A method for calculating the stress–strain state in the general boundary-value problem of metal forming—part 1

To simulate metal-forming processes, one has to calculate the stress–strain state of the metal, i.e. to solve the relevant boundary-value problems. Progress in the theory of plasticity in that respect is well known, for example, via the slip-line method, the finite element method, etc.) , yet many unsolved problems remain. It is well known that the slip-line method is scanty. In our opinion the finite element method has an essential drawback. (No one is against the idea of the discretization of the body being deformed and the approximation of the fields of mechanical variables.) The results of calculation of the stress state by the FEM do not satisfy Newtonian mechanics equations (these equations are said to be softened, i.e, satisfied approximately) and stress fields can be considered poor for solution of the subsequent fracture problem. We believe that it is preferable to construct an approximate solution by the FEM and soften the constitutive relations (not Newtonian mechanics equations) , especially as, in any event, they describe the rheology of actual deformable materials only approximately. We seem to have succeeded in finding the solution technique.Here we present some new results for solving rather general boundary-value problems which can be characterized by the following: the anisotropy of the materials handled; the heredity of their properties and compressibility; finite deformations; non-isothermal flow; rapid flow, with inertial forces; a non-stationary state; movable boundaries; alternating and non-classical boundary conditions, etc.Solution by the method proposed can be made in two stages: (1) integration in space with fixed time, with an accuracy in respect of some parameters; (2) integration in time of certain ordinary differential equations for these parameters.In the first stage the method is based on the principle of virtual velocities and stresses. It is proved that a solution does exist and that it is the only possible one. The approximate solution softens (approximately satisfies) the constitutive relations, all the rest of the equations of mechanics being satisfied precisely. The method is illustrated by some test examples.     

A stable unstructured finite volume method for parallel large-scale viscoelastic fluid flow calculations

A new stable unstructured finite volume method is presented for parallel large-scale simulation of viscoelastic fluid flows. The numerical method is based on the side-centered finite volume method where the velocity vector components are defined at the mid-point of each cell face, while the pressure term and the extra stress tensor are defined at element centroids. The present arrangement of the primitive variables leads to a stable numerical scheme and it does not require any ad-hoc modifications in order to enhance the pressure–velocity–stress coupling. The log-conformation representation proposed in [R. Fattal, R. Kupferman, Constitutive laws for the matrix–logarithm of the conformation tensor, J. Non-Newtonian Fluid Mech. 123 (2004) 281–285] has been implemented in order improve the limiting Weissenberg numbers in the proposed finite volume method. The time stepping algorithm used decouples the calculation of the polymeric stress by solution of a hyperbolic constitutive equation from the evolution of the velocity and pressure fields by solution of a generalized Stokes problem. The resulting algebraic linear systems are solved using the FGMRES(m) Krylov iterative method with the restricted additive Schwarz preconditioner for the extra stress tensor and the geometric non-nested multilevel preconditioner for the Stokes system. The implementation of the preconditioned iterative solvers is based on the PETSc library for improving the efficiency of the parallel code. The present numerical algorithm is validated for the Kovasznay flow, the flow of an Oldroyd-B fluid past a confined circular cylinder in a channel and the three-dimensional flow of an Oldroyd-B fluid around a rigid sphere falling in a cylindrical tube. Parallel large-scale calculations are presented up to 523,094 quadrilateral elements in two-dimension and 1,190,376 hexahedral elements in three-dimension.     

A new numerical algorithm for viscoelastic fluid flows : The grid-by-grid inversion method

We present a new algorithm for solving viscoelastic flows with a general constitutive equation. In our approach the hyperbolic constitutive equation is split such that the term for the convective transport of stress tensor is treated as a source. This allows the stress tensor at each grid point to be expressed mainly in terms of the velocity gradient tensor at the same point. Then, the set of six stress tensor components is found after inverting a six by six matrix at each grid point. Thus we call this algorithm the grid-by-grid inversion method. The convective transport of stress tensor in the constitutive equation, which has been treated as a source, is updated iteratively. The present algorithm can be combined with finite volume method, finite element method or the spectral methods. To corroborate the accuracy and robustness of the present algorithm we consider viscoelastic flow past a cylinder placed at the center between two plates, which has served as a benchmark problem. Also considered is the investigation of the pattern and strength of the secondary flows in the viscoelastic flows through a rectangular pipe. It is found that the present method yields accurate results even for large relaxation times.     

率相关本构方程积分新算法

提出一种积分率相关本构方程的隐式积分新算法,引入0～1范围内的缩放因子λ对本构方程进行间接求解,可以避免直接求解等效塑性应变或等效塑性应变率时,由于其数值过大或过小而造成的收敛困难或收敛失败,实现对率相关本构方程的快速准确求解.以B-P统一本构方程及双曲正弦本构方程为例,验证了算法的可行性.结果表明,新算法对于准静态变形条件下的无硬化本构方程也可以得出准确的解.     

Finite element method for viscoelastic flows based on the discrete adaptive viscoelastic stress splitting and the discontinuous Galerkin method: DAVSS-G/DG

Accurate and robust finite element methods for computing flows with differential constitutive equations require approximation methods that numerically preserve the ellipticity of the saddle point problem formed by the momentum and continuity equations and give numerically stable and accurate solutions to the hyperbolic constitutive equation. We present a new finite element formulation based on the synthesis of three ideas: the discrete adaptive splitting method for preserving the ellipticity of the momentum/continuity pair (the DAVSS formulation), independent interpolation of the components of the velocity gradient tensor (DAVSS-G), and application of the discontinuous Galerkin (DG) method for solving the constitutive equation. We call the method DAVSS-G/DG. The DAVSS-G/DG method is compared with several other methods for flow past a cylinder in a channel with the Oldroyd-B and Giesekus constitutive models. Results using the Streamline Upwind Petrov–Galerkin method (SUPG) show that introducing the adaptive splitting increases considerably the range of Deborah number (De) for convergence of the calculations over the well established EVSS-G formulation. When both formulations converge, the DAVSS-G and DEVSS-G methods give comparable results. Introducing the DG method for solution of the constitutive equation extends further the region of convergence without sacrificing accuracy. Calculations with the Oldroyd-B model are only limited by approximation of the almost singular gradients of the axial normal stress that develop near the rear stagnation point on the cylinder. These gradients are reduced in calculations with the Giesekus model. Calculations using the Giesekus model with the DAVSS-G/DG method can be continued to extremely large De and converge with mesh refinement.     

管内上随体Maxwell流体非定常流动

本文研究了上随体Maxwell流体在圆管内非定常流动规律,对于上随体Maxwell流体模型,导出了特殊的运动方程,分别应用隐式差分格式和Kantorovich变分法,求得数值解,对两类方法的结果进行比较,揭示了粘弹流效应对管内非定常流动规津的影响,根据上述研究认为,以上的特殊的变分方法适应于研究非定常流动。     

Coupling of finite element method and discontinuous Galerkin method to simulate viscoelastic flows

In this paper, a numerical method, which is about the coupling of continuous and discontinuous Galerkin method based on the splitting scheme, is presented for the calculation of viscoelastic flows of the Oldroyd‐B fluid. The momentum equation is discretized in time by using the Adams‐Bashforth second‐order algorithm, and then decoupled via the splitting approach. Considering the Oldroyd‐B constitutive equation, the second‐order Runge‐Kutta approach is selected to complete the temporal discretization. As for the spatial discretizations, the fundamental purpose is to make the best of finite element method (FEM) and discontinuous Galerkin (DG) method to handle different types of equations. Specifically speaking, for the subequations, FEM is chosen to treat the Poisson and Helmholtz equations, and DG is employed to deal with the nonlinear convective term. In addition, because of the hyperbolic nature, DG is also utilized to discretize the Oldroyd‐B constitutive equation spatially. This coupled method avoids resorting to extra stabilization technique occurred in standard FEM framework even for moderately high values of Weissenberg number and also reduces the complexity compared with unified DG scheme. The Oldroyd‐B model is applied to investigate several typical and challenging benchmarks, such as the 4:1 planar contraction flow and the lid‐driven cavity flow, with a wide range of Weissenberg number to illustrate the feasibility, robustness, and validity of our coupled method.     

关于动力分析精细积分算法精度的讨论

对动力问题分析的精细积分算法的精度问题进行深入研究,并在此基础上提出对原有的算法的改进策略,改进后的算法可以较好地克服算法精度对积分时间步长的依赖性问题。     

Analysis of a rubber cone tensioned by a concentrated force

Using the constitutive equation of a rubber-like materials given by Gao (1997), this paper investigates the problem of a cone under tension of a concentrated force at its apex. Under consideration is the axial-symmetry case and the large strain is taken into account. The stress strain fields near the apex are obtained by both asymptotic analysis and finite element calculation. The two results are consistent well. When the cone angle is 180°, the solution becomes that of non-linear Boussinesq's problem for tension case.     

热－塑变形局部化的有限元分析及其对激光破坏效应的应用

本文给出了热力耦合的热弹粘塑性材料的有限元分析方法，并讨论与之相关的时间积分算法，为改善线性插值函数所引起的不协调性及提高运算速度，应力协调迭代理论被引入相应的算法及程序中，最后对非绝热过程中热－塑变形局部化及激光诱导的剪切变形集中进行了数值模拟，其结果与理论分析有良好的吻合．     

Local and parallel finite element algorithms based on two-grid discretization for steady Navier-Stokes equations

Local and parallel finite element algorithms based on two-grid discretization for Navier-Stokes equations in two dimension are presented. Its basis is a coarse finite element space on the global domain and a fine finite element space on the subdomain. The local algorithm consists of finding a solution for a given nonlinear problem in the coarse finite element space and a solution for a linear problem in the fine finite element space, then droping the coarse solution of the region near the boundary. By overlapping domain decomposition, the parallel algorithms are obtained. This paper analyzes the error of these algorithms and gets some error estimates which are better than those of the standard finite element method. The numerical experiments are given too. By analyzing and comparing these results, it is shown that these algorithms are correct and high efficient.     

A simple method for simulating viscoelastic fluid flows in slit channel

A low-cost semi-analysis finite element technique, named the finite piece method (FPM) is presented in this article. It aims to solve three-dimensional (3D) viscoelastic slit flows. The viscoelastic stress of the fluid is modelled using an K-BKZ integral constitutive equation of the Wagner type. Picard iteration is used to solve non-linear equations. The FPM is tested on flow problems in both planar and contraction channels. The accuracy of the method is assessed by comparing flow distributions and pressure with results obtained by 3D finite element method (FEM). It shows that the solution accuracy is excellent and a substantial amount of computing time and memory requirement can be saved.     

粘弹性固体的精细积分有限元算法

粘弹性固体本构方程的数学表达式分为微分型和积分型两种，其数值求解主要是时域上离散计算。文中从微分型表达式出发导出其状态空间方程的数学表达式，通过严格推导论证了它与微、积分型表达式的等价性；引入状态空间方程，从而利用精细积分格式来求解粘弹性固体本构方程；给出了粘弹性固体本构方程的精细积分有限元算法，为求解粘弹性固体本构方程的数值解提供了一个新的途径，具有计算简便，求解精度高等优点。     

Implicit schemes for unsteady Euler equations on triangular meshes

An implicit finite element method is presented for the solution of steady and unsteady inviscid compressible flows on triangular meshes under transonic conditions. The method involves a first-order time-stepping scheme with a finite element discretization that reduces to central differencing on a rectangular mesh. On a solid wall the slip condition is prescribed and the pressure is obtained from an approximation of the normal momentum equation. With this solver no artificial viscosity is added to ensure the success of the calculation. Numerical examples are given for steady and unsteady cases.     

边坡稳定的剪切带计算

为了解决边坡稳定分析中剪切带有限元网格的依赖性问题,采用梯度塑性理论,从本构关系中引入特征长度入手,建立计算模型。提出了一种8节点缩减积分的梯度塑性单元,并采用梯度塑性理论推导了Drucker-Prager屈服准则的软化模型的有限元格式,在ABAQUS中进行了二次开发,嵌入了本文提出的8节点单元和本构模型,并用ABAQUS软件进行了边坡剪切带的计算。计算结果表明,本文提出的方法消除了经典有限元计算的网格依赖性问题,可以得到与单元剖分无关的稳定的剪切带宽度。本文所提出的方法可适用于其他场合的剪切带计算。     

Flow simulation on moving boundary‐fitted grids and application to fluid–structure interaction problems

We present a method for the parallel numerical simulation of transient three‐dimensional fluid–structure interaction problems. Here, we consider the interaction of incompressible flow in the fluid domain and linear elastic deformation in the solid domain. The coupled problem is tackled by an approach based on the classical alternating Schwarz method with non‐overlapping subdomains, the subproblems are solved alternatingly and the coupling conditions are realized via the exchange of boundary conditions. The elasticity problem is solved by a standard linear finite element method. A main issue is that the flow solver has to be able to handle time‐dependent domains. To this end, we present a technique to solve the incompressible Navier–Stokes equation in three‐dimensional domains with moving boundaries. This numerical method is a generalization of a finite volume discretization using curvilinear coordinates to time‐dependent coordinate transformations. It corresponds to a discretization of the arbitrary Lagrangian–Eulerian formulation of the Navier–Stokes equations. Here the grid velocity is treated in such a way that the so‐called Geometric Conservation Law is implicitly satisfied. Altogether, our approach results in a scheme which is an extension of the well‐known MAC‐method to a staggered mesh in moving boundary‐fitted coordinates which uses grid‐dependent velocity components as the primary variables. To validate our method, we present some numerical results which show that second‐order convergence in space is obtained on moving grids. Finally, we give the results of a fully coupled fluid–structure interaction problem. It turns out that already a simple explicit coupling with one iteration of the Schwarz method, i.e. one solution of the fluid problem and one solution of the elasticity problem per time step, yields a convergent, simple, yet efficient overall method for fluid–structure interaction problems. Copyright © 2005 John Wiley & Sons, Ltd.     

Operator Splitting Multiscale Finite Volume Element Method for Two-Phase Flow with Capillary Pressure

A numerical method used for solving a two-phase flow problem as found in typical oil recovery is investigated in the setting of physics-based two-level operator splitting. The governing equations involve an elliptic differential equation coupled with a parabolic convection-dominated equation which poses a severe restriction for obtaining fully implicit numerical solutions. Furthermore, strong heterogeneity of the porous medium over many length scales adds to the complications for effectively solving the system. One viable approach is to split the system into three sub-systems: the elliptic, the hyperbolic, and the parabolic equation, respectively. In doing so, we allow for the use of appropriate numerical discretization for each type of equation and the careful exchange of information between them. We propose to use the multiscale finite volume element method (MsFVEM) for the elliptic and parabolic equations, and a nonoscillatory difference scheme for the hyperbolic equation. Performance of this procedure is confirmed through several numerical experiments.     

Nonlinear Fractional Order Viscoelasticity at Large Strains

In this paper, we formulate a fractional order viscoelastic model for large deformations and develop an algorithm for the integration of the constitutive response. The model is based on the multiplicative split of the deformation gradient into elastic and viscous parts. Further, the stress response is considered to be composed of a nonequilibrium part and an equilibrium part. The viscous part of the deformation gradient (here regarded as an internal variable) is governed by a nonlinear rate equation of fractional order. To solve the rate equation the finite element method in time is used in combination with Newton iterations. The method can handle nonuniform time meshes and uses sparse quadrature for the calculations of the fractional order integral. Moreover, the proposed model is compared to another large deformation viscoelastic model with a linear rate equation of fractional order. This is done by computing constitutive responses as well as structural dynamic responses of fictitious rubber materials.     

Nonlinear Fractional Order Viscoelasticity at Large Strains

In this paper, we formulate a fractional order viscoelastic model for large deformations and develop an algorithm for the integration of the constitutive response. The model is based on the multiplicative split of the deformation gradient into elastic and viscous parts. Further, the stress response is considered to be composed of a nonequilibrium part and an equilibrium part. The viscous part of the deformation gradient (here regarded as an internal variable) is governed by a nonlinear rate equation of fractional order. To solve the rate equation the finite element method in time is used in combination with Newton iterations. The method can handle nonuniform time meshes and uses sparse quadrature for the calculations of the fractional order integral. Moreover, the proposed model is compared to another large deformation viscoelastic model with a linear rate equation of fractional order. This is done by computing constitutive responses as well as structural dynamic responses of fictitious rubber materials.     

On the numerical stability of mixed finite-element methods for viscoelastic flows governed by differential constitutive equations

Mixed finite-element methods for computation of viscoelastic flows governed by differential constitutive equations vary by the polynomial approximations used for the velocity, pressure, and stress fields, and by the weighted residual methods used to discretize the momentum, continuity, and constitutive equations. This paper focuses on computation of the linear stability of the planar Couette flow as a test of the numerical stability for solution of the upper-convected Maxwell model. Previous theoretical results prove this inertialess flow to be always stable, but that accurate calculation is difficult at high De because eigenvalues with fine spatial structure and high temporal frequency approach neutral stability. Computations with the much used biquadratic finite-element approximations for velocity and deviatoric stress and bilinear interpolation for pressure demonstrate numerical instability beyond a critical value of De for either the explicitly elliptic momentum equation (EEME) or elastic-viscous split-stress (EVSS) formulations, applying Galerkin's method for solution of the momentum and continuity equations, and using streamline upwind Petrov-Galerkin (SUPG) method for solution of the hyperbolic constitutive equation. The disturbance that causes the instability is concentrated near the stationary streamline of the base flow. The removal of this instability in a slightly modified form of the EEME formulation suggests that the instability results from coupling the approximations to the variables. A new mixed finite-element method, EVSS-G, is presented that includes smooth interpolation of the velocity gradients in the constitutive equation that is compatible with bilinear interpolation of the stress field. This formulation is tested with SUPG, streamline upwinding (SU), and Galerkin least squares (GLS) discretization of the constitutive equation. The EVSS-G/SUPG and EVSS-G/SU do not have the numerical instability described above; linear stability calculations for planar Couette flow are stable to values of De in excess of 50 and converge with mesh and time step. Calculations for the steady-state flow and its linear stability for a sphere falling in a tube demonstrate the appearance of linear instability to a time-periodic instability simultaneously with the apparent loss of existence of the steady-state solution. The instability appears as finely structured secondary cells that move from the front to the back of the sphere.Financial support for this research was given by the National Science Foundation, the Office of Naval Research, and the Defense Research Projects Agency. Computational resources were supplied by a grant from the Pittsburgh National Supercomputer Center and by the MIT Supercomputer Facility.