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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Structured Overset and Unstructured Grid Simulations for the Third AIAA Sonic Boom Prediction Workshop

Predictions using the Launch Ascent and Vehicle Aerodynamics (LAVA) Unstructured and Structured Curvilinear solvers for the Biconvex and C608 geometries are compared in support of the 3rd AIAA Sonic Boom Prediction workshop. Description of the mesh generation techniques and numerical methods are provided along with a comparison of nearfield and far-field predictions with available experimental data as well as other workshop sub-missions. Strong consistency was observed between the Biconvex and C608 nearfield predictions across the two solvers used for this study, as well as validation and verification data. Additionally, near-field and farfield ground signature results using a combination of a truncated computational fluid dynamics (CFD) domain coupled to a mid-field space marching method and propagated to the ground using sBOOM will be discussed. This approach is shown to provide an efficient way to propagate near-field pressure signatures to the ground with the same accuracy as the near-field CFD coupled to sBOOM, but at less computational cost.

CST↗
DOE OSTI2022

Linear source method of characteristics in HELIOS2

The Studsvik Scandpower code HELIOS2 is a fast lattice transport code that has gained wide use for reactor fuel cycle analysis in commercial, regulatory, and research environments. It contains two transport solvers - Collision Probabilities (CP) and Method of Characteristics (MoC) - with a general geometry ability and generalized depletion for a variety of fuel types, experimental facilities, and isotope production applications. The HELIOS2 lattice code has been extended with the development of a linear source MoC option. The linear source equations are derived within the scope of the HELIOS2 general geometry and non-cyclic ray tracing. The implementation was tested for fine and coarse spatial mesh models of the 2D C5G7 MOX computational benchmark, which provides a pure and extreme test of a transport solver. The linear source yields at least comparable accuracy with reduced computational resource requirements relative to the flat-source approximation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Voronoi Meshing to Accurately Capture Geological Structure in Subsurface Simulations

Mesh generation lies at the interface of geological modeling and reservoir simulation. Highly skewed or very small grid cells may be necessary to accurately capture the geometry of geological features, but the resulting poorly scaled or small grid cells can have a substantial negative impact on simulator accuracy and speed. One way to minimize numerical errors caused by gridding complex structures is to simulate on high-quality Voronoi meshes, which reduce grid orientation effects in fluid flow. This work presents a complete methodology to create Voronoi simulation grids, model fluid flow in complex geological systems, and visualize the results. A recently developed Voronoi meshing method that can automatically generate provably good unstructured meshes that conform to input surfaces creating closed volumes is used. Initially an analytical benchmark simulation is presented to validate the quality of the meshes and simulation results and demonstrate the superiority of simulation results using Voronoi meshes over flexed-hexahedral meshes on a domain with internal features. Next, meshes are created for test structures representing four of the most common geological features in the subsurface: layering, pinch-out, an interior lens that tapers to zero thickness on all sides and a fault with offset. Two benchmark flow simulations are run for each test structure. Finally, a realistic geological example for CO 2 injection into an anticline is simulated. Three realizations of the Voronoi mesh at the same resolution are generated for the simulations. Each mesh is highly refined near the injection wells and coarse in areas of less interest. These three meshes are used to model the CO 2 plume in the subsurface as it migrates to the top of the structure and then fills downward. Simulations on the meshes with randomly generated elements inside the input volumes each give slightly different fingering patterns for the viscous-unstable buoyant gas flow. The results presented in this work show a promising step towards utilizing fully automated Voronoi meshing for subsurface flow simulations in complex geology.

58 GEOSCIENCES↗
DOE OSTI2017

Investigations into alternative radiation transport codes for ITER neutronics analysis

As radiation transport models for ITER become increasingly complex, the use of traditional constructive solid geometry (CSG) modelling approaches such as MCWNP presents significant disadvantages during model creation and integration. Studies were performed to assess the capabilities of alternative mesh-based neutronics workflows offered by the MCNP, DAG-MCNP and Serpent-2 codes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

A Fourth-Order Embedded Boundary Finite Volume Method for the Unsteady Stokes Equations with Complex Geometries

A fourth-order finite volume embedded boundary (EB) method is presented for the unsteady Stokes equations. The algorithm represents complex geometries on a Cartesian grid using EB, employing a technique to mitigate the ``small cut-cell"" problem without mesh modifications, cell merging, or state redistribution. Spatial discretizations are based on a weighted least-squares technique that has been extended to fourth-order operators and boundary conditions, including an approximate projection to enforce the divergence-free constraint. Solutions are advanced in time using a fourth-order additive implicit-explicit Runge-Kutta method, with the viscous and source terms treated implicitly and explicitly, respectively. Formal accuracy of the method is demonstrated with several grid convergence studies, and results are shown for an application with a complex bio-inspired material. In conclusion, the developed method achieves fourth-order accuracy and is stable despite the pervasive small cells arising from complex geometries.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Mesh-free data transfer algorithms for partitioned multiphysics problems: Conservation, accuracy, and parallelism

In this study we analyze and extend mesh-free algorithms for three-dimensional data transfer problems in partitioned multiphysics simulations. We first provide a direct comparison between a mesh-based weighted residual method using the common-refinement scheme and two mesh-free algorithms leveraging compactly supported radial basis functions: one using a spline interpolation and one using a moving least square reconstruction. Through the comparison we assess both the conservation and accuracy of the data transfer obtained from each of the methods. We do so for a varying set of geometries with and without curvature and sharp features and for functions with and without smoothness and with varying gradients. Our results show that the mesh-based and mesh-free algorithms are complementary with cases where each was demonstrated to perform better than the other. We then focus on the mesh-free methods by developing a set of algorithms to parallelize them based on sparse linear algebra techniques. This includes a discussion of fast parallel radius searching in point clouds and restructuring the interpolation algorithms to leverage data structures and linear algebra services designed for large distributed computing environments. The scalability of our new algorithms is demonstrated on a leadership class computing facility using a set of basic scaling studies. Finally, these scaling studies show that for problems with reasonable load balance, our new algorithms for both spline interpolation and moving least square reconstruction demonstrate both strong and weak scalability using more than 100,000 MPI processes with billions of degrees of freedom in the data transfer operation.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2015

Full-Carpet Design of a Low-Boom Demonstrator Concept

The Cart3D adjoint-based design framework is used to mitigate the undesirable o -track sonic boom properties of a demonstrator concept designed for low-boom directly under the flight path. First, the requirements of a Cart3D design mesh are determined using a high-fidelity mesh adapted to minimize the discretization error of the CFD analysis. Low-boom equivalent area targets are then generated at the under-track and one off-track azimuthal position for the baseline configuration. The under-track target is generated using a trim- feasible low-boom target generation process, ensuring that the final design is not only low-boom, but also trimmed at the specified flight condition. The o -track equivalent area target is generated by minimizing the A-weighted loudness using an efficient adjoint-based approach. The configuration outer mold line is then parameterized and optimized to match the off-body pressure distributions prescribed by the low-boom targets. The numerical optimizer uses design gradients which are calculated using the Cart3D adjoint- based design capability. Optimization constraints are placed on the geometry to satisfy structural feasibility. The low-boom properties of the final design are verified using the adaptive meshing approach. This analysis quantifies the error associated with the CFD mesh that is used for design. Finally, an alternate mesh construction and target positioning approach offering greater computational efficiency is demonstrated and verified.

Ordaz, Irian↗
NASA NTRS2011

A Generalized Framework for Constrained Design Optimization of General Supersonic Configurations Using Adjoint Based Sensitivity Derivatives

The Aeronautics Research Mission Directorate (ARMD) sent out an NASA Research Announcement (NRA) for proposals soliciting research and technical development. The proposed research program was aimed at addressing the desired milestones and outcomes of ROA (ROA-2006) Subtopic A.4.1.1 Advanced Computational Methods. The second milestone, SUP.1.06.02 Robust, validated mesh adaptation and error quantification for near field Computational Fluid Dynamics (CFD), was addressed by the proposed research. Additional research utilizing the direct links to geometry through a CAD interface enabled by this work will allow for geometric constraints to be applied and address the final milestone, SUP2.07.06 Constrained low-drag supersonic aerodynamic design capability. The original product of the proposed research program was an integrated system of tools that can be used for the mesh mechanics required for rapid high fidelity analysis and for design of supersonic cruise vehicles. These Euler and Navier-Stokes volume grid manipulation tools were proposed to efficiently use parallel processing. The mesh adaptation provides a systematic approach for achieving demonstrated levels of accuracy in the solutions. NASA chose to fund only the mesh generation/adaptation portion of the proposal. So this report describes the completion of the proposed tasks for mesh creation, manipulation and adaptation as it pertains to sonic boom prediction of supersonic configurations.

Karman, Steve L., Jr.↗
NASA NTRS1994

Computerized Design of Low-noise Face-milled Spiral Bevel Gears

An advanced design methodology is proposed for the face-milled spiral bevel gears with modified tooth surface geometry that provides a reduced level of noise and has a stabilized bearing contact. The approach is based on the local synthesis of the gear drive that provides the 'best' machine-tool settings. The theoretical aspects of the local synthesis approach are based on the application of a predesigned parabolic function for absorption of undesirable transmission errors caused by misalignment and the direct relations between principal curvatures and directions for mating surfaces. The meshing and contact of the gear drive is synthesized and analyzed by a computer program. The generation of gears with the proposed geometry design can be accomplished by application of existing equipment. A numerical example that illustrates the proposed theory is presented.

Litvin, Faydor L.↗
DOE OSTI2023

Large deformation and brittle failure calculated using the dual-domain material point method

The dual domain material point (DDMP) method is explored as a candidate to be implemented in a general purpose code to perform simulations of materials with complex geometry that undergo large history-dependent deformation and failure. To test its candidacy, we study its mesh convergence, its sensitivity to mesh orientation, and its ability to handle softening and failure of a material. Simulations of large deformation and simulations of mechanical failure are performed using both DDMP and the material point method (MPM). When cell-crossing of material points is not an issue and when there are a sufficient number of material points in each computation cell, the numerical error decreases with the square of the cell size as expected for both MPM and DDMP. DDMP has reduced error compared with MPM when there are many instances of material points crossing cell boundaries due to the continuous nature of the modified gradient of the shape functions. Simulations of a specimen under tension are also performed where the background mesh is aligned and misaligned with the tension direction. MPM displays a significant mesh-dependent stress field, DDMP shows negligible mesh dependency. Despite a mesh orientation-dependent stress field from MPM, the critical tension and failure mode from both MPM and DDMP calculations have negligible mesh dependency when using a non-local failure model. If only the failure mode is important (i.e., local stresses are unimportant), MPM with a non-local failure model is a suitable method for modeling failure with small deformations. However, if local stresses are also important or if there are large deformations with many cell-crossings before failure, DDMP should be the method that is used. A needed improvement for DDMP is identified from our numerical simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Non-destructive simulation of node defects in additively manufactured lattice structures

Additive Manufacturing (AM), commonly referred to as 3D printing, offers the ability to not only fabricate geometrically complex lattice structures but parts in which lattice topologies in-fill volumes bounded by complex surface geometries. However, current AM processes produce defects on the strut and node elements which make up the lattice structure. This creates an inherent difference between the as-designed and as-fabricated geometries, which negatively affects predictions (via numerical simulation) of the lattice’s mechanical performance. Although experimental and numerical analysis of an AM lattice’s bulk structure, unit cell and struts have been performed, there exists almost no research data on the mechanical response of the individual as-manufactured lattice node elements. Here we propose a methodology that, for the first time, allows non-destructive quantification of the mechanical response of node elements within an as-manufactured lattice structure. A custom-developed tool is used to extract and classify each individual node geometry from micro-computed tomography scans of an AM fabricated lattice. Voxel-based finite element meshes are generated for numerical simulation and the mechanical response distribution is compared to that of the idealised computer-aided design model. The method demonstrates compatibility with Uncertainty Quantification methods that provide opportunities for efficient prediction of a population of nodal responses from sampled data. Overall, the non-destructive and automated nature of the node extraction and response evaluation is promising for its application in qualification and certification of additively manufactured lattice structures.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Sculpt test problem analysis.

This report details Sculpt's implementation from a user's perspective. Sculpt is an automatic hexahedral mesh generation tool developed at Sandia National Labs by Steve Owen. 54 predetermined test cases are studied while varying the input parameters (Laplace iterations, optimization iterations, optimization threshold, number of processors) and measuring the quality of the resultant mesh. This information is used to determine the optimal input parameters to use for an unknown input geometry. The overall characteristics are covered in Chapter 1. The speci c details of every case are then given in Appendix A. Finally, example Sculpt inputs are given in B.1 and B.2.

Sweetser, John David↗
DOE OSTI2022

Hardness Prediction by Incorporating Heat Transfer and Molten Pool Fluid Flow in a Multi-pass, Multi-layer Weld for Onsite Repair of Grade 91 steel

Introduction: In the current fleet of fossil-fired power plants, creep strength enhanced ferritic steels (CSEF) are used to sustain the harsh service conditions. Enhanced properties of Grade 91 steel result from tempered martensite with a fine distribution of MX and M23C6 carbides. Grade 91 steel is subjected to onsite welding repair to remedy their degradation due to extreme service condition. Knowledge of weld repairability of these steels, such as as-welded hardness distribution, is essential to establishing sound repair procedures. Experimental trial and error tests can consume a lot of time as many welding variables need to be studied. For numerical modelling, most of the multi-pass multi-layer models are based on finite element method, which are limited to solve the heat conduction equation and ignore convective heat transfer due to melt flow. Moreover, the mesh has to be pre-built based on a known or assumed weld cross-section geometry. These finite element based models thus have limited predictive capability as defects are not considered and nugget size are pre-assumed. This research aims at developing a thermal and microstructure evolution model incorporating molten pool dynamics in a multi-pass multi-layer material deposition to predict the as-welded hardness distribution. Technical Approach: All the thermal, physical, and metallurgical properties of Grade 91 as a function of temperature are collected from the literature and inputted into the thermo-fluid model based on Flow-3D, a computational fluid dynamics software. A multi-pass, multi-layer material deposition is simulated where the melting of filler wire into the molten pool is directly considered based on the volume of fluid (VOF) method. The flow behaviour of the molten pool is used to understand the formation of deposition geometry and defects. The temperature profiles during the multi-pass, multi-layer welding are calculated. The results computed using the new model are compared against the experimental data of fusion zone geometry and thermal cycles. Hardness prediction in the heat-affected zone (HAZ) are made using Johnson-Mehl-Avrami (JMA) equation for solid-state phase transformation kinetics. The JMA parameters are extracted from the experimental data available in the literature. For comparison, a standard finite element heat conduction model is also developed to predict the thermal cycles and hardness distribution in the multi-pass, multi-layer weld. Expected Result: Results obtained using the molten pool dynamic simulation versus the finite element heat conduction model are compared. Specifically, the effects of convective heat transfer on the accuracy of the calculated thermal history, bead shape and size, and HAZ hardness distribution are examined.

Modeling, Grade 91 steel, Multi-pass multi-layer d↗
NASA NTRSDate not supplied

A Moving Discontinuous Galerkin Method with Interface Condition Enforcement for Reacting Hypersonic Flows

The necessity of enforcing conservation in computational elements or cells (element conservation) for discontinuous solutions is well understood and respected for solving conservation laws in computational fluid dynamics (CFD). In contrast, interface conservation, where the conservation across cell interfaces is enforced, is long ignored, and yet is also ruled and required by the underlying physics just like element conservation. Violation of the interface conservation across discontinuities is the root cause why an exact discontinuous solution can never be achieved in shock capturing methods. The interface conservation is examined and explored in this talk. Moving discontinuous Galerkin (MDG) finite element method with interface conservation enforcement (MDG-ICE) [1],[2] are then presented for solving compressible flow problems with discontinuities based on the observation that the interface conservation can only be satisfied, only when mesh interfaces are aligned with discontinuities. In the MDG-ICE formulation, both conservative quantities and grid geometry are considered as independent variables. A space-time DG formulation is used to solve the multi-material compressible Euler equations in the standard discontinuous solution space and the discrete grid geometry is solved using a variational formulation in a continuous space. A self-adaptive Levenberg-Marquardt method is utilized to solve the resulting over-determined system of nonlinear equations arising from the MDG-ICE formulation. A number of numerical experiments for a variety of flow problems are conducted to assess the accuracy and performance of the MDG-ICE method. Numerical results obtained indicate that the MDG-ICE method is able to deliver the designed order of both h- and p-convergence even for discontinuous solutions, and detect all types of interfaces, via interface condition enforcement and satisfy, via grid movement, the compressible Euler equations and the associated interface condition.

Discontinuous Galekin↗
DOE OSTI2022

Hybrid Curve Fitting For Reducing Motion Commands In Object Construction

Existing slicing software for additive manufacturing typically requires a triangulated mesh as its input. Triangulated meshes are approximate representations of exact CAD models. Despite the loss in dimensional accuracy, triangulated meshes are used because they are computationally easier to cross-section and offset than the exact geometry in CAD format. When a triangulated object is prepared, the resulting machine instructions include only linear motion commands. Numerous modern motion controllers can move in arc and spline motions; however, the absence of slicing software that supports curvature prevents these commands from being leveraged. To address this limitation, this paper presents a method for the hybrid reconstruction of arcs and splines as a post-processing step to traditional slicing. This method can greatly reduce the number of motion commands required to construct an object by printing smooth curved surfaces. This concise representation of tool-pathing allows for more even extrusion and is computed without a major impact on slicing time.

Wade, Charles↗
DOE OSTI2012

Reactivity loss validation of high burn-up PWR fuels with pile-oscillation experiments in MINERVE

The ALIX experimental program relies on the experimental validation of the spent fuel inventory, by chemical analysis of samples irradiated in a PWR between 5 and 7 cycles, and also on the experimental validation of the spent fuel reactivity loss with bum-up, obtained by pile-oscillation measurements in the MINERVE reactor. These latter experiments provide an overall validation of both the fuel inventory and of the nuclear data responsible for the reactivity loss. This program offers also unique experimental data for fuels with a burn-up reaching 85 GWd/t, as spent fuels in French PWRs never exceeds 70 GWd/t up to now. The analysis of these experiments is done in two steps with the APOLLO2/SHEM-MOC/CEA2005v4 package. In the first one, the fuel inventory of each sample is obtained by assembly calculations. The calculation route consists in the self-shielding of cross sections on the 281 energy group SHEM mesh, followed by the flux calculation by the Method Of Characteristics in a 2D-exact heterogeneous geometry of the assembly, and finally a depletion calculation by an iterative resolution of the Bateman equations. In the second step, the fuel inventory is used in the analysis of pile-oscillation experiments in which the reactivity of the ALIX spent fuel samples is compared to the reactivity of fresh fuel samples. The comparison between Experiment and Calculation shows satisfactory results with the JEFF3.1.1 library which predicts the reactivity loss within 2% for burn-up of {approx}75 GWd/t and within 4% for burn-up of {approx}85 GWd/t. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2013

Development of a S{sub n} transport code based on discontinuous finite element method and coarse mesh finite difference formulation

The methods and performance of a three-dimensional S{sub n} transport code employing the Discontinuous Finite Element Method (DFEM) and the Coarse Mesh Finite Difference (CMFD) formulation are presented. The mesh generator GMSH and a post processing visualization tool Visit are combined with the code for flexible geometry processing and versatile visualization. The CMFD method for DFEM Sn applications is formulated and the performance of the CMFD acceleration of eigenvalue calculations is demonstrated for a simple set of neutron transport problems. (authors)

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1993

Three-dimensional unstructured grid method applied to turbomachinery

This work has three objectives: to develop a three-dimensional flow solver based on unstructured tetrahedral meshes for turbomachinery flows; to validate the solver through comparisons with experimental data; and to apply the solver for better understanding of the flow through turbomachinery geometries and design improvement. The work followed three different approaches: an existing external flow solver/grid generator (USM3D/VGRID) was extensively modified for internal flows; a three-dimensional, finite-volume solver based on Roe's flux-difference splitting and explicit Runge-Kutta time stepping; and three-dimensional unstructured tetrahedral mesh generation using an advancing-front technique. A discussion of these topics is presented in viewgraph form.

Oh Joon Kwon↗