed for the general three‐dimensional simulation of confined free‐surface flow of viscous incompressible fluids. The method is stable as it includes remeshing capabilities of the deforming free‐surface, and thus can handle large deformations. A simple algorithm is developed for mesh refinement of the deforming free‐surface mesh. Smooth transition between large and small elements is achieved without significant degradation of the aspect ratio of the elements in the mesh. The method is used to determine the flow field and free‐surface evolution inside cubic, rectangular and cylindrical containers. These problems illustrate the transient nature of the flow during the mixing process. Surface tension effects are also explored. Copyright © 2003 John Wiley & Sons, Ltd.     

Simplex space‐time meshes in two‐phase flow simulations

In this paper, we present the numerical solution of 2‐phase flow problems of engineering significance with a space‐time finite element method that allows for local temporal refinement. Arbitrary temporal refinement is applied to preselected regions of the mesh and is governed by a quantity that is part of the solution process, namely, the interface position in 2‐phase flow. Because of local effects such as surface tension, jumps in material properties, etc, the interface can in general be considered a region that requires high flexibility and high resolution, both in space and in time. The new method, which leads to tetrahedral (for 2D problems) and pentatope (for 3D problems) meshes, offers an efficient yet accurate approach to the underlying 2‐phase flow problems.     

Spurious currents in finite element based level set methods for two‐phase flow

A study of spurious currents in continuous finite element based simulations of the incompressible Navier–Stokes equations for two‐phase flows is presented on the basis of computations on a circular drop in equilibrium. The conservative and the standard level set methods are used. It is shown that a sharp surface tension force, expressed as a line integral along the interface, can give rise to large spurious currents and oscillations in the pressure that do not decrease with mesh refinement. If instead a regularized surface tension representation is used, exact force balance at the interface is possible, both for a fully coupled discretization approach and for a fractional step projection method. However, the numerical curvature calculation introduces errors that cause spurious currents. Different ways to extend the curvature from the interface to the whole domain are discussed and investigated. The impact of using different finite element spaces and stabilization methods is also considered. Copyright © 2011 John Wiley & Sons, Ltd.     

A two‐phase flow interface capturing finite element method

A new interface capturing algorithm is proposed for the finite element simulation of two‐phase flows. It relies on the solution of an advection equation for the interface between the two phases by a streamline upwind Petrov–Galerkin (SUPG) scheme combined with an adaptive mesh refinement procedure and a filtering technique. This method is illustrated in the case of a Rayleigh–Taylor two‐phase flow problem governed by the Stokes equations. Copyright © 2006 John Wiley & Sons, Ltd.     

On the usage of NURBS as interface representation in free‐surface flows

When simulating free‐surface flows using the finite element method, there are many cases where the governing equations require information which must be derived from the available discretized geometry. Examples are curvature or normal vectors. The accurate computation of this information directly from the finite element mesh often requires a high degree of refinement—which is not necessarily required to obtain an accurate flow solution. As a remedy and an option to be able to use coarser meshes, the representation of the free surface using non‐uniform rational B‐splines (NURBS) curves or surfaces is investigated in this work. The advantages of a NURBS parameterization in comparison with the standard approach are discussed. In addition, it is explored how the pressure jump resulting from surface tension effects can be handled using doubled interface nodes. Numerical examples include the computation of surface tension in a two‐phase flow as well as the computation of normal vectors as a basis for mesh deformation methods. For these examples, the improvement of the numerical solution compared with the standard approaches on identical meshes is shown. Copyright © 2011 John Wiley & Sons, Ltd.     

Coupling methods between finite element–based Boussinesq‐type wave and particle‐based free‐surface flow models

We develop one‐way coupling methods between a Boussinesq‐type wave model based on the discontinuous Galerkin finite element method and a free‐surface flow model based on a mesh‐free particle method to strike a balance between accuracy and computational cost. In our proposed model, computation of the wave model in the global domain is conducted first, and the nonconstant velocity profiles in the vertical direction are reproduced by using its results. Computation of the free‐surface flow is performed in a local domain included within the global domain with interface boundaries that move along the reproduced velocity field in a Lagrangian fashion. To represent the moving interfaces, we used a polygon wall boundary model for mesh‐free particle methods. Verification and validation tests of our proposed model are performed, and results obtained by the model are compared with theoretical values and experimental results to show its accuracy and applicability.     

Fringe element reconstruction for front tracking for three‐dimensional incompressible flow analysis

Fringe element reconstruction technique for tracking the free surface in three‐dimensional incompressible flow analysis was developed. The flow field was calculated by the mixed formulation based on a four‐node tetrahedral element with a bubble function at the centroid (P1+/P1). Since an Eulerian approach was employed in this study, the flow front interface was advected by the flow through a fixed mesh. For accurate modelling of interfacial movement, a fringe element reconstruction method developed can provide not only an accurate treatment of material discontinuity but also surface tension across the interface. The effect of surface tension was modelled by imposing tensile stress directly on the constructed surface elements at the flow front interface. To verify the numerical approach developed, the developed algorithm was applied to two examples whose solutions are available in references. Good agreement was obtained between the simulation results and these solutions. Copyright © 2005 John Wiley & Sons, Ltd.     

An ALE finite element method for a coupled Stefan problem and Navier–Stokes equations with free capillary surface

In this article, an ALE finite element method to simulate the partial melting of a workpiece of metal is presented. The model includes the heat transport in both the solid and liquid part, fluid flow in the liquid phase by the Navier–Stokes equations, tracking of the melt interface solid/liquid by the Stefan condition, treatment of the capillary boundary accounting for surface tension effects and a radiative boundary condition. We show that an accurate treatment of the moving boundaries is crucial to resolve their respective influences on the flow field and thus on the overall energy transport correctly. This is achieved by a mesh‐moving method, which explicitly tracks the phase boundary and makes it possible to use a sharp interface model without singularities in the boundary conditions at the triple junction. A numerical example describing the welding of a thin‐steel wire end by a laser, where all aforementioned effects have to be taken into account, proves the effectiveness of the approach.Copyright © 2012 John Wiley & Sons, Ltd.     

An unfitted interior penalty discontinuous Galerkin method for incompressible Navier–Stokes two‐phase flow

A discontinuous Galerkin method for the solution of the immiscible and incompressible two‐phase flow problem based on the nonsymmetric interior penalty method is presented. Therefore, the incompressible Navier–Stokes equation is solved for a domain decomposed into two subdomains with different values of viscosity and density as well as a singular surface tension force. On the basis of a piecewise linear approximation of the interface, meshes for both phases are cut out of a structured mesh. The discontinuous finite elements are defined on the resulting Cartesian cut‐cell mesh and may therefore approximate the discontinuities of the pressure and the velocity derivatives across the interface with high accuracy. As the mesh resolves the interface, regularization of the density and viscosity jumps across the interface is not required. This preserves the local conservation property of the velocity field even in the vicinity of the interface and constitutes a significant advantage compared with standard methods that require regularization of these discontinuities and cannot represent the jumps and kinks in pressure and velocity. A powerful subtessellation algorithm is incorporated to allow the usage of standard time integrators (such as Crank–Nicholson) on the time‐dependent mesh. The presented discretization is applicable to both the two‐dimensional and three‐dimensional cases. The performance of our approach is demonstrated by application to a two‐dimensional benchmark problem, allowing for a thorough comparison with other numerical methods. Copyright © 2012 John Wiley & Sons, Ltd.     

A local domain‐free discretization method for simulation of incompressible flows over moving bodies

This paper presents a local domain‐free discretization (DFD) method for the simulation of unsteady flows over moving bodies governed by the incompressible Navier–Stokes equations. The discretization strategy of DFD is that the discrete form of partial differential equations at an interior point may involve some points outside the solution domain. All the mesh points are classified as interior points, exterior dependent points and exterior independent points. The functional values at the exterior dependent points are updated at each time step by the approximate form of solution near the boundary. When the body is moving, only the status of points is changed and the mesh can stay fixed. The issue of ‘freshly cleared nodes/cells’ encountered in usual sharp interface methods does not pose any particular difficulty in the presented method. The Galerkin finite‐element approximation is used for spatial discretization, and the discrete equations are integrated in time via a dual‐time‐stepping scheme based on artificial compressibility. In order to validate the present method for moving‐boundary flow problems, two groups of flow phenomena have been simulated: (1) flows over a fixed circular cylinder, a harmonic in‐line oscillating cylinder in fluid at rest and a transversely oscillating cylinder in uniform flow; (2) flows over a pure pitching airfoil, a heaving–pitching airfoil and a deforming airfoil. The predictions show good agreement with the published numerical results or experimental data. Copyright © 2010 John Wiley & Sons, Ltd.     

An approach of dynamic mesh adaptation for simulating 3‐dimensional unsteady moving‐immersed‐boundary flows

In this paper, we present an approach of dynamic mesh adaptation for simulating complex 3‐dimensional incompressible moving‐boundary flows by immersed boundary methods. Tetrahedral meshes are adapted by a hierarchical refining/coarsening algorithm. Regular refinement is accomplished by dividing 1 tetrahedron into 8 subcells, and irregular refinement is only for eliminating the hanging points. Merging the 8 subcells obtained by regular refinement, the mesh is coarsened. With hierarchical refining/coarsening, mesh adaptivity can be achieved by adjusting the mesh only 1 time for each adaptation period. The level difference between 2 neighboring cells never exceeds 1, and the geometrical quality of mesh does not degrade as the level of adaptive mesh increases. A predictor‐corrector scheme is introduced to eliminate the phase lag between adapted mesh and unsteady solution. The error caused by each solution transferring from the old mesh to the new adapted one is small because most of the nodes on the 2 meshes are coincident. An immersed boundary method named local domain‐free discretization is employed to solve the flow equations. Several numerical experiments have been conducted for 3‐dimensional incompressible moving‐boundary flows. By using the present approach, the number of mesh nodes is reduced greatly while the accuracy of solution can be preserved.     

A residual‐based Allen–Cahn phase field model for the mixture of incompressible fluid flows

The hydrodynamics of fluid mixtures is receiving more and more attention in many science and engineering applications. Within the techniques for dealing with front displacements and moving boundaries between different density and/or viscosity fluids, phase fields are a class of models in which a diffusive transition region is taken into account instead of a steep interface. Although these models have a physical motivation, they require the definition of extra parameters. In order to make it less parameter dependent, the classic Allen–Cahn phase field model is modified, exploring its similarities with residual‐based discontinuity‐capturing schemes, making the phase field equation dependent on its own residual. We solve the coupling between incompressible viscous fluid flow and the phase field advective–diffusive–reactive transport to simulate the main processes in interface tension and/or buoyancy driven problems. For the solution of the Navier–Stokes and transport equations, we use a stabilized finite element formulation. The implementation has been performed using the libMesh finite element library, written in C++ , which provides support for adaptive mesh refinement and coarsening. A chemical convection benchmark problem is used to validate the proposed model, and then we solve two bubble interaction problems. Copyright © 2014 John Wiley & Sons, Ltd.     

Adaptive non‐conformal mesh refinement and extended finite element method for viscous flow inside complex moving geometries

Two different techniques to analyze non‐Newtonian viscous flow in complex geometries with internal moving parts and narrow gaps are compared. The first technique is a non‐conforming mesh refinement approach based on the fictitious domain method (FDM), and the second one is the extended finite element method (XFEM). The refinement technique uses one fixed reference mesh, and to impose continuity across non‐conforming regions, constraints using Lagrangian multipliers are used. The size of elements locally in the high shear rate regions is reduced to increase accuracy. FDM is shown to have limitations; therefore, XFEM is applied to decouple the fluid from the internal moving rigid bodies. In XFEM, the discontinuous field variables are captured by using virtual degrees of freedom that serve as enrichment and by applying special integration over the intersected elements. The accuracy of the two methods is demonstrated by direct comparison with results of a boundary‐fitted mesh applied to a two‐dimensional cross section of a twin‐screw extruder. Compared with non‐conforming FDM, XFEM shows a considerable improvement in accuracy around the rigid body, especially in the narrow gap regions. Copyright © 2011 John Wiley & Sons, Ltd.     

A high‐order element based adaptive mesh refinement strategy for three‐dimensional unstructured grid

Adaptive mesh refinement (AMR) shows attractive properties in automatically refining the flow region of interest, and with AMR, better prediction can be obtained with much less labor work and cost compared to manually remeshing or the global mesh refinement. Cartesian AMR is well established; however, AMR on hybrid unstructured mesh, which is heavily used in the high‐Reynolds number flow simulation, is less matured and existing methods may result in degraded mesh quality, which mostly happens in the boundary layer or near the sharp geometric features. User intervention or additional constraints, such as freezing all boundary layer elements or refining the whole boundary layer, are required to assist the refinement process. In this work, a novel AMR strategy is developed to handle existing difficulties. In the new method, high‐order unstructured elements are first generated based on the baseline mesh; then the refinement is conducted in the parametric space; at last, the mesh suitable for the solver is output. Generating refined elements in the parametric space with high‐order elements is the key of this method and this helps to guarantee both the accuracy and robustness. With the current method, 3‐dimensional hybrid unstructured mesh of huge size and complex geometry can be automatically refined, without user intervention nor additional constraints. With test cases including the 2‐dimensional airfoil and 3‐dimensional full aircraft, the current AMR method proves to be accurate, simple, and robust.     

Advances in the simulation of multi‐fluid flows with the particle finite element method. Application to bubble dynamics

In this work, we extend the Particle Finite Element Method (PFEM) to multi‐fluid flow problems with the aim of exploiting the fact that Lagrangian methods are specially well suited for tracking interfaces. We develop a numerical scheme able to deal with large jumps in the physical properties, included surface tension, and able to accurately represent all types of discontinuities in the flow variables. The scheme is based on decoupling the velocity and pressure variables through a pressure segregation method that takes into account the interface conditions. The interface is defined to be aligned with the moving mesh, so that it remains sharp along time, and pressure degrees of freedom are duplicated at the interface nodes to represent the discontinuity of this variable due to surface tension and variable viscosity. Furthermore, the mesh is refined in the vicinity of the interface to improve the accuracy and the efficiency of the computations. We apply the resulting scheme to the benchmark problem of a two‐dimensional bubble rising in a liquid column presented in Hysing et al. (International Journal for Numerical Methods in Fluids 2009; 60 : 1259–1288), and propose two breakup and coalescence problems to assess the ability of a multi‐fluid code to model topology changes. Copyright © 2010 John Wiley & Sons, Ltd.     

Development of a hybrid particle‐mesh method for two‐phase flow simulations

A hybrid particle‐mesh method was developed for efficient and accurate simulations of two‐phase flows. In this method, the main component of the flow is solved using the constrained interpolated profile/multi‐moment finite volumemethod; the two‐phase interface is rendered using the finite volume particle (FVP) method. The effect of surface tension is evaluated using the continuum surface force model. Numerical particles in the FVP method are distributed only on the surface of the liquid in simulating the interface between liquid and gas; these particles are used to determine the density of each mesh grid. An artificial term was also introduced to mitigate particle clustering in the direction of maximum compression and sparse discretization errors in the stretched direction. This enables accurate interface tracking without diminishing numerical efficiency. Two benchmark simulations are used to demonstrate the validity of the method developed and its numerical stability. Copyright © 2016 John Wiley & Sons, Ltd.     

A stabilized Nitsche‐type extended embedding mesh approach for 3D low‐ and high‐Reynolds‐number flows

This paper presents a stabilized extended finite element method (XFEM) based fluid formulation to embed arbitrary fluid patches into a fixed background fluid mesh. The new approach is highly beneficial when it comes to computational grid generation for complex domains, as it allows locally increased resolutions independent from size and structure of the background mesh. Motivating applications for such a domain decomposition technique are complex fluid‐structure interaction problems, where an additional boundary layer mesh is used to accurately capture the flow around the structure. The objective of this work is to provide an accurate and robust XFEM‐based coupling for low‐ as well as high‐Reynolds‐number flows. Our formulation is built from the following essential ingredients: Coupling conditions on the embedded interface are imposed weakly using Nitsche's method supported by extra terms to guarantee mass conservation and to control the convective mass transport across the interface for transient viscous‐dominated and convection‐dominated flows. Residual‐based fluid stabilizations in the interior of the fluid subdomains and accompanying face‐oriented fluid and ghost‐penalty stabilizations in the interface zone stabilize the formulation in the entire fluid domain. A detailed numerical study of our stabilized embedded fluid formulation, including an investigation of variants of Nitsche's method for viscous flows, shows optimal error convergence for viscous‐dominated and convection‐dominated flow problems independent of the interface position. Challenging two‐dimensional and three‐dimensional numerical examples highlight the robustness of our approach in all flow regimes: benchmark computations for laminar flow around a cylinder, a turbulent driven cavity flow at Re = 10000 and the flow interacting with a three‐dimensional flexible wall. Copyright © 2016 John Wiley & Sons, Ltd.     

Numerical errors of the volume‐of‐fluid interface tracking algorithm

One of the important limitations of the interface tracking algorithms is that they can be used only as long as the local computational grid density allows surface tracking. In a dispersed flow, where the dimensions of the particular fluid parts are comparable or smaller than the grid spacing, several numerical and reconstruction errors become considerable. In this paper the analysis of the interface tracking errors is performed for the volume‐of‐fluid method with the least squares volume of fluid interface reconstruction algorithm. A few simple two‐fluid benchmarks are proposed for the investigation of the interface tracking grid dependence. The expression based on the gradient of the volume fraction variable is introduced for the estimation of the reconstruction correctness and can be used for the activation of an adaptive mesh refinement algorithm. Copyright © 2002 John Wiley & Sons, Ltd.     

Development of circular function‐based gas‐kinetic scheme (CGKS) on moving grids for unsteady flows through oscillating cascades

In this paper, the circular function‐based gas‐kinetic scheme (CGKS), which was originally developed for simulation of flows on stationary grids, is extended to solve moving boundary problems on moving grids. Particularly, the unsteady flows through oscillating cascades are our major interests. The main idea of the CGKS is to discretize the macroscopic equations by the finite volume method while the fluxes at the cell interface are evaluated by locally reconstructing the solution of the continuous Boltzmann Bhatnagar–Gross–Krook equation. The present solver is based on the fact that the modified Boltzmann equation, which is expressed in a moving frame of reference, can recover the corresponding macroscopic equations with Chapman–Enskog expansion analysis. Different from the original Maxwellian function‐based gas‐kinetic scheme, in improving the computational efficiency, a simple circular function is used to describe the equilibrium state of distribution function. Considering that the concerned cascade oscillating problems belong to cases that the motion of surface boundary is known a priori, the dynamic mesh method is suitable and is adopted in the present work. In achieving the mesh deformation with high quality and efficiency, a hybrid dynamic mesh method named radial basic functions‐transfinite interpolation is presented and applied for cascade geometries. For validation, several numerical test cases involving a wide range are investigated. Numerical results show that the developed CGKS on moving grids is well applied for cascade oscillating flows. And for some cases where nonlinear effects are strong, the solution accuracy could be effectively improved by using the present method. Copyright © 2017 John Wiley & Sons, Ltd.