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At least 343 records · Page 19

Towards improved speed and accuracy of laser powder bed fusion simulations via multiscale spatial representations

Due to the growing popularity of laser powder bed fusion (LPBF) as a metal additive manufacturing technique, there is a strong need to be able to accurately predict build outcomes. Full fidelity simulations of this process are not feasible due to the vast range of length and time scales inherent to it. While part-scale codes for simulating residual stress and distortion have shown reasonable predictive capability, they often neglect many aspects of the process occurring over smaller length/time scales, and thus are unable to capture effects of process parameter adjustments or the behavior of fine features. One way of capturing aspects at more refined length scales is through the use of adaptive mesh refinement (AMR). AMR allows for the process to be simulated at scales approaching the physical spatial dimensions without drastically increasing the total degrees of freedom in the simulation. This manuscript describes the implementation of an AMR algorithm within a multiphysics, parallelized finite element code, and its application to the LPBF problem. In this work, part-scale examples are provided where the use of AMR has allowed for higher fidelity thermal and thermomechanical simulations, as compared to experimental measurements. Results from these higher resolution simulations show that while AMR is a necessary component for increased accuracy in a computationally efficient manner, other improvements are also necessary, including handling of the multiple time scales inherent to the problem and the need for improved AM-specific material models.

42 ENGINEERING↗

DNS of Flame Stabilization Dynamics of a Swirl-Stabilized Spray Burner Using Sustainable Aviation Fuels

Concern for emission reduction has motivated the development of new cost-effective alternative sustainable aviation fuels (SAFs). Drop-in SAFs with blends of the certified and the alternative fuels are beneficial because they do not require engine modifications for use in current aviation engines. Combustion characteristics are of particular concern when comparing a new fuel with Jet-A. Lean blow-off and flame stabilization have been identified to be governed by the fuel propensity to autoignition, i.e. derived cetane number. However, fundamental investigation is required to identify the impact of derived cetane number on the combustion mode of flame stabilization in a realistic combustor. The combustion mode has also a direct impact on turbulent combustion modeling closures. DNS simulations are performed in the low-Mach solver of the Pele Suite called PeleLMeX. Lagrangian multi-phase modeling is used to capture the liquid spray injection of Jet-A (reference fuel) and C1 as a representative of a low cetane number SAF. Adaptive Mesh Refinement (AMR) is used to enable a more efficient simulation of a more realistic domain size and embedded boundary treatment is used to model a bluff-body geometry. Local extinction and edge flame propagation were observed for both fuels. The edge flame propagation mode was quantified in terms of a Damkohler number defined as the ratio between progress variable reaction rate and its diffusive flux. Initial analysis suggests that a mixed mode combustion occurs for the edge flame propagation, with flame propagation assisted by ignition and autoignition co-existing for both Jet-A and C1 flames. The analysis of the extinction region shows a larger progress variable for Jet-A which can further increase the local displacement speed and present a faster reignition of the stoichiometric mixture fraction.

adaptive mesh refinement↗

High-Fidelity Simulations of Plasma-Assisted Oxidation of Hydrocarbon Fuels Using Nanosecond Pulsed Discharges

Next, a robust and efficient framework for simulating NSPD in multiple dimensions is developed. The reactive Navier-Stokes equations are extended to include a drift-diffusion plasma-fluid model with a local field approximation (LFA) in a finite-volume solver, which uses an adaptive mesh refinement (AMR) strategy to address the wide separation of length scales in the problem. A two-way coupling strategy is used whereby the plasma-fluid model and reactive Navier-Stokes equations are integrated simultaneously. The oxidation of ethylene/air mixtures mediated by NSPD is simulated in a pin-to-pin configuration. All phases of the plasma discharge are simulated explicitly (including streamer ignition, propagation, and connection, as well as the subsequent spark phase), along with the evolution of the plasma during the inter-pulse period. Temporally and spatially-resolved results are presented, with an emphasis on the analysis of heating and energy deposition, as well as of the evolution of the concentration of active particles generated during the NSPD and their influence on ignition.

adaptive mesh refinement↗

Numerical Analysis of Combustion Dynamics in a Full-Scale Rotating Detonation Rocket Engine using Large Eddy Simulations

Large eddy simulations (LES) using detailed chemistry and leveraging adaptive mesh refinement (AMR) are performed to gain insights into the combustion dynamics within a full-scale methane-oxygen non-premixed rotating detonation rocket engine (RDRE) employing impinging discrete injection schemes. In particular, a comparative analysis of two operating conditions corresponding to the same global equivalence ratio but different mass flow rates is carried out to investigate the resultant impact on detonation wave characteristics and RDRE global performance. Multiple co-rotating detonation waves with spatially-distributed wave structure and preferential alignment with the inner wall of the annulus (due to asymmetry in fuel distribution) are encountered under both conditions. Both cases exhibit pre-detonation deflagrative burning in the fill region, while one of the cases shows higher susceptibility to backflow into the feed plenums due to lower plenum pressures. Furthermore, heat release analysis shows that the thrust obtained from the RDRE is closely linked to the distribution of total heat release between detonative and deflagrative combustion. On the other hand, combustion efficiency is associated with the fraction of heat release occurring in fuel-rich versus fuel-lean regions within the RDRE.

33 ADVANCED PROPULSION SYSTEMS↗

The development of a high-resolution Eulerian radiation-hydrodynamics simulation capability for laser-driven Hohlraums

Hohlraums are hollow cylindrical cavities with high-Z material walls used to convert laser energy into uniform x-ray radiation drives for inertial confinement fusion capsule implosions and high energy density physics experiments. Credible computational modeling of hohlraums requires detailed modeling and coupling of laser physics, hydrodynamics, radiation transport, heat transport, and atomic physics. We report on improvements to Los Alamos National Laboratory's xRAGE radiation-hydrodynamics code in order to enable hohlraum modeling. xRAGE's Eulerian hydrodynamics and adaptive mesh refinement make it uniquely well suited to study the impacts of multiscale features in hohlraums. In order to provide confidence in this new modeling capability, we demonstrate xRAGE's ability to produce reasonable agreement with data from several benchmark hohlraum experiments. We also use xRAGE to perform integrated simulations of a recent layered high density carbon capsule implosion on the National Ignition Facility in order to evaluate the potential impacts of the capsule support tent, mixed cell conductivity methodologies, plasma transport, and cross-beam energy transfer (XBT). We find that XBT, seeded by plasma flows in the laser entrance hole (LEH), causes a slight decrease in energy coupling to the capsule and that all of these impact the symmetry of the x-ray drive such that they have an appreciable impact on the capsule implosion shape.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Detonation structure in the presence of mixture stratification using reaction-resolved simulations

Many investigations of detonation-based combustors have identified reactant mixture inhomogeneity as having a leading-order impact on wave dynamics and combustion efficiency. To examine this phenomenon in a simplified context, an array of two- and three-dimensional channel detonation simulations are conducted in the present work. The reactant mixture consists of stratified fuel and air, wherein the randomly distributed equivalence ratio field features a characteristic stratification length scale. Detailed chemical kinetics are implemented in an adaptive mesh refinement solution framework where the region near the shock front is resolved with Ο (100) cells per representative ZND induction length. The results show that in comparison to baseline cases with uniform reactant mixtures, reactant stratification has a marked impact on the detonation structure. Increasing the stratification length scale increases the size and irregularity of the detonation cells, yielding larger variations in wave speed. Triple point collisions in fuel-rich regions lead to local wave speeds above the notional mean CJ speed, but wave passage through inert regions causes the local wave speed and strength to diminish. Further, conditional statistics show that increasing the stratification length scale increases the variance in pressure and temperature in the primary reaction zone, as well as the variance in heat release over a range of mixture conditions. In addition to the reactant mixture, the impact of the boundary condition behind the detonation is also investigated. The results show that an inflow boundary condition acts to over-drive the wave, leading to higher peak pressures, smaller detonation cells, and increased reactant consumption. On the other hand, cases with a wall behind the wave exhibit weaker waves with lower peak pressures and heat release rates, as well as greater variance in conditional quantities. Comparisons between complementary two- and three-dimensional simulations show reasonable qualitative agreement in wave structure, speed, and conditional statistics.

42 ENGINEERING↗

Adaptive clipping‐and‐redistribution algorithms for bounded and conservative high‐order interpolations applied to discontinuous and reactive flows

Abstract A new adaptive clipping‐and‐redistribution method is presented which provides bounds‐preservation for multidimensional interpolation in the context of high‐order finite‐volume discretizations with adaptive mesh refinement (AMR). The underlying finite‐volume method (FVM) for the computational fluid dynamics applications is fourth‐order accurate for smooth solutions and utilizes AMR for computational efficiency in solving multiscale problems involving turbulence and combustion. High‐order interpolation between different AMR levels is required. However, this operation often leads to numerical issues because combustion species must have physical bounds preserved. The present study overcomes two major challenges in the development of the high‐order interpolation method. First, the method needs to be bound‐preserving near extrema or discontinuities to prevent the emergence of unphysical oscillations while maintaining fourth‐order accuracy in smooth flows. Second, the method needs to satisfy the conservation requirement in multiple dimensions, particularly in the context of curvilinear coordinate transformations. Additionally, the method is designed to be localized and computationally inexpensive. The new interpolation scheme is demonstrated by solving reacting flows, which are extremely sensitive to unphysical overshoots in conserved quantities. The test problems are shock‐induced ‐ combustion and a ‐air flame in a practical bluff‐body combustor. Results show the method prevents new extrema near discontinuities while maintaining high‐order accuracy in smooth regions. In particular, the method is extremely beneficial for combustion with stiff chemistry. With the proposed new method, even if flame fronts cross AMR interfaces or new grids are created in the vicinity of the flame, solution stability is retained.

97 MATHEMATICS AND COMPUTING↗

Chemical timescale effects on detonation convergence

Numerical simulations of detonation-containing flows have emerged as crucial tools for designing next- generation power and propulsion devices. As these tools mature, it is important for the combustion community to properly understand and isolate grid resolution effects when simulating detonations. To this end, the objective of this work is to provide a comprehensive analysis of the numerical convergence of unsteady detonation simulations, with focus on isolating the impacts of chemical timescale modifications on convergence characteristics in the context of operator splitting. With the aid of an AMReX-based adaptive mesh refinement flow solver-which enables resolutions up to ($\mathcal{O}$ (1000) cells-per-induction length-the convergence analysis is conducted using two kinetics configurations: (1) the simplified three-step Arrhenius-based model mechanism of Short and Quirk (1997), where chemical timescales in the detonation are modified by adjusting activation energies in the initiation and branching reactions, and (2) a detailed hydrogen- air mechanism, where the chemical timescales are adjusted by varying the ambient pressure. The convergence of unsteady self-sustained detonations in one-dimensional channels is then analyzed with reference to steady-state theoretical baseline solutions using these mechanisms. The goal of the analysis is to provide a detailed comparison of the effects of grid resolution on both macroscopic (peak pressures and wave speeds) and microscopic (wave structure) quantities of interest, drawing connections between the deviations from steady-state baselines and minimum chemical timescales. In particular, chemical timescale reductions were found to have minimal impact on the convergence of macroscopic properties. Furthermore, analyses of microscopic convergence trends, particularly in the reaction front location, revealed a key insight: maintaining the induction time while eliminating prohibitive chemical timescales through mechanism simplifications and combustion modeling can significantly enhance detonation convergence properties. Ultimately, this work uncovers resolution-dependent unsteady detonation convergence regimes and highlights the important role played by not only the chemical timescales, but also the ratio between the chemical timescale and induction time on the numerical convergence of the detonation wave structure.

Adaptive mesh refinement↗

T RI M E ++: Multi-threaded triangular meshing in two dimensions

We present T RI M E ++, a multi-threaded software library designed for generating two-dimensional meshes for intricate geometric shapes using the Delaunay triangulation. Multi-threaded parallel computing is implemented throughout the meshing procedure, making it suitable for fast generation of large-scale meshes. Three iterative meshing algorithms are implemented: the DistMesh algorithm, the centroidal Voronoi diagram meshing, and a hybrid of the two. We compare the performance of the three meshing methods in T RI M E ++, and show that the hybrid method retains the advantages of the other two. The software library achieves significant parallel speedup when generating large-scale meshes containing between 10 4 to 10 7 points. T RI M E ++ can handle complicated geometries and generates adaptive meshes of high quality.

97 MATHEMATICS AND COMPUTING↗

A hybrid adaptive multiresolution approach for the efficient simulation of reactive flows

Computational studies that use block-structured adaptive mesh refinement (AMR) approaches suffer from unnecessarily high mesh resolution in regions adjacent to important solution features. This deficiency limits the performance of AMR codes. In this work a novel hybrid adaptive multiresolution (HAMR) approach to AMR-based calculations is introduced to address this issue. The multiresolution (MR) smoothness indicators are used to identify regions of smoothness on the mesh where the computational cost of individual physics solvers may be decreased by replacing direct calculations with interpolation. We suggest an approach to balance the errors due to the adaptive discretization and the interpolation of physics quantities such that the overall accuracy of the HAMR solution is consistent with that of the MR-driven AMR solution. The performance of the HAMR scheme is evaluated for a range of test problems, from pure hydrodynamics to turbulent combustion.

97 MATHEMATICS AND COMPUTING↗

Computations of Aerodynamic Performance Databases Using Output-Based Refinement

Objectives: Handle complex geometry problems; Control discretization errors via solution-adaptive mesh refinement; Focus on aerodynamic databases of parametric and optimization studies: 1. Accuracy: satisfy prescribed error bounds 2. Robustness and speed: may require over 105 mesh generations 3. Automation: avoid user supervision Obtain "expert meshes" independent of user skill; and Run every case adaptively in production settings.

Nemec, Marian↗

Transient thermal-structural analysis using adaptive unstructured remeshing and mesh movement

An adaptive unstructured remeshing technique is applied to transient thermal-structural analysis. The effectiveness of the technique, together with the finite element method and an error estimation technique, is evaluated by two applications which have exact solutions: (1) the steady-state thermal analysis of a plate subjected to a highly localized surface heating, and (2) the transient thermal-structural analysis of a simulated convectively cooled leading edge subjected to a translating heat source. These applications demonstrate that the remeshing technique significantly reduces the problem size as well as the analysis solution error as compared to the results produced using standard structured meshes.

Dechaumphai, Pramote↗

Accelerate microstructure evolution simulation using graph neural networks with adaptive spatiotemporal resolution

Abstract Surrogate models driven by sizeable datasets and scientific machine-learning methods have emerged as an attractive microstructure simulation tool with the potential to deliver predictive microstructure evolution dynamics with huge savings in computational costs. Taking 2D and 3D grain growth simulations as an example, we present a completely overhauled computational framework based on graph neural networks with not only excellent agreement to both the ground truth phase-field methods and theoretical predictions, but enhanced accuracy and efficiency compared to previous works based on convolutional neural networks. These improvements can be attributed to the graph representation, both improved predictive power and a more flexible data structure amenable to adaptive mesh refinement. As the simulated microstructures coarsen, our method can adaptively adopt remeshed grids and larger timesteps to achieve further speedup. The data-to-model pipeline with training procedures together with the source codes are provided.

36 MATERIALS SCIENCE↗

Unstructured CFD and Noise Prediction Methods for Propulsion Airframe Aeroacoustics

Using unstructured mesh CFD methods for Propulsion Airframe Aeroacoustics (PAA) analysis has the distinct advantage of precise and fast computational mesh generation for complex propulsion and airframe integration arrangements that include engine inlet, exhaust nozzles, pylon, wing, flaps, and flap deployment mechanical parts. However, accurate solution values of shear layer velocity, temperature and turbulence are extremely important for evaluating the usually small noise differentials of potential applications to commercial transport aircraft propulsion integration. This paper describes a set of calibration computations for an isolated separate flow bypass ratio five engine nozzle model and the same nozzle system with a pylon. These configurations have measured data along with prior CFD solutions and noise predictions using a proven structured mesh method, which can be used for comparison to the unstructured mesh solutions obtained in this investigation. This numerical investigation utilized the TetrUSS system that includes a Navier-Stokes solver, the associated unstructured mesh generation tools, post-processing utilities, plus some recently added enhancements to the system. New features necessary for this study include the addition of two equation turbulence models to the USM3D code, an h-refinement utility to enhance mesh density in the shear mixing region, and a flow adaptive mesh redistribution method. In addition, a computational procedure was developed to optimize both solution accuracy and mesh economy. Noise predictions were completed using an unstructured mesh version of the JeT3D code.

Pao, S. Paul↗

Robust Metric-Aligned Quad-Dominant Meshing Using L(sub p) Centroidal Voronoi Tessellation

We introduce a meshing algorithm that can be used to both generate and adapt meshes for bounded domains in an anisotropic manner. This is particularly beneficial when anisotropic flow features like shock waves or contact discontinuities are present in the computational domain. The algorithm presented in this paper is based upon meshing under the imposed Riemannian metric tensor, which controls the orientation and size of the mesh elements. In this way there is no need for user intervention to recognize these features. We demonstrate that the method indeed aligns the elements with the underlying metric and produces right-angled simplices that can be recombined into quadrilateral elements. The aim is to eventually incorporate this meshing strategy in the monolithic high-order spectral element solver that is currently being developed at NASA Ames. This paper has two main contributions: First, we demonstrate that we can generate quad-dominant metric-aligned meshes for bounded domains using a generalized form of L(sub p)-Centroidal Voronoi Tessellation (L(sub p)-CVT). Unlike previous works, we do not rely on a background mesh and discretize the bounded domain in a hierarchical way by first discretizing the boundaries and then the volume using the underlying metric. Second, we present an alternative for clipping the Voronoi cells on the boundary, which is common practice in CVT-based meshing algorithms, by reconstructing the Voronoi cells using the defined metric field. In this way we avoid the geometrical complexity of the clipping procedure and we show that we evaluate the energy and its gradient correctly. We show that the reconstruction of the computational domain is consistent with the Lloyds’ algorithm that is used to compute the L(sub p)-CVT.

Centroidal↗

A projection method for particle resampling

Particle discretizations of partial differential equations are advantageous for high-dimensional kinetic models in phase-space due to their better scalability than continuum approaches with respect to dimension. Complex processes collectively referred to as particle noise hamper long time simulations with particle methods. One approach to address this problem is particle mesh adaptivity, or remapping, known as particle resampling and remeshing. Here, this work introduces a resampling method that projects particles to and from a (finite element) function space. The method is simple, using standard sparse linear algebra and finite element techniques, and it preserves all moments up to the order of a polynomial represented exactly by the continuum function space. It is distinguished from most other mesh-based methods in that new particle positions and number are decoupled from the mesh, allowing particle and continuum meshes to be adapted relatively independently. While this work is developed with structured particle and continuum phase-space grids on 1X + 1V Vlasov-Poisson models of Landau damping and two-stream instability, the method is well-suited to unstructured grids. Stable long time dynamics are demonstrated up to time T = 500. Reproducibility artifacts and data are publicly available.

Kinetic methods↗

A Domain-Decomposed Multi-Level Method for Adaptively Refined Cartesian Grids with Embedded Boundaries

The work presents a new method for on-the-fly domain decomposition technique for mapping grids and solution algorithms to parallel machines, and is applicable to both shared-memory and message-passing architectures. It will be demonstrated on the Cray T3E, HP Exemplar, and SGI Origin 2000. Computing time has been secured on all these platforms. The decomposition technique is an outgrowth of techniques used in computational physics for simulations of N-body problems and the event horizons of black holes, and has not been previously used by the CFD community. Since the technique offers on-the-fly partitioning, it offers a substantial increase in flexibility for computing in heterogeneous environments, where the number of available processors may not be known at the time of job submission. In addition, since it is dynamic it permits the job to be repartitioned without global communication in cases where additional processors become available after the simulation has begun, or in cases where dynamic mesh adaptation changes the mesh size during the course of a simulation. The platform for this partitioning strategy is a completely new Cartesian Euler solver tarcreted at parallel machines which may be used in conjunction with Ames' "Cart3D" arbitrary geometry simulation package.

Aftosmis, M. J.↗

Cart3D Simulations for the First AIAA Sonic Boom Prediction Workshop

Simulation results for the First AIAA Sonic Boom Prediction Workshop (LBW1) are presented using an inviscid, embedded-boundary Cartesian mesh method. The method employs adjoint-based error estimation and adaptive meshing to automatically determine resolution requirements of the computational domain. Results are presented for both mandatory and optional test cases. These include an axisymmetric body of revolution, a 69deg delta wing model and a complete model of the Lockheed N+2 supersonic tri-jet with V-tail and flow through nacelles. In addition to formal mesh refinement studies and examination of the adjoint-based error estimates, mesh convergence is assessed by presenting simulation results for meshes at several resolutions which are comparable in size to the unstructured grids distributed by the workshop organizers. Data provided includes both the pressure signals required by the workshop and information on code performance in both memory and processing time. Various enhanced techniques offering improved simulation efficiency will be demonstrated and discussed.

Predictions↗