Parallel three‐dimensional simulation of the injection molding process

This paper describes the development of a parallel three‐dimensional unstructured non‐isothermal flow solver for the simulation of the injection molding process. The numerical model accounts for multiphase flow in which the melt and air regions are considered to be a continuous incompressible fluid with distinct physical properties. This aspect avoids the complex reconstruction of the interface. A collocated finite volume method is employed, which can switch between first‐ and second‐order accuracy in both space and time. The pressure implicit with splitting of operators algorithm is used to compute the transient flow variables and couple velocity and pressure. The temperature equation is solved using a transport equation with convection and diffusion terms. An upwind differencing scheme is used for the discretization of the convection term to enforce a bounded solution. In order to capture the sharp interface, a bounded compressive high‐resolution scheme is employed. Parallelization of the code is achieved using the PETSc framework and a single program multiple data message passing model. Predicted numerical solutions for several example problems are considered. The first case validates the solution algorithm for moderate Reynolds number flows using a structured mesh. The second case employs an unstructured hybrid mesh showing the capability of the solver to describe highly viscous flows closer to realistic injection molding conditions. The final case presents the non‐isothermal filling of a thick cavity using three mesh sizes and up to 80 processors to assess parallel performance. The proposed algorithm is shown to have good accuracy and scalability. Copyright © 2008 John Wiley & Sons, Ltd.     

Calculation of three‐dimensional turbulent flow with a finite volume multigrid method

A numerical method for the efficient calculation of three‐dimensional incompressible turbulent flow in curvilinear co‐ordinates is presented. The mathematical model consists of the Reynolds averaged Navier–Stokes equations and the k–ε turbulence model. The numerical method is based on the SIMPLE pressure‐correction algorithm with finite volume discretization in curvilinear co‐ordinates. To accelerate the convergence of the solution method a full approximation scheme‐full multigrid (FAS‐FMG) method is utilized. The solution of the k–ε transport equations is embedded in the multigrid iteration. The improved convergence characteristic of the multigrid method is demonstrated by means of several calculations of three‐dimensional flow cases. Copyright © 1999 John Wiley & Sons, Ltd.     

A hybrid vortex method for the simulation of three‐dimensional flows

This paper presents an integral vorticity method for solving three‐dimensional Navier–Stokes equations. A finite volume scheme is implemented to solve the vorticity transport equation, which is discretized on a structured hexahedral mesh. A vortex sheet algorithm is used to enforce the no‐slip boundary condition through a vorticity flux at the boundary. The Biot–Savart integral is evaluated to compute the velocity field, in conjunction with a fast algorithm based on multipole expansion. This method is applied to the simulation of uniform flow past a sphere. Copyright © 2007 John Wiley & Sons, Ltd.     

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 adaptive front tracking technique for three‐dimensional transient flows

An adaptive technique, based on both surface stretching and surface curvature analysis for tracking strongly deforming fluid volumes in three‐dimensional flows is presented. The efficiency and accuracy of the technique are demonstrated for two‐ and three‐dimensional flow simulations. For the two‐dimensional test example, the results are compared with results obtained using a different tracking approach based on the advection of a passive scalar. Although for both techniques roughly the same structures are found, the resolution for the front tracking technique is much higher. In the three‐dimensional test example, a spherical blob is tracked in a chaotic mixing flow. For this problem, the accuracy of the adaptive tracking is demonstrated by the volume conservation for the advected blob. Adaptive front tracking is suitable for simulation of the initial stages of fluid mixing, where the interfacial area can grow exponentially with time. The efficiency of the algorithm significantly benefits from parallelization of the code. Copyright © 2000 John Wiley & Sons, Ltd.     

Similar solution for three‐dimensional flow in an Oldroyd‐B fluid over a stretching surface

The present investigation deals with the three‐dimensional flow of an Oldroyd‐B fluid over a stretching surface. The governing equations for the three‐dimensional flow are developed. Similarity transformations are invoked for the conversion of nonlinear partial differential equations into the coupled system of ordinary differential equations. Computations for the series solution are presented through implementation of homotopy analysis method. The salient features of the involved parameters have been pointed out. Copyright © 2011 John Wiley & Sons, Ltd.     

Large eddy simulation of turbulent incompressible flows by a three‐level finite element method

The variational multiscale method provides a methodical framework for large eddy simulation of turbulent flows. In this work, a particular implementation in the form of a three‐level finite element method separating large resolved, small resolved, and unresolved scales is proposed. Residual‐free bubbles are used for the numerical approximation of the small‐scale momentum equation. A stabilizing term is added, in order to take into account the effect of the small‐scale continuity equation. This implementation guarantees the stability of the method without further provisions and offers substantial computational savings on the small‐scale level. Furthermore, it is accounted for the unresolved scales by a specific dynamic modelling procedure. The method is tested for two different turbulent flow situations. Copyright © 2005 John Wiley & Sons, Ltd.     

Three‐dimensional modeling of non‐hydrostatic free‐surface flows on unstructured grids

A three‐dimensional numerical model is presented for the simulation of unsteady non‐hydrostatic shallow water flows on unstructured grids using the finite volume method. The free surface variations are modeled by a characteristics‐based scheme, which simulates sub‐critical and super‐critical flows. Three‐dimensional velocity components are considered in a collocated arrangement with a σ‐coordinate system. A special treatment of the pressure term is developed to avoid the water surface oscillations. Convective and diffusive terms are approximated explicitly, and an implicit discretization is used for the pressure term to ensure exact mass conservation. The unstructured grid in the horizontal direction and the σ coordinate in the vertical direction facilitate the use of the model in complicated geometries. Solution of the non‐hydrostatic equations enables the model to simulate short‐period waves and vertically circulating flows. Copyright © 2015 John Wiley & Sons, Ltd.     

An implicit three‐dimensional fully non‐hydrostatic model for free‐surface flows

An implicit method is developed for solving the complete three‐dimensional (3D) Navier–Stokes equations. The algorithm is based upon a staggered finite difference Crank‐Nicholson scheme on a Cartesian grid. A new top‐layer pressure treatment and a partial cell bottom treatment are introduced so that the 3D model is fully non‐hydrostatic and is free of any hydrostatic assumption. A domain decomposition method is used to segregate the resulting 3D matrix system into a series of two‐dimensional vertical plane problems, for each of which a block tri‐diagonal system can be directly solved for the unknown horizontal velocity. Numerical tests including linear standing waves, nonlinear sloshing motions, and progressive wave interactions with uneven bottoms are performed. It is found that the model is capable to simulate accurately a range of free‐surface flow problems using a very small number of vertical layers (e.g. two–four layers). The developed model is second‐order accuracy in time and space and is unconditionally stable; and it can be effectively used to model 3D surface wave motions. Copyright © 2004 John Wiley & Sons, Ltd.     

Homogeneous and heterogeneous distributed cluster processing for two‐ and three‐dimensional viscoelastic flows

A finite‐element study of two‐ and three‐dimensional incompressible viscoelastic flows in a planar lid‐driven cavity and concentric rotating cylinders is presented. The hardware platforms consist of both homogeneous and heterogeneous clusters of workstations. A semi‐implicit time‐stepping Taylor–Galerkin scheme is employed using the message passing mechanism provided by the Parallel Virtual Machine libraries. DEC‐alpha, Intel Solaris and AMD‐K7(Athlon) Linux clusters are utilized. Parallel results are compared against single processor (sequentially) solutions, using the parallelism paradigm of domain decomposition. Communication is effectively masked and practically ideal, linear speed‐up with the number of processors is realized. Copyright © 2002 John Wiley & Sons, Ltd.     

Simulation of three‐dimensional flows over moving objects by an improved immersed boundary–lattice Boltzmann method

An improved immersed boundary–lattice Boltzmann method (IB–LBM) developed recently [28] was applied in this work to simulate three‐dimensional (3D) flows over moving objects. By enforcing the non‐slip boundary condition, the method could avoid any flow penetration to the wall. In the developed IB–LBM solver, the flow field is obtained on the non‐uniform mesh by the efficient LBM that is based on the second‐order one‐dimensional interpolation. As a consequence, its coefficients could be computed simply. By simulating flows over a stationary sphere and torus [28] accurately and efficiently, the proposed IB–LBM showed its ability to handle 3D flow problems with curved boundaries. In this paper, we further applied this method to simulate 3D flows around moving boundaries. As a first example, the flow over a rotating sphere was simulated. The obtained results agreed very well with the previous data in the literature. Then, simulation of flow over a rotating torus was conducted. The capability of the improved IB–LBM for solving 3D flows over moving objects with complex geometries was demonstrated via the simulations of fish swimming and dragonfly flight. The numerical results displayed quantitative and qualitative agreement with the date in the literature. Copyright © 2011 John Wiley & Sons, Ltd.     

Multigrid solution of the incompressible Navier–Stokes equations for three‐dimensional recirculating flow: coupled and decoupled smoothers compared

A comparison of multigrid methods for solving the incompressible Navier–Stokes equations in three dimensions is presented. The continuous equations are discretised on staggered grids using a second‐order monotonic scheme for the convective terms and implemented in defect correction form. The convergence characteristics of a decoupled method (SIMPLE) are compared with those of the cellwise coupled method (SCGS). The convergence rates obtained for computations of the three‐dimensional lid‐driven cavity problem are found to be very similar to those obtained for computations of the corresponding two‐dimensional problem with comparable grid density. Although the convergence rate of SCGS is thus superior to that of SIMPLE, the decoupled method is found to be more efficient computationally and requires less computing time for a given level of convergence. The linewise implementation of the coupled method (CLGS) is also investigated and shown to be more efficient than SCGS, although the convergence rate and computing time required per cycle are both found to depend on the direction of sweep. The optimal implementation of CLGS is found to be only marginally more effective than SIMPLE, but a change to the structure of the data storage would increase the advantage. Copyright © 1999 John Wiley & Sons, Ltd.     

Bounds on outputs of the exact weak solution of the three‐dimensional Stokes problem

A method for obtaining rigorous upper and lower bounds on an output of the exact weak solution of the three‐dimensional Stokes problem is described. Recently bounds for the exact outputs of interest have been obtained for both the Poisson equation and the advection‐diffusion‐reaction equation. In this work, we extend this approach to the Stokes problem where a novel formulation of the method also leads to a simpler flux calculation based on the directly equilibrated flux method. To illustrate this technique, bounds on the flowrate are calculated for an incompressible creeping flow driven by a pressure gradient in an endless square channel with an array of rectangular obstacles in the center. Copyright © 2009 John Wiley & Sons, Ltd.     

An unstructured grid,three‐dimensional model based on the shallow water equations

A semi‐implicit finite difference model based on the three‐dimensional shallow water equations is modified to use unstructured grids. There are obvious advantages in using unstructured grids in problems with a complicated geometry. In this development, the concept of unstructured orthogonal grids is introduced and applied to this model. The governing differential equations are discretized by means of a semi‐implicit algorithm that is robust, stable and very efficient. The resulting model is relatively simple, conserves mass, can fit complicated boundaries and yet is sufficiently flexible to permit local mesh refinements in areas of interest. Moreover, the simulation of the flooding and drying is included in a natural and straightforward manner. These features are illustrated by a test case for studies of convergence rates and by examples of flooding on a river plain and flow in a shallow estuary. Copyright © 2000 John Wiley & Sons, Ltd.