Three-dimensional non-isothermal extrusion flows

A three-dimensional (3-D) non-isothermal study of viscous free-surface flows with exponential dependence of viscosity on temperature is presented. The effects of non-isothermal conditions and/or geometry on the extrudate shape are investigated with a fully three-dimensional finite element/Galerkin formulation. Apart from the well known thermally induced extrudate swelling phenomenon, bending and distortion of the extrudate may occur because of temperature differences and/or geometric asymmetries. A temperature difference across the die can be imposed by heating or cooling the die walls, but can also arise because of asymmetric viscous heat generation due to the die geometry. Temperature differences affect velocity profiles because of the temperature dependence of viscosity and lead to extrudate bending, an effect known as kneeing in the fiber spinning industry. It is also shown numerically and confirmed experimentally that the die geometry induces extrudate bending even in the case of isothermal Newtonian flows.     

An efficient three-dimensional semi-implicit finite element scheme for simulation of free surface flows

An efficient semi-implicit finite element model is proposed for the simulation of three-dimensional flows in stratified seas. The body of water is divided into a number of layers and the two horizontal momentum equations for each layer of water are first integrated vertically. Nine-node Lagrangian quadratic isoparametric elements are employed for spatial discretization in the horizontal domain. The time derivatives are approximated using a second-order-accurate semi-implicit time-stepping scheme. The distinguishing feature of the proposed numerical scheme is that only nodal values on the same vertical line are coupled. Two test cases for which analytic solutions are available are employed to test the proposed scheme. The test results show that the scheme is efficient and stable. A numerical experiment is also included to compare the proposed scheme with a finite difference scheme.     

An inverse finite element method with an application to extrusion with solidification

The flow and solidification of planar jets are analysed by means of an efficient inverse isotherm finite element method. The method is based on a tessellation that is constructed by isotherms as characteristic co-ordinate lines transverse to the flow direction. Thus opposite sides of finite elements lie on isotherms. The method allows the simultaneous determination of the location of the isotherms with the primary unknowns, namely, the velocity, the pressure, the temperature and the location of the free surface. Thus the determination of the location of the solidification front (which is known to pose significant computational difficulties) is automatic. This facilitates the control of the location of the solidification front by controlling macroscopic variables such as the flow rate, the cooling rate and the capillary design. The location of the solidification may then be suitably chosen to influence the frozen-in orientation and structure in extrusion of high-performance materials such as composites and polymers, in continuous casting of metals and in growth of crystals.     

Singular finite elements for the sudden-expansion and the die-swell problems

The singular finite element method is used to solve the sudden-expansion and the die-swell problems in order to improve the accuracy of the solution in the vicinity of the singularity and to speed up the convergence. The method requires minor modifications to standard finite element schemes, and even coarse meshes give more accurate results than refined ordinary finite element meshes. Improved normal stress results for the sudden-expansion problem have been obtained for various Reynolds numbers up to 100 using the singular elements constructed for the creeping flow problem. In addition, the normal stresses at the walls appear to be insensitive to the singularity powers used in the construction of the singular basis functions. The die-swell problem is solved using the singular elements constructed for the stick–slip problem. The singular elements accelerate the convergence of the free surface dramatically.     

Analysis of high-speed continuous casting with inverse finite elements

A recently proposed inverse isotherm finite element method is further extended in order to account for processes with distorted isotherms. With this method a variety of problems can be solved which require the explicit calculation of characteristic material lines along with the common field of unknowns in transport phenomena. The method is applied to high-speed metal casting, where the location and shape of the extensive solidification front is calculated simultaneously with the primary unknowns, the velocity and the pressure, whereas the temperature is fixed at the moving nodes of the finite element tessellation. This is achieved by solving the energy equation inversely along with the rest of the conservation equations, i.e. the temperature field is fixed and its location is calculated. Empirical correlations may be derived which give the shape of the solidification front as a function of the process parameters. This may be used to improve the control means of metal casting, which is currently based on one-dimensional approximate analyses.     

Three-dimensional hydrodynamics on finite elements. Part II: Non-linear time-stepping model

The development and application of a non-linear 3D hydrodynamic model are described. The model is based on the wave equation rearrangement of the primitive 3D shallow water equations with a general eddy viscosity formulation for the vertical shear. A Galerkin procedure is used to discretize these on simple sixnode elements: linear triangles in the horizontal with linear variations in the vertical. Resolution of surface, bottom and interfacial boundary layers is facilitated and total flexibility is preserved for specifying spatial and temporal variations in the vertical viscosity and density fields. A semi-implicit time-stepping algorithm allows the solutions for elevation and velocity to be uncoupled during each time step. The elevation solution is essentially a 2D wave equation calculation with a stationary sparse matrix representing the gravity waves. With nodal quadrature the subsequent velocity calculation is achieved by factoring only a tridiagonal diffusion matrix representing the vertical viscous terms. As a result the overall calculation scales computationally as only a 2D problem but provides the full 3D solution. Application to field-scale problems is illustrated for the English Channel/Southern Bight system and the Lake Maracaibo system.     

Transient finite element method for calculating steady state three-dimensional free surfaces

In order to reduce the cost of large three-dimensional calculations of steady state free surfaces, we have combined a time-dependent approach, a decoupling algorithm and a conjugate gradient solver along the lines introduced earlier by Gresho and Chan. The free surface is calculated separately by applying the kinematic condition to a number of faces defined on the undeformed surface. For the pseudo-time-marching technique we show that it is economical to adopt different time steps for the free surface calculation and the other fields. The accuracy of the method is tested on the well-known circular die problem; the method is then used to reveal the effects of inertia and shear thinning on square and rectangular dies.     

Numerical analysis of three-dimensional Newtonian extrudate swell

The present paper considers the problem of predicting extrudate shapes from asymmetrical dies for Newtonian fluids. The flow is fully three-dimensional and an exploration of finite elements is made with a view to finding accurate, stable and economical schemes. A number of elements are compared and we conclude that some of the Fortin elements are most useful on the grounds of computational overhead and solution accuracy. These are used to investigate some symmetrical (square dies) and asymmetrical (unequal lip) planar and general L-shaped die flows. Finally, we show that in an unconstrained extrudate the final shape must be such that particles describe a helix in space; special cases include circular flow and rectilinear flow.     

An accurate finite element scheme with moving meshes for computing 3D‐axisymmetric interface flows

An accurate finite element scheme for computing 3D‐axisymmetric incompressible free surface and interface flows is proposed. It is based on the arbitrary Lagrangian Eulerian (ALE) approach using free surface/interface‐resolved moving meshes. Key features like the surface force, consisting of surface tension and the local curvature, and jumps in the density and viscosity over different fluid phases are precisely incorporated in the finite element formulation. The local curvature is approximated by using the Laplace–Beltrami operator technique combined with a boundary approximation by isoparametric finite elements. A new approach is used to derive the 3D‐axisymmetric form from the variational form in 3D‐Cartesian coordinates. Several test examples show the high accuracy and the robustness of the proposed scheme. Copyright © 2007 John Wiley & Sons, Ltd.     

Toward application of conformal decomposition finite elements to non‐colloidal particle suspensions

Particle suspensions play an important role in many engineering applications, yet their behavior in a number of respects remains poorly understood. In conjunction with careful experiments, modeling and simulation of these systems can provide key insight into their complex behavior. However, these two‐phase systems pose the challenge of simultaneously, accurately, and efficiently capturing the complex geometric structure, kinematics, and dynamics of the particulate discrete phase and the discontinuities it introduces into the variables (e.g., velocity, pressure, density) of the continuous phase. To this end, a new conformal decomposition finite element method (CDFEM) is introduced for solid particles in a viscous fluid. The method is verified in several simple test problems that are representative of aspects of particle suspension behavior. In all cases, we find the CDFEM to perform accurately and efficiently leading to the conclusion that it forms a prime candidate for application to the full direct numerical simulation of particle suspensions. Copyright © 2012 John Wiley & Sons, Ltd.     

A free surface finite element model for low Froude number mould filling problems on fixed meshes

The simulation of low Froude number mould filling problems on fixed meshes presents significant difficulties. As the Froude number decreases, the coupling between the position of the interface and the resulting flow field increases. The usual two‐phase flow model provides poor results for such flow. In order to overcome the difficulties, a free surface model that applies boundary conditions at the interface accurately is used. Moreover, the use of wall laws on curved boundaries also fails in the case of low Froude number flows. To solve this second problem, we combine wall laws with ‘do nothing’ boundary conditions. A special feature of our approach is that ‘do nothing’ boundary conditions are only applied in the normal direction. These two key ingredients together with the Level Set method allow us to simulate three‐dimensional mould filling problems borrowed directly from the foundry. Copyright © 2010 John Wiley & Sons, Ltd.     

钢筋混凝土结构的三维有限元非线性分析

提出了一个简单的混凝土三维本构模型,结合两种钢筋分布模式编制了钢筋混凝土结构非线性分析的三维有限元程序,通过两个经典的算例对比分析,表明本文提出的混凝土本构模型能够有效地模拟结构的破坏荷载和破坏过程。     

Fifty years of finite elements — a solid mechanics perspective

The finite element method has been considered as one of the most significant engineering advances of the twentieth century. This computational methodology has made substantial impact on many fields in science and also has profoundly changed engineering design procedures and practice. This paper, mainly from a solid mechanics perspective, and the Swansea viewpoint in particular, describes very briefly the origin of the methodology, then summaries selected milestones of the technical developments that have taken place over the last fifty years and illustrates their application to some practical engineering problems.     

Reissner板问题的有限元广义混合法

用一般弹性体的广义混合变分原理,导出了适合Ｒｅｉｓｓｎｅｒ板弯曲问题的广义混合变分原理及其有限元广义混合法。算例说明,该有限元模式的刚度可以改变,比常规位移法的精度高,同时还能克服常规Ｒｅｉｓｓｎｅｒ板位移元用于计算薄板时所出现的“剪切自锁”现象,计算结果稳定,最后分析该法能够克服“剪切自锁”现象的原因。     

Compatibility between finite volumes and finite elements using solutions of shallow water equations for substance transport

This paper formulates a finite volume analogue of a finite element schematization of three‐dimensional shallow water equations. The resulting finite volume schematization, when applied to the continuity equation, exactly reproduces the set of matrix equations that is obtained by the application of the corresponding finite element schematization to the continuity equation. The procedure allows the consistent and mass conserving coupling of the finite element Telemac model for three‐dimensional flow with the finite volume Delft3D‐WAQ model for water quality. The work has been carried out as part of a joint development by LNHE and WL∣Delft Hydraulics to explore the mutual interaction of their software. Copyright © 2006 John Wiley & Sons, Ltd.     

汽车覆盖件工具曲面有限元网格自适应转换方法

提出一种适用于汽车覆盖件曲面有限元网格转化和在单元水平上提高模拟精度的方法,将平面下通过合并三角形单元成四边形单元的有限元网格转换方法的应用范围扩展到曲面,并且降低了对初始网格形状的要求。算法的关键在于增加了对曲面相邻单元不同夹角情况下的处理和优化规则,以使其能够更好地拟合原始CAD曲面。     

Die design: An implicit formulation for the inverse problem

Let us call a direct extrusion problem (DEP) the problem of finding the shape of the extrudate coming out of a die of prescribed shape. An implicit finite element formulation of the DEP which is geometrically general and for which a Newton-Raphson technique can be implemented has recently been proposed by Legat and Marchal. However, the problem posed to the die designer is frequently the inverse extrusion problem (IEP), i.e. finding the die shape which produces an extrudate of prescribed shape. This paper presents an extension of our original method for solving the IEP which avoids the ‘trial-and-error’ iteration on the die geometry itself. The advantage of the formulation lies in its capability to handle complex geometrics and in its low cost, because the CPU time and memory required to solve the IEP are almost identical to those of the DEP. We present benchmark results for squares and rectangles and new results obtained for geometries involving multiple corners. For an octagonal shape we also consider the case of a power-law fluid. For all results presented in this paper, surface tension has not been included.     

Dynamic simulation of free surfaces in capillaries with the finite element method

The mathematical formulation of the dynamics of free liquid surfaces including the effects of surface tension is governed by a non-linear system of elliptic differential equations. The major difficulty of getting unique closed solutions only in trivial cases is overcome by numerical methods. This paper considers transient simulations of liquid–gas menisci in vertical capillary tubes and gaps in the presence of gravity. Therefore the CFD code FIDAP 7.52 based on the Galerkin finite element method (FEM) is used. Calculations using the free surface model are presented for a variety of contact angles and cross-sections with experimental and theoretical verification. The liquid column oscillations are compared for numerical accuracy with a mechanical mathematical model, and the sensitivity with respect to the node density is investigated. The efficiency of the numerical treatment of geometric non-trivial problems is demonstrated by a prismatic capillary. Present restrictions limiting efficient transient simulations with irregularly shaped calculational domains are stated. © 1998 John Wiley & Sons, Ltd.